Introduction
For Canadian businesses utilizing overhead cranes, compliance with load testing standards is crucial to maintaining safety, reducing downtime, and avoiding costly breakdowns. This guide covers the essential aspects of load testing, including CSA B167-16 and ASME standards, best practices for conducting load tests, and an example of manufacturer-specific requirements for equipment such as the R&M SX Hoists and Condra Hoists.
Additionally, Venter Cranes is the Canadian agent for WaterWeights, a leading solution for safe and effective load testing using water bags. This innovative approach offers precise load verification without the risks associated with solid weights. For more details, visit https://www.ventercranes.com/load-testing
What is Load testing?
Purpose of Load Testing
Load testing is designed to identify mechanical issues, design flaws, or deficiencies in cranes that could lead to unsafe operations. CSA B167-16 Annex I highlights that load testing is essential in ensuring cranes can lift and carry loads safely. However, it is crucial to note that routine load testing is typically reserved for new installations, post-repair, or when recommended by the manufacturer.
Regulatory Standards for Load Testing in Canada
CSA B167-16 Load Testing Requirements
Under CSA B167-16, load testing must be conducted with caution and for specific reasons, such as new or relocated overhead cranes, gantry cranes, monorails, hoists, and jib cranes & after significant repairs or crane modifications. Clause 7.3.3 also requires testing of the crane's motions, holding brakes, and travel brakes with a load of 125% of the rated capacity. The results should be thoroughly documented in the crane's logbook.
ASME B30.2 Guidelines
The ASME B30.2 standards complement the CSA B167-16, particularly emphasizing the need for 125% overload tests to verify all crane mechanisms' structural integrity and performance.
ASME B30.2 Load Testing Requirements
The ASME B30.2 standards provide clear guidelines for the load testing of cranes, specifically addressing new, reinstalled, altered, repaired, or modified cranes:
Section 2-2.1 Inspection outlines that new, reinstalled, altered, repaired, and modified cranes should undergo a load test before being placed into operation. This ensures that any alterations or repairs meet the crane's safety requirements and performance expectations.
ASME B30.2.2005 2-2.2.2 highlights the following:
(a) Cranes that are newly installed or have undergone significant repairs or modifications must be load tested under the supervision of a qualified person.
(b) For repaired or altered cranes, the load testing may be limited to the parts of the crane affected by the modification, at the discretion of a qualified inspector.
(c) The replacement of load chains and ropes is exempt from a full load test, but an operational test must still be carried out to verify the hoist’s functionality before resuming use.
(d) If a load test is conducted, it should range between 100% and 125% of the crane's rated capacity, unless otherwise specified by the manufacturer or qualified personnel.
(e) A written report documenting the load test results and procedures must be prepared and filed.
(f) During the test, the following operations should be conducted to ensure safety:
Hoist the test load to ensure the load is fully supported by the crane and hoist brake.
Trolley the load along the full length of the bridge.
Bridge travel with the load from one end of the runway to the other.
Lower the test load, confirming the brakes can safely stop and hold the load.
These requirements are essential to validating the crane's operational safety and mechanical integrity, ensuring it is capable of handling its rated load after any significant work has been done.
Types of Load Testing
Load testing typically involves both static and dynamic tests, as outlined by CSA B167-16 and ASME B30.2:
Static Load Test: Ensures the crane can hold its rated and overload capacities without movement.
Dynamic Load Test: Tests the crane’s full range of motion while carrying a load, ensuring all components function properly.
Key Components of a Load Test
Load tests are divided into several stages, each testing different crane functionalities:
Operational Test: A pre-load test conducted with no load to ensure controls and limit switches are functioning properly.
Low Load Test: Conducted at approximately 10% of the rated load to confirm basic operations.
100% Load Test: Verifies the crane can lift and carry its full-rated load.
125% Load Test: Overload test to ensure the structural integrity of the crane.
Each stage must be documented, and deficiencies must be corrected before proceeding to the next test.
An Example of Manufacturer-Specific Requirements: R&M Hoists and Condra Hoists
In addition to following the guidelines of CSA B167-16 and ASME B30.2, it is critical to adhere to manufacturer-specific requirements for hoist maintenance and load testing. Both R&M Hoists and Condra Hoists offer detailed instructions for maintaining and inspecting their equipment.
R&M Hoists: The SX Hoist includes specific requirements such as regular inspections of the braking system, drum, and wire rope. Additionally, an annual overload protection test must be performed to ensure the proper functioning of the hoist's safety mechanisms.
Condra Hoists: Maintenance instructions for Condra hoists highlight regular brake adjustments for wear, checking gearboxes for oil levels and leaks, and thorough inspections of the wire rope and drum. Condra requires that the brake lining be replaced when it wears down to 5 mm, with frequent lubrication of moving parts to avoid operational failure.
Adhering to these specific manufacturer requirements, alongside general inspection and testing guidelines, ensures both the safety and longevity of the equipment.
Qualified Personnel for Load Testing
According to CSA B167-16, load tests must be performed by qualified personnel with a minimum of 8,000 hours of experience in crane maintenance and inspection. At Venter Cranes, all our inspectors meet these qualifications, ensuring that load tests are carried out in compliance with both CSA standards and manufacturer-specific requirements.
Documentation and Compliance
Under Clause 7.3.4 of CSA B167-16, load testing results must be thoroughly documented and stored in the crane's logbook. This documentation not only ensures compliance but also provides a historical record that can be reviewed during future inspections or audits.
What are WATER WEIGHTS®
The use of WATER WEIGHTS® water filled proof load bags for proof load testing is recognized worldwide as the sensible and safest solution.
Our bags offer the simplest and most cost-effective means of load testing any lifting equipment or load-bearing structure.
We supply a comprehensive range of bags with capacities from 1 to 110 metric tons. Combining bags and specially designed beams allow for very large capacity tests.
They were safer, more flexible, and—since the bags themselves weigh only 2% of the total achievable load when filled—infinitely easier and more economical to ship, handle, and store. They are also environmentally responsible.
Turnkey or equipment rental, contact us for more information.
Conclusion
Load testing is critical to crane safety and maintenance. It is designed to prevent failures and ensure overhead cranes can operate efficiently under load. Venter Cranes offers comprehensive load testing services, ensuring that every crane we test complies with CSA B167-16, ASME B30.2, and manufacturer-specific guidelines.
As the Canadian agent for WaterWeights, we offer cutting-edge solutions for accurate load testing. Our expert team provides detailed inspection reports to communicate any issues or potential problems clearly and promptly.
For more information on load testing services or to schedule a test, visit https://www.ventercranes.com/load-testing or contact us directly at (306) 380-8725
About the Author:
Bradley Sliedrecht is the Operations Manager at Venter Cranes and has over 30 years of experience as an Overhead Crane Technician. He is a certified OHC trainer, qualified electrician, journeyman millwright, CWB welding supervisor, trained water weight technician, and rigging inspector. Bradley holds both a Bachelor's and a Master's degree. He brings a wealth of knowledge and hands-on expertise to the industry. His commitment to safety and high standards in crane maintenance has made him a trusted professional in his field.
For additional information on how we can work together to improve the safety and reliability of your overhead crane systems, please feel free to contact our operations manager directly at brad@ventercranes.com or 1 (306) 380-8725.
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