UNIT 1.

7 - VERIFICATION OF LIFTING EQUIPMENT

(TESTING AND EXAMINATION)
Contents
Into!"#t$on
1. Pe%&$n' (o &n e)&*$n&t$on
+. Con!"#t$n' &n e)&*$n&t$on
2.1 Chain slings
2.2 Hooks
2.3 Shackles
2.4 Eyebolts
2.5 Wire ropes
2.6 Fabricated ites
2.! "i#ting achines
2.$ %arking or re&arking
,. Test &n! e)&*$n&t$on e-"$%*ent
3.1 'est achines and #orce(load eas)ring e*)ipent
3.2 +iensional eas)ring e*)ipent
3.3 ,on&destr)cti-e test e*)ipent
.. T/%es o( test &n! 01&t t1e/ *$'1t te22 "s
4.1 +iensional -eri#ication
4.2 .perational test
4.3 "ight load test
4.4 SW" and de#lection eas)reent
4.5 /roo# load test
4.6 0reaking load test(ini) breaking load test
4.! Hardness test
4.$ "i*)id penetration crack detection
4.1 %agnetic particle crack detection
4.12 3adiography 45&ray6 crack detection
4.11 Eddy c)rrent crack detection
4.12 7ltrasonic crack detection
4.13 Electroagnetic 8ire rope e9aination
3. A#t$ons (o22o0$n' &n e)&*$n&t$on
1
: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
Into!"#t$on
;ll li#ting e*)ipent )st be -eri#ied=
4a6 to ens)re it is sa#e be#ore #irst )se> and
4b6 periodically once it is in ser-ice to ens)re it reains sa#e to )se.
7ntil the end o# the t8entieth cent)ry> all o# the -ario)s 7? reg)lations> and there#ore
the standards> called #or li#ting e*)ipent to be proo# load tested and e9ained to
ens)re this 8as the case. 'his 8as irrespecti-e o# the logic or need #or s)ch a test.
7sers 8ere then re*)ired to retain the @test certi#icate and e9aination reportsA.
%odern legislation> standards and codes o# practice take a ore sensible approach.
For certain prod)cts> proo# load testing reains -alid. Ho8e-er> #or any coon
ites> this is not the case and other tests are ore eaning#)l.
Standards gi-e the -eri#ication ethods #or ne8 prod)cts> altho)gh it is no longer
necessary #or the )ser to be gi-en the res)lts. For in&ser-ice e*)ipent> "."E3
places the d)ty #or deciding i#> and 8hat> tests are necessary on the @copetent
personA aking a thoro)gh e9aination. Bt re*)ires the details o# any tests ade to
be incl)ded on the e9aination report. ,ote the 8ords @any testA. 'he report needs
to incl)de any #)nctional> light load> non&destr)cti-e tests etc> not C)st a proo# load
test.
'his )nit considers the thoro)gh e9aination> the general re*)ireents #or test
e*)ipent )sed in the e9aination> and the tests a-ailable to the e9ainer.
;s noted in )nit 1.1> "."E3 does not )se the 8ord @testA b)t instead re#ers to a
@thoro)gh e9ainationA. 'he p)rpose o# the e9aination is to deterine i# the ite
being e9ained is sa#e to )se or other8ise. For any ites> the e9aination 8ill be
liited to a #)ll -is)al e9aination. For others it 8ill need to be s)ppleented by any
one o# a n)ber o# tests i# the correct concl)sion is to be reached.
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1. Pe%&$n' (o &n e)&*$n&t$on
Bn all b)t a #e8 cases> li#ting accessories and an)ally operated achines 8ill be
readily accessible #or e9aination. Bn contrast> #or a r)n8ay or crane> the
e9aination )st be ade in sit) and special proced)res are necessary. St)dy is
there#ore con#ined to the ore basic types o# e9aination that can be ade at the
bench or> in soe cases> on the #loor. Ho8e-er> the general principles are the sae
#or all e9ainations.
'he area in 8hich the e9aination is to be ade )st be clean and clear o# any
debris that ay hinder the e9aination or har the ite )nder e9aination. Bt )st
be 8ell lit> either by nat)ral or arti#icial light> and #ree #ro shado8s or tinting> 8hich
ay ipede the -is)al detection o# #a)lts. B# it is necessary to s)spend an ite 4e.g.
chain block6> the s)spension point sho)ld be at the correct height to allo8 rele-ant
parts to be e9ained easily. Bn soe cases> additional lighting s)ch as a pencil
torch or lead light ay be necessary. 'his is partic)larly the case 8ith s)spended
achines.
%ost e9ainations are ade by the naked eye. Ho8e-er> #or soe ites> the )se o#
a agni#ying glass> dental irror or siilar -is)al aid ay be necessary.
