Testing and Certifying of Lifting Equipment and Gears
Testing and Certifying of Lifting Equipment and Gears
Testing and Certifying of Lifting Equipment and Gears
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<strong>Testing</strong> & Certification <strong>of</strong><br />
<strong>Lifting</strong> <strong>Equipment</strong> <strong>and</strong><br />
<strong>Gears</strong>
WHY DO WE TEST & CERTIFY<br />
<strong>Lifting</strong> <strong>Equipment</strong> & <strong>Gears</strong>?<br />
To prove the equipment is <strong>of</strong><br />
adequate strength, sound material,<br />
good construction <strong>and</strong> suitable for<br />
the duty which it has to perform <strong>and</strong><br />
ultimately it is safe to use.
What is “<strong>Lifting</strong> <strong>Equipment</strong>”<br />
LIFTING APPLIANCES (<strong>Lifting</strong> <strong>Equipment</strong>)<br />
Any mechanical device capable <strong>of</strong> raising or lowering<br />
a load:-<br />
Cranes, Forklift Trucks, Lifts, Suspended Cradles,<br />
Powered Hoists, Manual Hoists, Lever Hoists, Rope<br />
Hoists Beam Trolleys Beam Clamps, Sheave Blocks,<br />
Winches, Runway Beams.
What are “<strong>Lifting</strong> <strong>Gears</strong>”<br />
Any device whatsoever which is<br />
used or designed to be used<br />
directly or indirectly to connect<br />
a load to a lifting appliance <strong>and</strong><br />
which does not form part <strong>of</strong> the<br />
load :-<br />
Wire Ropes Slings, Chain Slings,<br />
Man made fibre slings, Hooks<br />
<strong>and</strong> fittings, Swivels, Shackles,<br />
Eye Bolts, Rigging Screws,<br />
Wedge Sockets, Plate Clamps.
INSPECTION<br />
Examination <strong>of</strong> a product, design, service, process or<br />
plant, <strong>and</strong> determination <strong>of</strong> their conformity with specific<br />
requirements or, on the basis <strong>of</strong> pr<strong>of</strong>essional judgment,<br />
general requirement.<br />
Inspection -“conformity evaluation by observation<br />
<strong>and</strong> judgement accompanied as appropriate by<br />
measurement, testing or gauging”.<br />
Source: BS EN ISO/IEC 17020:2004 (General criteria for the operation <strong>of</strong> various types <strong>of</strong> bodies performing inspection)
EXAMINATION<br />
An examination is a detailed inspection or analysis <strong>of</strong> the<br />
equipment or item.
COMPETENT PERSON<br />
A person who has the practical <strong>and</strong> theoretical knowledge<br />
<strong>and</strong> experience <strong>of</strong> the lifting <strong>Equipment</strong> to be thoroughly<br />
examined which enables them to detect defects or<br />
weaknesses <strong>and</strong> to assess their importance in relation to<br />
the safety <strong>and</strong> continued use <strong>of</strong> the lifting equipment.
TEST CERTIFICATE<br />
A test certificate is a document issued by a Competent<br />
Person giving details <strong>of</strong> the test or tests <strong>and</strong> thorough<br />
examination conducted on each item <strong>of</strong> lifting equipment<br />
to certify its fitness for safe use.<br />
The test certificate must be retained for inspection when<br />
required.
Ministerial Order No. 32 for the Year<br />
1982, Article 20 Legislation-An Overview<br />
<strong>Lifting</strong> <strong>Equipment</strong> Inspection <strong>and</strong> the UAE Law<br />
In accordance with UAE Ministerial Order No. 32 for the year<br />
1982, it is to be noted that:-<br />
a) Cranes <strong>and</strong> lifts for men <strong>and</strong> materials shall be <strong>of</strong> sound<br />
construction <strong>and</strong> manufacture, regularly maintained <strong>and</strong><br />
checked by a qualified technician at least once every 12 months.<br />
b) The area where lifts are fitted shall be fenced in such a way as to<br />
prevent access or egress whilst moving. Doors should not be<br />
able to be opened whilst in motion.<br />
Source: Ministerial Order No. [32] for the Year 1982, Article 20
Ministerial Order No. 32 for the Year<br />
1982, Article 20 Legislation-An Overview<br />
c) Chains, ropes, wire ropes <strong>and</strong> other lifting equipment shall be<br />
continuously <strong>and</strong> completely maintained <strong>and</strong> checked by a<br />
competent technician at least once every 6 months.<br />
d) The maximum capacity <strong>of</strong> machine or lift shall be displayed in<br />
a prominent position.<br />
d) An employee may not be asked to carry loades above his<br />
capacity, <strong>and</strong> in any case no load shall exceed 50kg per man<br />
<strong>and</strong> 20kg per woman, <strong>and</strong> where possible mechanical lifting<br />
equipment shall be used.<br />
Source: Ministerial Order No. [32] for the Year 1982, Article 20
<strong>Lifting</strong> <strong>Equipment</strong> <strong>and</strong> the UK Law<br />
The main regulations for the use <strong>of</strong> <strong>Lifting</strong> <strong>Equipment</strong> are:-<br />
� The Provision <strong>and</strong> Use <strong>of</strong> Work <strong>Equipment</strong> Regulations 1998<br />
( PUWER) <strong>and</strong>.<br />
� The <strong>Lifting</strong> Operations <strong>and</strong> <strong>Lifting</strong> <strong>Equipment</strong> Regulations 1998<br />
( LOLER).<br />
Both are accompanied by approved codes <strong>of</strong> practice (AcoPs) <strong>and</strong> guidance<br />
eg The Code <strong>of</strong> Practice for the Safe Use <strong>of</strong> Cranes BS 7121 Series.<br />
PUWER applies to:-<br />
All equipment provided for use at work <strong>and</strong><br />
LOLER is:-<br />
Additional for lifting equipment.<br />
Therefore for lifting equipment, both sets <strong>of</strong> regulations apply.<br />
The above regulations are ‘risk based’ <strong>and</strong> ‘goal setting’ <strong>and</strong> generally apply<br />
across all industries.
