TUV SOUTH WEST

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PROCEDURE FOR INSPECTION AND

CERTIFICATION OF

OVER HEAD CRANES

Prepared By: Naresh Kumar

Reviewed By: Hamza

Authorized By: Waqas Arshad

Procedure Ref #.: SW/TIP-OHC/001 Rev.05 Issue Date:25/04/2022

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I. Objective

To define and outline the responsibilities, sequence and procedural requirements for
Overhead Crane Inspection in accordance with International Standards mentioned
below.

II. Scope:
This procedure covers all Inspection bodies in all areas.

III. Duties / Responsibilities:

 The Inspector assigned for the job has to be a competent person with sufficient
experience and knowledge in the inspection/ test of lifting equipment.
 Lifting head is responsible for the review of this Procedure.
 Lifting head is responsible for the preparation and revision of this procedure.
 The dept manager is responsible for the review of the procedure and General
Manager is responsible for the Approval.

IV. Relevant Standards and Code of Practice

Sr. No Applicable Standards Title Identifier
1 BS 7121: 2016 Code of Practice for the Safe Use of Cranes - General
Code of practice for the safe use of cranes Inspection,
2 BS 7121-2-1:2012
maintenance and thorough examination. (General )
Code of practice for the safe use of cranes, Inspection,
3 BS 7121-2-7:2012+A2:2022 maintenance and thorough examination. Bridge and Gantry
Cranes, including light crane systems
4 BS 7262 :1990 Specification for Safe Load Indicators
Rules for the design of cranes. Specification for classification,
5 BS 2853:2011
stress calculations and design of mechanisms
Cranes. General design. Limit states and proof of competence
6 BS EN 13001-3-2:2014
of wire ropes in reeving systems
Cranes. General design. Limit states and proof of competence
7 BS EN 13001-3-3:2014
of wheel/rail contacts
8 BS EN 13001-2:2014 Crane safety. General design. Load actions
9 BS EN 13001-1:2015 Cranes. General design. General principles and requirements
Cranes. General Design. Limit States and proof competence
10 BS EN 13001-3-1:2012+A1:2013
of steel structure
UAE. Federal Ministry of Law Federal Ministry of Law and Social Affairs, 10.1.83 - M.O. No:
11
10.1.83 32 – Article 20
Cranes — Wire ropes — Care and maintenance, inspection
12 ISO 4309:2017
and discard
13 ASME B30.2 Overhead & Gantry Cranes

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14 Regulation CS-4.0 Chapter 21 Code of Constructions Safety Practice

15 Trakhees Regulation IO-11 EHS Lifting Equipment Protocol

OSHAD Code of Practice 34 v3.0-
16 Safe Use of Lifting Equipment and Lifting Accessories
2016
Note:
1. Also, considerations and reference to the standard /code to which the equipment has been built has
to be given due attention.
2. Related reference standard may also be referred during inspection / test.
3. In addition to requirements stipulated in this document, Project site/ Client specific requirements are
applied and shall be followed all the time.

V. Overview of the Procedure for Thorough Examination:

Subsequent to client request, the unit has to be thoroughly examined visually
for all its sections i.e. hooks, wire ropes, supporting structures, winches, control
panel, safe load indicator/over load cut off device. Then test the Crane functionally
prior to any loading. Apply applicable codes/standards to evaluate any
discontinuities either as Satisfactory OR Unsatisfactory with any part or function.

Also inspect the Ground should be well consolidated and capable of

withstanding the loads that will be applied on it. Confirm with the client if there are
any doubt

This ensures that there are no visible discontinuity/s that may be detrimental
during a lift later.