'he ite4s6 )nder e9aination )st be clean and #ree #ro r)st> grease> paint etc>
8hich ight obsc)re de#ects. Where ites re*)ire cleaning> an appropriate ethod
sho)ld be )sed 8hich 8ill not har the ite. Bn the case o# coposite ites 4#or
e9aple> a spreader 8ith top and botto slings shackled to the bea6 and
achines> these sho)ld be stripped do8n as ay be necessary #or the e9aination>
prior to cleaning. 'he parts )st be clearly identi#ied and kept together.
E9aples o# cleaning ethods=
0r)shing or 8ire br)shing to reo-e light r)st and debris.
'he )se o# proprietary sol)tions to reo-e stronger r)st
penetrations. Dreat care )st be e9ercised here. %any o# these
prod)cts are acid&based and> 8hilst dil)te acid preparation ay be
)sed on soe ites o# li#ting gear> this is not generally the case. Bn
partic)lar> alloy steels are prone to hydrogen ebrittleent 8hen they
ha-e been in contact 8ith acid or ca)stic conditions.
Shot blasting or r)bling to reo-e scale.
+egreasing to reo-e oils and #ats.
;ltho)gh it is not part o# the copetent personAs d)ty to strip do8n and reb)ild
e*)ipent> in practice the e9ainer ay #ind it is necessary to do this to soe
e9tent. %)ch 8ill depend on the eployer> or the conditions that pre-ail on the site
8here the e9aination is being )ndertaken. 'he re*)ireents 8ill also -ary 8ith the
cople9ity o# the ite4s6 )nder e9aination. ;s part o# the preparation> the
e9ainer sho)ld ens)re that all the necessary tools are to hand.
+iensional checks #or part o# any e9aination. 'he e9ainer sho)ld there#ore
also ha-e all the appropriate eas)ring instr)ents 4e.g. r)le> icroeter etc6 and
ga)ges #or the ites )nder e9aination. For re#erence p)rposes> copies o# the
rele-ant 0ritish or other Standards> dra8ings or 8ork speci#ications sho)ld be
3
: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
a-ailable. Finally> the e9ainer sho)ld ha-e the necessary staps or other
appropriate arking de-ices to ark> or re&ark> the ite 8ith its disting)ishing
n)ber> SW" and any other necessary in#oration.
+. Con!"#t$n' &n e)&*$n&t$on
'he e9aination sho)ld start 8ith correct identi#ication o# the ite. Bn the case o# a
ne8ly an)#act)red ite> 8here the e9aination is ade #ollo8ing the initial test>
the details sho)ld be checked against the test record. Bn the case o# an ite that has
been in ser-ice> i# there is any do)bt as to its identity and(or history> the pre-io)s
e9aination reports and aintenance records sho)ld be checked as appropriate.
3eeber that "."E3 lea-es it to the discretion o# the copetent person in
deciding i# a test is necessary and> i# so> the nat)re and #or o# any s)ch test> in
reaching a concl)sion as to 8hether or not the ite is sa#e. 'he on)s as to 8hether
or not the e*)ipent ay enter> or ret)rn to ser-ice is on the )ser> not the e9ainer.
'he d)ty o# the copetent person is only to deterine i# the e*)ipent is sa#e to )se
or not & and to report the #act.
'he e9aination )st be cond)cted systeatically to ens)re all parts are thoro)ghly
e9ained. Bn the case o# slings or long lengths o# chain> rope or 8ire rope> the
e9aination sho)ld start at one end and proceed along the length ens)ring all parts
are obser-ed. For e9aple> reeber to t)rn a chain #)lly < it has #o)r sides not
t8o. B# the e9aination is interr)pted> it sho)ld be started again #ro the beginning
to ens)re no part is issed.
Bt is iportant to reeber that the perissible ao)nts o# 8ear> elongation> broken
8ires etc gi-en in this co)rse> standards> an)#act)rerAs instr)ctions and siilar
so)rces are maximums. ; C)dgeent has to be ade as to 8hether the ite is #it to
contin)e #or a period o# ser-ice < that is> it 8ill be sa#e to operate )ntil the ne9t
e9aination is d)e & in the pre-ailing ser-ice conditions.
Carry o)t diensional checks against the standard> speci#ication or dra8ing. Carry
o)t any other checks necessary to ens)re the ite is in copliance 8ith the
standard and(or speci#ication. Carry o)t a #)ll -is)al e9aination. 0elo8 are soe
e9aples o# soe typical ites and a list o# the points to be considered d)ring their
e9aination #ollo8ing a period o# ser-ice. Bn later )nits> 8hen speci#ic ites are
disc)ssed> these atters are considered in greater detail.
