The Crane Manufacturers Association of America (CMAA) has released the 2025 revision of its Specification for Crane Inspection and Maintenance Personnel: Qualifications and Training Requirements. CMAA Specification 78 provides a unified framework for developing, evaluating, and documenting the qualifications of those responsible for maintaining and inspecting overhead traveling cranes.

This specification establishes a uniform foundation for training programs, inspection procedures, and maintenance practices across the overhead lifting industry. The 2025 update provides clearer guidance for employers, trainers, and safety managers. Its contents detail the qualifications necessary to inspect, service, and maintain cranes in compliance with recognized best practices. The following overviews each section of the updated publication.

Chapter 1 – Scope and Purpose

This opening chapter defines the purpose of CMAA Specification 78: to establish consistent criteria for training, qualification, and oversight of personnel who inspect and maintain overhead cranes. It clarifies that the document applies to both top-running and under-running cranes covered in CMAA Specification 70 and CMAA Specification 74. This ensures a shared foundation across all crane designs.

The 2025 update further strengthens the connection between CMAA Specification 78 and regulatory references such as OSHA 1910.179 and ASME B30.2. It emphasizes that qualified inspection and maintenance personnel are critical to preventing mechanical failure and protecting workers in industrial environments. The expanded content also explains how employers can integrate CMAA 78 guidance into existing safety management programs.

Chapter 2 – Personnel Classifications and Qualifications

The 2025 edition details personnel classifications that mirror the real-world roles found in crane operations today. It distinguishes between maintenance and inspection functions, detailing the responsibilities, skills, and competencies required for each.

• Maintenance personnel repair or adjust mechanical, structural, and electrical components, ensuring cranes remain in safe working condition.
• Inspection personnel evaluate the crane’s structural integrity, performance, and regulatory compliance.

Each role now includes minimum experience levels, required training hours, and competency validation methods. The revision also clarifies that employers are responsible for verifying qualifications, whether achieved through formal coursework, certification, or demonstrated field experience.

Chapter 3 – Training Requirements

Chapter 3 of CMAA Specification 78 expands significantly on the content and administration of training programs. CMAA now provides clearer expectations for the topics, duration, and frequency of training that inspection and maintenance personnel must complete.

Training programs must cover the fundamentals of overhead crane operation, component identification, maintenance practices, inspection procedures, and applicable OSHA and ASME requirements. Refresher training is necessary whenever procedures, technology, or equipment configurations change.

The section also defines instructor qualifications. It specifies that only individuals who possess both technical expertise and practical field experience can conduct training. Employers should evaluate instructor competency periodically to ensure that instruction reflects current regulatory and engineering practices.

Finally, the 2025 revision adds greater detail about training documentation. Records must include participant names, completion dates, course topics, instructor identity, and verification of proficiency. Maintaining accurate and retrievable records is essential for compliance verification and program auditing.

Chapter 4 – Inspection Program Structure

This chapter details inspection categories, intervals, and procedures. CMAA differentiates between initial, pre-shift, frequent, and periodic overhead crane inspections:

Initial Inspection

Conducted on all new, modified, or repaired cranes before their placement into service. This inspection verifies that installation, load testing, and operational checks meet design and safety criteria. The 2025 updates include specific guidance for documentation and sign-off procedures before commissioning.

Pre-shift Inspection

A visual and functional check performed by the operator at the start of each shift. It focuses on hoist brakes, limit switches, wire rope condition, hooks, controls, and indicators. The revision emphasizes the immediate reporting and documentation of any unusual pre-shift findings to ensure early detection of safety issues.

Frequent Inspections

Occurring daily to monthly, these evaluations verify that all safety devices, wire rope, and mechanical components are operating correctly.

Periodic Inspections

Performed quarterly to annually, these deeper reviews assess structural integrity, alignment, and wear trends. A detailed table provides a visual reference for determining how often to perform these inspections based on service class and usage frequency.

This chapter of the updated CMAA Specification 78 also offers an explanation of how to determine the correct inspection category based on duty cycle, service class, and environmental conditions. CMAA advises standardizing inspection report templates, either digital or paper based. Doing so promotes clarity, traceability, and consistent evaluation criteria across facilities.

Chapter 5 – Genuine OEM (Factory) Parts

Chapter 5 of the 2025 edition underscores the critical role of genuine original equipment manufacturer (OEM) parts in crane maintenance and repair. The OEM should be the primary source for replacement components, engineered upgrades, and performance improvements. Using non-approved parts can compromise crane integrity, void warranties, and create serious safety risks.

The OEM ensures that every replacement part fits properly, uses correct materials, and is free of defects. Because the OEM designed the crane, it can confirm proper part interaction, recommend modernization options, and support root-cause analysis when issues arise—whether due to normal wear or premature failure.

CMAA notes that OEMs often supply repair kits to streamline common fixes and identify mating parts that should be replaced together. The specification also cautions against counterfeit or imitation components, referencing federal laws that prohibit their sale or use. CMAA Specification 78 notes that by sourcing genuine OEM parts and working directly with manufacturers, crane owners maintain design integrity, ensure compliance, and extend safe equipment life.

Chapter 6 – Crane Classifications

Chapter 6 defines crane service classes to help users specify the most appropriate and economical crane based on expected operating conditions. Class determination is based on a load spectrum. This represents the average effective load applied over time and the number of load cycles a crane will experience during its service life.

CMAA outlines six primary service classes:

• Class A (Standby or Infrequent Service) – Minimal use with long idle periods, such as in powerhouses.
• Class B (Light Service) – Occasional lifting in repair shops or light assembly areas.
• Class C (Moderate Service) – Regular lifting in machine shops or paper mills.
• Class D (Heavy Service) – Frequent, high-speed lifting in foundries and steel plants.
• Class E (Severe Service) – Continuous lifting near rated capacity in scrap or container yards.
• Class F (Continuous Severe Service) – Constant operation at or near capacity in critical production environments.

The specification also relates each class to load cycles and mean effective load factors. This guideline helps inform the selection of the crane and its proper maintenance schedule for safe, efficient long-term performance.

Learn More About CMAA Specification 78

Along with many other overhead handling resources, CMAA Specification 78-2025 is downloadable via www.mhi.org/cmaa.

CMAA members represent the industry’s leading suppliers of overhead crane systems. They design, manufacture, assemble, install and service overhead cranes and components. CMAA members, with the combined experience of more than 30,000 crane installations in North America in the last decade, are committed to providing products which focus on safety and innovation.

In addition to its engineering specifications, the organization offers a variety of other resources. These include buyers’ guides, OSHA Alliance safety tip and fact sheets, inspection and maintenance checklists, and safety seminars. Learn more via CMAA’s website at www.MHI.org/CMAA.