LIFTING EQUIPMENT<br />
INSPECTION (EXAMINATION) AND<br />
TESTING OF A MOBILE CRANE
Examination consists <strong>of</strong> 3 Stages<br />
1. Examination <strong>of</strong> Documents to ensure certification (Wire ropes,<br />
Hook blocks etc).<br />
2. Carry out pre-examination operation test (All limits <strong>and</strong> safety<br />
devices).<br />
3. A thorough examination <strong>of</strong> critical components (Engine(s), Torque<br />
converter (s), Brakes <strong>and</strong>/or clutches, hydraulics if applicable, Boom,<br />
Jib if applicable, Slew (Swing) Motions, Slew Bearing, all controls,<br />
safety devices <strong>and</strong> monitoring equipment (SLI).
Guidelines used for Inspection<br />
British st<strong>and</strong>ards BS 7121 Part 2: 2003<br />
Components to be inspected will vary from crane to<br />
crane <strong>and</strong> the manufacturer’s specification
Pro<strong>of</strong> Load <strong>Testing</strong><br />
Vary from manufacture to manufacture<br />
<strong>and</strong><br />
Even model to model<br />
Always refer to, if possible, to the manufacturer’s<br />
Duty listing <strong>and</strong> Stability chart.<br />
If this is not available,<br />
Check the Last Test Certificate
Pro<strong>of</strong> Load <strong>Testing</strong><br />
Always refer to, if possible, to the manufacturer’s<br />
Duty listing <strong>and</strong> Stability chart.<br />
If this is not available,<br />
Check the Last Test Certificate
Pro<strong>of</strong> Load <strong>Testing</strong><br />
But further is testing the crane……<br />
For all the forces<br />
that it will be subjected to<br />
in<br />
normal service.
Mobile, Truck & Crawler Cranes have….<br />
Large Variety <strong>of</strong>:<br />
1. Support Systems.<br />
2. Boom.<br />
3. Jib Configurations.<br />
4. Counterweight.<br />
5. Special Attachments.
Examples are:<br />
(Crawler Tracks, Outriggers & Counterweights)
Examples are:<br />
(Jib Booms, Fly Jibs & Leveling)<br />
4.Jib Booms<br />
Jibs <strong>of</strong> different<br />
duties<br />
Check manufactures<br />
manual & load charts.
Examples are:<br />
(<strong>Lifting</strong> on Tires & <strong>Lifting</strong> Capacities)<br />
7.<strong>Lifting</strong> on Tires<br />
Air pressure is a<br />
critical factor / Size &<br />
Type <strong>of</strong> tires<br />
Check manual & load<br />
charts for any<br />
restrictions.
Visual Examination<br />
Prior to carrying out the pro<strong>of</strong> load test<br />
A Visual Inspection<br />
shall be carried out<br />
to ensure that a crane is in a fit condition to test.
Pro<strong>of</strong> load Test<br />
To be carried out on a:<br />
1. Flat stable surface.<br />
2. Sufficient strength to carry loads.<br />
3. Free <strong>of</strong> Obstruction.<br />
4. Sufficient area for safe crane movements.<br />
5. All jacks/Outriggers – Set as per manufacturers instructions.
As per BS 7121 Part 2 2003<br />
Mobile & Crawler Cranes shall be tested at:<br />
Shall be tested at 3 different radii,<br />
And with three different configurations for<br />
safe working load <strong>and</strong> pro<strong>of</strong> load<br />
3
Safe Load Indicators<br />
Most Mobile, Truck or Crawler Cranes are:<br />
Fitted with some form <strong>of</strong><br />
Safe Load Indicators<br />
In some cases – Automatically cut <strong>of</strong>f – Before an<br />
overload is achieved<br />
In this case –<br />
Load Indicator have to be<br />
overridden – to complete the test<br />
Very Important : Reconnect immediately on<br />
completion <strong>of</strong> Load testing
Post Test Thorough Examination<br />
On Completion <strong>of</strong> a test:<br />
1. Further thorough examination shall be carried out – To ensure<br />
equipment has withstood testing without deformation.<br />
2. Any operation devices should be reset <strong>and</strong> their operation<br />
verified.
Issuance <strong>of</strong> Test Certificate<br />
When the procedures above have been<br />
satisfactorily completed,<br />
the Inspector will issue<br />
the Appropriate Test Certificate.
Issuance <strong>of</strong> Test Certificate
Thank You…
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