Certification of Lifting Devices and Equipment

Black Square Engineering have a history of designing and certifying all sort of lifting
gear, to a wide range of Australian and International Standards including;
 Swivels
 Bull horns
 Spreader bars and lifting beams
 Pad eyes and lifting lugs
 Jibs
 C Hooks
 Lifting frames
 Man baskets
 Equipment baskets
 Lifting skids and supports
 Strong backs
 AS 4991 - 2004 Lifting devices
 ISO 17096 - 2015 Cranes - Safety - Load lifting attachments
 AS 1418.1 - 2002 Cranes, Hoists and Winches - General Requirements (and
others in this set)
 AS 2318 - 2006 Swivels for lifting applications
  API 8C Ed. 5 (2012) Drilling and production lifting equipment (PSL 1 & PSL
2)
 Machinery Directive 2006/42/EC
In this post we will talk specifically about AS 4991 - lifting devices as it is one of the
standards we use most commonly. AS 4991 - lifting devices (Section 12) gives 2
methods to certify lifting equipment as detailed below:

Proof Load Testing

This method utilises a variable scale:
1. Up to a 10 t Working Load Limit (WLL) is a 2x WLL (0 - 20t)
2. From 10t to 160 t a test of 1.04 x WLL + 9.6 (20 – 176 t)
3. Above 160 t requires a 1.1 x WLL (176 t + )

To pass the test each device must hold the load for at least 1 minute and must not have
any permanent set deflection exceeding 0.25% and all testing needs to complete as per
AS 17025 General requirements for the competence of testing and calibration
laboratories.
Following the proof test the lifting device is to receive adequate Non-Destructive
Examination and Testing (NDE AKA. NDT) to check for evidence of flaws or
defects.
Due to the potential cost and safety implications if a proof test fails, its recommended
that lifting equipment is theoretically analysis before proof testing to identify any
potential design flaws. However, this analysis can be a lot less rigorous then that be
carried out if performing certification by engineering analysis (the second method).
Engineering Analysis
The second method is certification by engineering analysis. This method requires that
the design undergoes analysis and certification by a third party and that the
manufactured lifting device is subject to a test regime that includes:
 Material identification
 NDE of welds, Castings and other potential points of failure (as specified by
the designer or Competent person)
Some specialised equipment may still require reduced proof load tests or alternative
testing to prove the lifting device is fit for service.
Which Method of Lifting Equipment Certification is Best?
The best method of certification really depends on your specific requirements for
example:
 Is it’s a one of device or something that will be serially manufactured? Serially
manufactured equipment generally asks for a more optimised design to bring
down production costs, leading to certification by design to be the preferred
method.
 What is the size, WLL and type of equipment it is designed to lift? How
accessible is suitable test equipment? Lifting devices designed to lift large,
awkward or heavy equipment may require specialised equipment to be
developed or procured to complete testing which can significantly increase the
cost.
 Is it an existing lifting device that has been in service for some time without
material traceability or design documentation? Old or existing equipment
without design of manufacturing documentation is generally easier to certify
via testing. Removing the need for reverse engineering and material testing.
 How complex are the restraint mechanisms used; is friction, magnetic or
vacuum gripping used? These mechanisms may still require type testing or
proof load testing if certifying by engineering analysis.
 Is the lifting equipment going to be subject to a high number of load cycles?
Proof load testing doesn’t take into account failure by fatigue so should not be
used where fatigue may be an issue.
Recently, we were approached by a client that operates an aging production plant. It
had come to their attention that that they had a number (approx. 20) of small lifting
 beams, frames and attachments around their plant that did not have any certification.
The lifting devices where used for several different applications from holding bulky
bags to positioning specialised equipment and ranged in WLL from 1 to 5 t.
As there was no design or manufacture documentation available for the lifting devices
it was decided that proof load testing would be the best way to certify them. All the
lifting equipment was proof tested by our engineer at the clients site using BSQE’s
Load cells and equipment already available on site, allowing all the lifting equipment
to be certified quickly with minimal interruption to production.
If you require any assistance certifying your lifting equipment via either method don’t
hesitate to contact Black Square Engineering on 07 3188 0455 for our Brisbane based
office or 07 4548 0686 for our Toowoomba office.
All our works meet the Professional Engineers Act (RPEQ) and we have access to and
utilise the best engineering tools to find the best solution for your problem including;
 First principles engineering analysis
 Finite Element Analysis (FEA)
 Load cells (up to 200T)
 Tensile Test Machines (up to 200t)
 A variety of test weights
 Accelerometers and data recorders
Note: The Information summarised in this article is to be used as a guide only. Please
refer to the relevant standards for exact requirements.
#Liftinggear #Certification #liftingbeam #padeye #liftinglug #AS4991
#Liftingequipment #prooftesting
 Lifting Equipment
 •
 Engineering
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