VI. The Documents to be reviewed prior to examination are:

 Record of Pre use & in-services check lists
- Information on type and model of equipment
- Any identification mark or number
- Its normal location
- Date and time of that inspection was carried out
- Who carried out the inspection
- Any faults
- Any action taken
- To whom the faults have been reported
- The date when repairs or other necessary action were
carried out
 Previous Reports of thorough examination
 Wire rope certificate, (if replaced)
 Safe Working Load clearly marked on the crane and duty charts fixed
to it
 Lifting attachments marked with their safe working load
 Individual Certifications of personnel involved
 Maintenance records
 Prior to performing any tests loads, the manufacturer’s instructions
should be obtained or alternatively, a referenced authority on the
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design and construction of the crane. The said Information should be

consulted, understood and implementation prior to test load

VII. Procedure Instructions:

A. Site Conditions
1. Ground should be well consolidated and capable of withstanding the loads that
will be applied on it. Confirm with the client if there are any doubt
2. Make a general observation to ensure that there are no dangers such as cable
ducts, drains, backed filled areas, power lines etc.,
3. Test should not be performed over any high risk areas e.g. public highway,
occupied building where people are working within the vicinity.
4. It should be remembered that test are performed to ensure cranes can withstand
the desired loading. A crane can fail under at any time, so remember, all -
essential personnel should be removed from the area and the crane inspector
should stand in a position where he is unlikely to be injured in the event of
tipping or structural.
5. Fire extinguisher & first aid box should be nearby.

B. Toolbox Meeting & General Risk Assessment

Before proceeding in any kind of job, test or inspection, a Toolbox Meeting should
be conducted that focuses on safety topics related to the specific job, such as
workplace hazards and safe work practices.

C. Test weights

Test weights used should be:

 Weights of proven accuracy to within ± 2%
 Weights proven on weighbridge, valid 12 months calibration certificate
required.
 Weights suspended from calibrated weighing device, 12 month calibration
certificate required.

D. Preparation of PPE & Tools:

The inspector should ensure that:

 Personal safety equipment that is appropriate for the conditions of the
location is available, such as helmets, safety spectacles, fall protection
equipment, safety boots, ear defenders and life jackets or other buoyancy
aids;
 Equipment is inspected before and after use and maintained in good working
order
 Ensure all the equipment used during inspection/test i.e caliper, Spirit Level,
measuring tape, Load cell etc shall be in good condition and shall be
certified where ever applicable.

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E. Thorough Examination:

Prior to the test, it should be observed with the crane in motion and at rest that the
crane is:
 Free from any defect that would prevent safe handling of the test load
 Within the correct configuration as per manufacturer’s instruction.
 Equipped with sufficient falls of rope for the load to be lifted.
 The inspector should be in any doubt and considers it necessary, the test
and examination should be supplemented by the following:
 Methods of non-destructive testing that determine the condition of any part of
the crane without causing any detrimental change to the material.
 The opening up of any encased parts of the machine or equipment by a
skilled person to the extent required by the inspector.
 Lifting gear should be thoroughly examined before the test and the inspector
conducting the test should satisfy himself that the slinging and rigging
arrangements are safe.
 Uncertified lifting gear should not be use.
 The weight of the lifting gear should be included as part of the test load.
 On completion of the test, an examination should be carried out by the
inspector to verify that the crane withstood the test loading without signs of
structural damage that may affect the safety of the crane, namely: Cracking
o Permanent deformation
o Paint flaking (structural deflection has occurred)
o Loosening of or damage to structural connections
o Mechanisms functions correctly and are free from defect.

F. Insulation tests:

 Before connection of power supply, the insulation of electric system should

be test using a dc voltage of not less than twice the rated voltage of the
system. All phases should be checked for each crane motion or system.
 The insulation resistance should be not less than 0.5MΩ (ohm). If necessary
it is permissible to disconnect individual item to prevent the damage while
make the test.
 If the reading is less than 0.5MΩ (ohm). The system under test can be
subdivided and each subdivision should show a reading of not less than
0.5MΩ (ohm).

Earth continuity: At no point should the reading be greater than 0.5 Ω (ohm).

Note: - the client should arrange a professional electrician to perform

insulation & earth continuity tests. TUV SW’s appointed technical personnel
(inspector) should be present during the tests.

G. Functional tests:

 The crane should be test for correct operation of all controls, switches,
contactors, relays and other devices.
 The function and correct adjustment of Breaks limit switches and overload
protection devices.

