The 2025 safety guide
In the industrial, construction, and logistics sectors, the daily use of lifting equipment — such as cranes, hoists, overhead cranes, and slings — is essential. However, with frequent use comes responsibility: keeping this equipment safe, functional, and compliant with regulations is not optional — it’s a legal obligation.
In this article, you’ll learn everything you need to know about maintaining lifting equipment: from best practices and legal requirements to frequently asked questions.
Why Maintenance Matters
Regular maintenance not only avoids the risk of serious accidents, but also improves the efficiency of lifting processes and reduces the costs of unexpected breakdowns.
Moreover, it is a legal obligation: neglecting maintenance can lead to fines, stoppages of operations or, in the worst cases, criminal liability in the event of accidents.
Regulatory Framework: What the Law Requires
Maintenance of lifting equipment is not only a best practice — it is legally required across the European Union. Here are the key regulations and directives you need to know:
- Directive 2006/42/EC – Machinery Directive
This is the main European reference for the design, maintenance, and inspection of machinery, including lifting equipment. It mandates that equipment must be maintained in safe working condition throughout its lifecycle, and any risk of mechanical failure must be minimized through proper maintenance. - Directive 2009/104/EC – Use of Work Equipment
This directive states that employers must ensure periodic inspections and maintenance of work equipment to detect and eliminate safety risks. Equipment must be inspected by competent persons and records of inspections must be kept. - National Laws and Inspections
Each country may implement additional national rules. In Italy, for instance:
- The D.Lgs. 81/2008 (Consolidated Safety Law) obliges regular maintenance and risk assessment.
- The DPR 462/2001 defines the periodic verification procedures for certain electrical and mechanical installations, including lifting equipment.
- ISO and EN Standards
Several ISO and EN technical standards apply to lifting devices, including:
- ISO 12480-1: Safe use of cranes
- EN 13157: Hand-powered lifting equipment
- EN 15011: Bridge and gantry cranes – maintenance and inspection
Failing to comply with these regulations can result in:
- Fines or operational suspensions
- Increased accident risk
- Loss of insurance coverage
Keeping your maintenance procedures aligned with these laws ensures safety, compliance, and business continuity.
Types of Maintenance You Should Know
🔧Preventive Maintenance
Scheduled checks to prevent equipment failure. This includes:
Regular lubrication
Inspection for wear on ropes and chains
Testing of stop and safety devices
⚠️ Corrective Maintenance
Interventions made when a component breaks or shows visible signs of malfunction.
📈 Predictive Maintenance
Uses sensors and data analytics to predict failures before they occur — a growing trend in Industry 4.0 environments.
How Often Should Maintenance Be Performed?
Maintenance frequency depends on the type of equipment and intensity of use, but these general guidelines apply:
Daily visual checks by the operator
Weekly or monthly maintenance, including lubrication and functional testing
Annual mandatory inspections by certified technicians or accredited bodies
All inspections must be documented and archived, so you can demonstrate compliance in the event of audits or inspections.
Best Practices for Effective Maintenance
Train staff in the correct use of lifting equipment
Use detailed checklists and inspection forms
Keep a digital maintenance log
Rely on qualified technicians for complex repairs
Don’t overlook less-visible components: hooks, brakes, couplings, and limit switches
FAQ about Lifting Equipment Maintenance
- Who is responsible for equipment maintenance?
The employer is legally responsible for the safety of lifting equipment and must ensure that maintenance is performed by qualified personnel and properly documented. - Is it mandatory to hire external companies for inspections?
Yes, for inspections required by law (such as those under Italian DPR 462/2001 or European machinery directives), you must use notified bodies or health and safety authorities. - How often should a lifting rope be replaced?
It depends on wear and workload. On average, every 12–24 months or sooner if there are visible signs of damage. - Can in-house personnel perform maintenance without certification?
Routine maintenance can be done internally, but personnel must be trained and competent. Mandatory inspections, however, must be carried out by authorized professionals.
Investing in the maintenance of lifting equipment means protecting your people, assets, and business continuity.
It’s not just about meeting legal requirements — it’s about building a safer, more reliable work environment.
Need help planning or performing lifting equipment maintenance?
Contact us — our team is ready to support you with tailored solutions, even for the most complex equipment.