+.1 C1&$n S2$n's
E9aine and check #or=
1. SiEes o# chain> links and hooks #or loads re*)ired.
2. Stretch d)e to 8ear and loading 45F a9i)6> -ariation in the
lengths o# the legsG 4copare 8ith past records6.
3. Hooks #or openings and distortion 4see belo86.
4. "inks and rings #or distortion or ro)ndness.
5. Chain #or bent and t8isted links. 'he links sho)ld artic)late #reely.
6. ;ll parts #or 8ear> 4$F red)ction in diaeter6> corrosion> nicks and
cheical attack.
!. Cracks> 8eld #a)lts and arks in 8eld areas.
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: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
+.+ 4oo5s
E9aine and check #or=
1. .pening o# hook against an)#act)rerHs catalog)e> 1(12th a9i) 4i#
it e9ceeds this> scrap hook6. .ther distortion.
2. Wear in eye> saddle etc> ie $F red)ction in thickness.
3. Cracks> nicks> scores and gall arks in the body o# the hook.
4. Shank #or alignent> s8i-el #or #ree r)nning> so)ndness and
copleteness o# thread etc.
5. Corrosion and cheical attack.
+., S1&#52es
E9aine and check #or=
1. SiEes #or loads to be li#ted.
2. Correct pin #itted> #ree 8orking o# pin.
3. Wear o# the pin thread.
4. ;lignent o# holes in shackle.
5. Wear in pin and bo8 4as per steel chain> ie $F red)ction in diaeter6.
6. ;ll parts #or nicks> cracks> corrosion and cheical attack.
+.. E/e6o2ts
E9aine and check #or=
1. SiEe #or loads to be carried.
2. 'hread #or copleteness> 8ear and alignent. Correct )nderc)t or
relie-ing at the base o# the shank.
3. ;lignent o# shank and eye.
4. Cracks in shank and eye.
5. Wear in eye and link etc> ie $F red)ction in diaeter.
6. Corrosion and cheical attack.
+.3 7$e Ro%es
E9aine and check #or=
1. SiEe o# loads to be li#ted.
2. ?inks in the rope.
3. Wear in rope.
4. Change in diaeter 4increase or decrease6 and increase in length.
5. ")brication and internal condition.
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: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
6. 0roken 8ire 4a9i) 5F in any length e*)al to 12 ties the
diaeter6. 3eeber that> in certain applications> e-en one broken
8ire presents a haEard to the )ser or e*)ipent.
!. Condition o# splices> #err)le sec)red eyes etc.
$. Corrosion and cheical attack. ,0= With soe constr)ctions o# 8ire
rope> internal corrosion can ca)se an increase in diaeter.
+.8 F&6$#&te! Ite*s
E9aine and check #or=
1. Deneral condition o# aterials> paying partic)lar attention to the #inish
o# c)t and achined parts. 'hese sho)ld be sooth 8ith no stress
raisers.
2. ,icks> cracks> distortion> corrosion and cheical attack.
3. 'he so)ndness o# 8elds. 'hey sho)ld be #ree o# slag> cracks> porosity
and )nderc)t.
4. 0olts sho)ld be o# correct length and threaded sections sho)ld not be
s)bCect to shear. ,)ts sho)ld be #)lly engaged and sec)re. "ocking
de-ices and 8ashers )st be in place.
+.7 L$(t$n' M&#1$nes
E9aine and check #or=
1. Deneral operation. 'his 8ill -ary 8ith the type o# achine> b)t sho)ld
generally be sooth> 8itho)t Cerkiness.
2. .peration o# brake or other s)staining echanis.
3. .peration o# liits and sa#ety de-ices.
4. Correct ating o# o-ing parts> eg gears.
5. Deneral condition o# aterials and anchorages.
6. %echanical daage> cracks> distortion> corrosion and cheical attack.
Note9 Coposite ites> s)ch as a spreader bea 8ith t8o leg top s)spension chain
sling> shackles and pendant 8ire ropes> sho)ld be broken do8n into the coponent
parts as necessary and e9ained on that basis. 'he coplete assebly sho)ld
then be checked #or correct #itting> alignent o# parts etc.
+.: M&5$n' o Re-*&5$n'
;s 8ell as arking ne8 e*)ipent> it is soeties necessary to re&ark the
in#oration on in&ser-ice e*)ipent. Bt )st be realised that> in staping an ite> a
potential #a)lt is being introd)ced> as the indentations act as stress raisers. 'he
arking is there#ore ade on selected areas o# the ite 8here the e##ects are
iniised. Care )st be taken so that the staping is neither too sharp nor
e9cessi-e in depth> partic)larly 8hen )sing ne8 staps. 'he siEe o# the staps
)sed sho)ld not e9ceed the #ollo8ing=
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: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
D$&*ete o( M&te$&2 S$;e o( St&*%
7p to and incl)ding 12.5 3
.-er 12.5 )p to and incl)ding 26 4.5
.-er 26 6
,. Test &n! e)&*$n&t$on e-"$%*ent
,.1 Test *&#1$nes &n! (o#e<2o&! *e&s"$n' e-"$%*ent
%any o# the prod)ct standards and codes o# practice 8hich re*)ire the application o#
a load> or #orce> lay do8n the acc)racy to 8hich the test load or #orce )st coply.
