2 Load Testing

2.1 General
2.1.1 Lifting appliance shall be load tested after it has been installed at its operational
location:
— Before being taken into use the first time
— After any substantial alteration or renewal, or after repair of any stress bearing part
— At least once in every five years (preferably at regular five-yearly intervals after the
data on which the appliance was first taken into use).

Above requirements are in compliance with international and national regulations.

2.1.2 Every item of loose gear shall be load tested:

— Before being taken into use first time
— After substantial alteration or renewal
— After repair of any stress bearing part.

2.2 Test weights

2.2.1 Movable, certified weights shall be used by initial load-testing and by all load-testing
where SWL exceeds 15 tonnes.
2.2.2 A mechanical or hydraulic precision dynamometer may be used:
— In cases of periodical retesting and after repair/renewal of mechanical parts of lifting
appliances with SWL ≤15 tonnes.
— In cases where a test that follows repair/renewal of a structural part is carried out.

The accuracy of the dynamometer shall be within +2 per cent and the indicated load of
such dynamometers under test load shall remain constant for approximately 5 minutes.

2.2.3 Test equipment used for the testing of loose gear, either assembled units or
components of loose gear, is to have been checked for accuracy (calibrated) at least once
during the 12 months preceding the test.

2.3 Test loads

2.3.1 The test load applied to a lifting appliance shall exceed the safe working load (SWL)
of the appliance as fallows:
2.3.2 For hydraulic cranes where, due to limitation of hydraulic oil pressure by the safety
valve, it is not possible to lift a test load in accordance with Table 12-1, it will suffice to lift
the greatest possible load.
Generally this should not be less than 10 per cent in excess of the SWL.
2.3.3 The test load applied to a cargo or pulley block and to loose gear shall exceed the
safe working load (SWL) of the block and gear as follows:

2.3.4 Built-in sheaves and other items permanently attached to the lifting appliance are
not considered loose gear. The test of the lifting appliance “as rigged” will be accepted as
the load test of these items.
2.3.5 Where hand-operated blocks are used with pitched chains and permanently
attached rings, hooks, shackles or swivels, the hand-operated blocks, the pitched chains
and the permanently attached rings, hooks, shackles and swivels shall be tested with a
test load 50% in excess of the safe working load.
2.4 Examination after testing
2.4.1 After testing, the lifting appliance including gear accessories are to be examined
thoroughly to observe whether any part has been damaged or permanently deformed by
the test. Dismantling and/or non-destructive testing may be required if deemed necessary
by the surveyor. The above also applies to blocks and loose gear.
2.4.2 Any overload protection system and automatic safe load indicators that may have
been disconnected during load testing shall be reconnected. Accordingly safety valves
and/or electrical circuit-breakers shall be adjusted. Set points shall be verified and sealed
by the surveyor.

2.5 Certificates
2.5.1 When a lifting appliance or component to a lifting appliance after testing and
examination have been found satisfactory the following certificates (CG forms) shall be
issued (as far as applicable and relevant):
Form No. CG2: Certificate of test and thorough examination of lifting appliances.
Form No. CG3: Certificate of test and thorough examination of loose gear.
Form No. CG4: Certificate of test and thorough examination of wire rope.
2.5.2 As final documentation (certificate) for a lifting appliance installed and to be taken
into use for the first time, Form No. CG1 Register of Lifting Appliances and Items of Loose
Gear shall be presented. See also App.F.
Guidance note:
The Forms Nos. CG2, CG3 and CG4 shall be attached to Form No. CG 1 in completed
order.
2.6 Procedure for load testing of a lifting appliance
2.6.1 Before load testing, the surveyor shall ensure that:
— support of the lifting appliance is acceptable
— for a ship or other vessel, necessary pre-cautions with respect to stability, ballasting or
similar conditions have been taken
— for a mobile crane, the crane has a sufficient margin of stability against overturning
— required test certificates for blocks and loose gear are available and acceptable
— for a new installation, design approval and survey during fabrication of the lifting
appliance are documented.

2.6.2 A written test programme acceptable to the surveyor should preferably be available.
2.6.3 The test weights shall be lifted by the lifting machinery used for the regular handling
of loads. Testing a lifting appliance driven by electrical motor(s) the regular electrical
supply shall be used. For ships, electrical shore connection is acceptable when the power
is distributed through the ship's main switchboard and distribution panels.
2.6.4 For cranes, the test load is to be hoisted, slewed and luffed at slow speed. Gantry
and travelling cranes together with their trolleys, where appropriate, shall be traversed
and travelled over the full length of their track.
2.6.5 For variable load-radius cranes, the tests are generally to be carried out with the
appropriate test load at maximum, minimum and at an intermediate radius.
2.6.6 Additional winch testing for subsea cranes, see Sec.7 [4].