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 Each motion of the crane should be checked throughout its range of

operation.

H. Test at rated capacity:

 After the functional tests, the crane should be tested with a load equivalent to
the rated capacity. At the start of the test, the crane should be positioned
over a supporting stanchion or column of the gantry or beneath the
connection point of a suspended track, as appropriate, with the crab or hoist
positioned adjacent to the end carriage. With the crane in this position,
provision should be made for measuring the deflection of the crane main
girders at the centre span.
 The load should then be raised until each tooth of the train of gears has
been subjected to the load, then the load should be lowered to between 100
mm to 200 mm above the ground. The load should be held in this position for
10 min to check the brake. The load should then be raised from the
suspended position by a further 200 mm to check the ability to re-hoist and
then lowered to between100 mm to 200 mm above the ground.
 The crab should be traversed to mid-span and the deflection measured and
recorded. The load should be lowered to the ground to relieve the structure
and then raised to determine whether the deflection remains constant.
 The load should be traversed to the opposite gantry, and the crane should
be travelled along the track until each tooth of the train of gears of the long
travel motion has been subjected to the load. The load should be traversed
across the bridge to the opposite side of the supporting structure and the
crane should be returned to its original lift position.
 The deflection of the main bridge with the crab and load at the centre of the
bridge should not exceed the maximum deflection permitted in the standard
to which the crane was manufactured
 The measure deflection should be recorded and compared to the
calculated design value. Conformance within 10% or 5mm, whichever
greater, is considered acceptable. The measured value should be retained
in the machine history file to provide a baseline for comparison with any
future measurements
Crane manufactured to BS 466:1984 have a maximum deflection of 1/750 of
the span.
Crane manufactied to BS 466:1960 have a maximum deflection of 1/500 of
the span.

I. Testing of cranes and supporting structures:

 All cranes and supporting structures should be overload tested before first
use. In some circumstances it might be necessary to treat them as separate
entities, for example where a structure supports more than one crane.
 The extent of the testing should be clearly stated in the test report. Cranes
and supporting structures should be overload tested after major repairs or
modifications.

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 The deflection measurement should be repeated for each span along the
complete length of the structure. The procedure should be repeated for the
other side of the structure.
 For structures built in accordance with BS 449-2 the maximum deflection
should not exceed1/360 of the span. For structures built in accordance with
BS 5950-1 or BS EN 1993-6, the maximum deflection should not exceed
1/600 of the span.

J. Over load test:

 The load should then be increased to at least 110% of rated capacity. The
test load should include repeated starting and stopping of each motion,
including all combined movements as provided by intended use over the
whole sequence and range of movements. Emergency stop button and
collision with buffers should not tested during this test.
 The load should then lowered to between 100 mm to 200mm above the
ground. The load should be increased to 125% of the rated capacity without
the use of hoist drives, e.g. by external means
 For Cranes built in accordance with BS2573, the load can be lifted to
between 100 mm to 200 mm using the hoist mechanism
 The test should be carried out in the critical trolley positions, such as middle
span, extreme positions of transverse, including any cantilevers. Where
movements are performed during the test, they should made separately; a
new movement should not be initiated until vibrations caused by the
proceeding movements have dampened out
 The test load should be applied for a period necessary to make the
observations and measurements to evaluate the crane.
 During the overload test the crane should remain stable and structurally
sound and the brakes on each motion should function effectively. The
traverse and travel braking systems should also function effectively with the
overload applied.
 During the overload test the crane should be operated at speeds appropriate
to the safe control of the load, for example the lowest speed possible for the
crane.
During load testing, special care shall be taken and load shall be arranged gradual manner

K. Over load test on supporting structures:

 The overload test load on each crane should be that determined and
positioned in accordance with (J. Over load test)
 The load lifted by each crane should be traversed to the end of the crane
bridge nearest the side of the structure being tested. The cranes should be
travelled the full length of the structure in such relative positions as to impose
the maximum combined loading. The procedure should be repeated for the
other side of the structure.

