Why Regular Magnet Inspections Are Critical

When you’re responsible for moving heavy steel plates, bars, or beams, you depend on the reliability of your lifting magnet. A single overlooked flaw in the magnet’s handle, a wornout hoist ring, or a crack in the magnet’s housing can lead to a dropped load and serious injury. That’s why inspections aren’t just paperwork: they protect your team and keep production on schedule.

Permanent magnets operate without power, which means they provide a constant gripping force. However, their components, such as handles, latches, and pole surfaces, wear over time. Inadequate inspections create blind spots where minor defects turn into failure points. By understanding the types of inspections required and the specific items to examine, you can confidently operate your magnet and comply with standards like ASME B30.20 and OSHA.

Understanding Inspection Classes

The American Society of Mechanical Engineers (ASME) divides liftingmagnet inspections into three classes based on how often they occur and how thoroughly the magnet is examined.

1. Every Lift Inspection:Operators visually check the magnet before and during each lift for surface contamination and proper handle operation. This quick inspection ensures the magnet face is clean and that the ON/OFF mechanism works smoothly.
2. Frequent Inspection:Designated personnel perform a more thorough examination at regular intervals without recording results. ASME B30.20 recommends monthly checks for normal service, weekly to monthly for heavy service, and daily to weekly for severe service. Special or infrequent service requires inspection before and after each lift.
3. Periodic Inspection:A documented inspection looks for wear or damage and establishes whether the magnet remains safe to use. For equipment in normal service, ASME recommends an annual inspection; heavy-service magnets require quarterly inspections, while severe-service magnets require monthly inspections. Idle magnets that haven’t been used for 1–12 months must be inspected before returning to service.

These classes mirror OSHA’s approach to crane inspections: frequent checks (daily to monthly) and periodic checks (one to twelve months) depending on usage intensity. Even though OSHA’s regulations apply directly to cranes, the agency stresses that similar principles should be applied to any lifting device. Tailoring inspection intervals to service severity is therefore equally relevant for permanent magnets.

What to Inspect Every Time

At the start of each shift or before any lift, operators should verify that the magnet works as intended. Leading manufacturers outline the following points in their safety guides and operation manuals:

• OFF Position Holding Force:The magnet should have zero attractive force when switched off, and no metal should cling to its bottom face.
• Bottom Surface Condition:The pole faces should be smooth, clean, and free of deep scratches or dents. Contamination or roughness reduces holding force.
• Hoist Ring Integrity:The top ring must be free of cracks or thinning.
• Handle and Safety Latch Operation:The lever should rotate smoothly and lock firmly; a sticky or loose latch signals internal wear.
• General Deformation or Corrosion:Look for cracks, corrosion, or missing labels anywhere on the magnet.

If the magnet fails any of these checks, it must be removed from service until repaired. Inspection records should be maintained, and magnets should not resume work until all issues are resolved.

Frequent and Periodic Inspection Checklists

During frequent and periodic inspections, a qualified person should examine the magnet more thoroughly. ASME B30.20 recommends checking the following:

• Magnet Face and Load Surface:Ensure both surfaces are clean and smooth to maximize magnetic contact.
• Control Mechanism:Confirm that the handle, safety latch, and any indicators or meters operate correctly and without sticking.
• Structural Integrity:Inspect all parts for deformation, cracks, wear, corrosion, and unauthorized modifications. Pay particular attention to fasteners, welds, and suspension hardware.
• Identification and Labels:Ensure the magnet’s capacity label is legible and that safety warnings remain intact.

For magnets not used regularly, ASME requires inspections before the magnet is returned to service. If the magnet has been idle for one month to a year, perform a frequent inspection; if idle for over a year, perform a periodic inspection. Any repairs must be tested and approved by a qualified person before the magnet is used again. OSHA’s construction regulations echo this approach, requiring documented inspections before equipment that has been idle for extended periods returns to service.

Legal Requirements and Industry Standards

In the United Kingdom, the Health and Safety Executive (HSE) mandates thorough examinations and inspections under the Lifting Operations and Lifting Equipment Regulations (LOLER). Lifting equipment must be thoroughly examined at least once a year, and its accessories, such as detachable magnets, must be inspected at least every six months. Equipment must be clearly marked with its safe working load and maintained in a safe, efficient condition. The HSE’s guidance notes that failing to schedule these examinations could result in enforcement actions or legal liability.

Why Inspection Frequency Matters

Determining inspection frequency depends on how often and how severely the magnet is used. A magnet lifting thick steel plates in a fabrication shop may need monthly documented inspections, whereas one used occasionally in light service may need only annual checks. Failing to tailor your schedule to usage can lead to unforeseen deterioration.

• Protect Workers and Equipment:Inspecting for cracks, wear, and malfunction prevents dropped loads and injuries.
• Ensure Compliance:Following ASME and HSE guidelines helps demonstrate due diligence during audits or incident investigations.
• Extend Service Life:Early detection of wear allows for timely maintenance, reducing replacement costs and downtime.

Tailored Inspection Plans Keep Magnets Safe

Permanent lifting magnets remain one of the safest ways to move steel, provided you respect their limitations and inspect them properly. ASME B30.20 and OSHA guidelines provide a framework—everylift checks, frequent inspections, and periodic documented inspections—but your actual schedule should reflect how often and how hard your magnets work. A magnet used daily under heavy loads needs more frequent attention than one that sees occasional light duty. Regular cleaning, mechanical checks, and documented inspections not only reduce risk and keep you compliant with HSE and LOLER requirements but also extend the life of your equipment. If you’re uncertain how to tailor an inspection plan, Permadur can help you assess your usage patterns, train your staff, and perform load testing. A proactive inspection program protects your people, preserves your gear, and keeps your operation running smoothly.