L. Testing of cranes with two or more hoists:

 Where cranes are equipped with more than one hoist mechanism that can
be used separately, they should be tested individually prior to the crane test
unless previously tested by the manufacturer. The crane should be tested
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with the most unfavorable loading combinations of the hoist mechanism in

the specified use

 Inspection According to ASME B30.2

a. in running ropes, 12 randomly distributed broken wires in 1 lay, or 4

broken wires in 1 strand in 1 lay;
b. in rotation-resistant ropes, two randomly distributed broken wires in
six rope diameters, or four randomly distributed broken wires in thirty
rope diameters;
c. one outer wire broken at the contact point with the core of the rope
indicated by an externally protruding wire or loop of loose wires;
d. wear of one-third the original diameter of outside individual wires;
e. kinking, crushing, bird caging, or any other damage resulting in
distortion of the rope structure;
f. evidence of heat damage from any cause;

 Inspection According to BS ISO 4309:2017

a. Broken wires:
o Randomly distributed broken wires: The total number of visible wire
breaks should not exceed 10 % in any length of wire rope of eight
rope diameters.

Note: If the broken wires are localized or all in one strand, the rope should be
discarded before the number of broken wires reaches 10 % in any length of wire rope of
eight rope diameters.

o Localized broken wires in the vicinity of terminations: The wire rope

should be discarded when there are three or more visible broken wires
in the immediate vicinity of terminations.
o Detachable terminations such as a wedge and socket should be
examined for broken wires within and under the terminations.

Note: If the wire rope is shortened so that the broken wires are removed, it may be
considered for re-termination and reuse. Broken wires at or adjacent to the termination,
even if low in number, are indicative of high stresses at this point and can be caused by
incorrect fitting of the termination. The causes of the broken wires should be investigated
before the rope is re-terminated.

b. Wear: Wear of wire ropes can be either general or localized and results
from contact of the wire rope with sheaves, drums or other hard surfaces
or from rope to rope pressure. Wear can be uniform along or around the
rope or only occur along one side of the rope.
o When working over metal sheaves, six-strand and eight-strand rope
should be discarded when the rope diameter at any point is reduced to
90 % of the nominal diameter.
o In the case of rotation-resistant ropes, internal wear or damage is
frequently more critical than external wear and can also be
accompanied by an accumulation of internal debris.

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o If the rope diameter falls to 10 % of the nominal diameter or rises

above 100 % of the nominal diameter, a more detailed examination
should be carried out to ascertain the significance of this change, and
discard might be necessary. The rope should be discarded when the
diameter has reduced to 90 % of the nominal diameter.
c. Localized damage or distortion:
Other forms of damage or distortion that can affect the safe working of
wire ropes are like follows:
o Waviness;
o Basket distortion;
o Strand or core protrusion;
o Wire extrusion;
o Local increase in diameter of rope;
o Bends and kinks;
o Flattened portions;
o Damage due to heat or electric arcing

M. Post-test thorough examination of the crane:

 On completion of the tests, a further thorough examination of the crane

should be carried out by the competent person (see BS 7121-2-1:2012, 8.12)
and any overload protection devices should be reset and their correct
operation checked.

 When the testing and subsequent thorough examination has been

completed, the inspector should issue a report of thorough examination
which should include details of the overload test.

VIII. Certification:

 A test certificate shall be issued as per company procedure that indicates

compliance to appropriate regulations.
 Test certificates should be supported with necessary information to ensure that
there is no doubt as to crane rigging at the time of test.
 Should the inspector consider it necessary to restrict the use of the crane or
equipment, (e.g. site limitations prevent the testing of the full range of duties of the
machine) then the restrictions should be noted on the certificate and the use of the
crane should be subject to these restrictions.
 A notice of these restrictions should be posted in the crane.
 Where the inspector feels it necessary to change the safe working load (SWL), the
markings and tables of the SWL on the machine should be amended to reflect the
restrictions and recorded on the test certificate.

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IX. RECORDS
SN Control Name Retention Period
1 Inspection Report or Certificate of Inspection 3 years
2 Filled-up Inspection Checklist / Rough Reports 1 years

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