For e9aple> 0S E, $1$&1 #or chain re*)ires an acc)racy o# I1F> as does 0S !121
#or cranes. Historically> a lesser acc)racy o# I2F or I1.5F 8as re*)ired #or -ario)s
ites. Soe o# these old standards still reain in place.
'he "EE; 'echnical 3e*)ireents #or %ebers> +oc)ent re#erence "EE; 244
dated ! ;pril 2224> Cla)se 3.1 & 'ension and Copression 'esting %achines and
"oad(Force %eas)ring E*)ipent> gi-es the ini) re*)ireents #or this
e*)ipent. Bt re*)ires that test achines and load cells are calibrated and -eri#ied
by a copetent person> or a)thority> in accordance 8ith 0S E, BS. !522&1 at
inter-als not e9ceeding 12 onths. Bt #)rther re*)ires that the acc)racy o# the
applied load(#orce )st be 8ithin that re*)ired by the standard being 8orked to and>
in all cases> 8ithin I2F o# the noinal load(#orce.
0S E, BS. !522&1 has -ario)s classes or grades o# achines= 2.5> 1.2 or 2.2. 'his
relates directly to the acc)racy. Drade 2.5 J I2.5F> 1.2 J I1F and 2.2 J I2F. 'his
in#oration 8ill be gi-en on the certi#icate o# calibration and -eri#ication. Bn soe
cases> dependent on the design and constr)ction o# a test achine> or load
eas)ring de-ice> t8o grades ay be sho8n. For e9aple> grade 1.2 #or one range
o# readings> grade 2.2 #or a #)rther range o# readings.
'he certi#icate 8ill also gi-e the "o8er "iit o# Calibration. 'his 8ill be e9pressed as
a load or #orce> depending on the )nits in 8hich the achine or de-ice is calibrated.
'his is the ini) load(#orce that can be read #ro the display 8ithin the re*)ired
acc)racy. 'est loads belo8 this cannot be eas)red 8ith this e*)ipent. Bn soe
cases there ay also be a siilar restriction on the )pper liit.
'he person per#oring any #or o# load test )st be a8are o# the liitations #or )se
iposed on the test achine> or load(#orce eas)ring e*)ipent> and ens)re that
the acc)racy o# the applied load eets the re*)ireents o# the standard being
8orked to.
,.+ D$*ens$on&2 *e&s"$n' e-"$%*ent
.nly the ost basic o# diensional eas)ring e*)ipent> s)ch as a tape or r)le> is
)s)ally called #or in the -eri#ication o# li#ting gear. 'his sho)ld be grad)ated to
national standards in increents o# 1 .
For certain ites> a -ernier ga)ge ay be necessary. Bn this case a grad)ation o#
2.1 is )s)ally s)##icient 8hen e9aining general li#ting gear.
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: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
"EE; 'echnical 3e*)ireents> Cla)se 3.6> re*)ires that a proced)re is in place #or
checking and -eri#ying eas)ring de-ices at appropriate periods. 'he g)idance to
the re*)ireents says that> #or tapes and r)les> it 8ill probably only be necessary to
reg)larly check the to ens)re that they are )ndaaged> partic)larly at the Eero
end> and reain legible. Ho8e-er> precision eas)ring e*)ipent 8ill re*)ire
periodic -eri#ication> e.g. against slip ga)ges> depending on the nat)re o# the de-ice
and the d)ty #or 8hich it is )sed.
,., Non-!est"#t$=e test e-"$%*ent
,.,.1 C&#5 !ete#t$on
When dealing 8ith general li#ting gear> )s)ally only r)diental crack detection 4s)ch
as dye penetrate or agnetic particle6 is per#ored to e9aine 8elds. 'hese call #or
basic training o# the operati-e to enable the to interpret the res)lts. 'he e*)ipent
re*)ires no calibration. 'hey are relati-ely ine9pensi-e> both in ters o# the
e*)ipent and the labo)r necessary to per#or the tests.
For ore detailed crack detection e9ainations> partic)larly on high -al)e ites or
8here additional sa#ety re*)ireents re*)ire a higher degree o# e9aination> other
ethods )sed are eddy c)rrent> radiography and )ltrasonic. 'hese are e9pensi-e to
per#or and call #or a high degree o# training and skill to interpret the res)lts.
,.,.+ 4&!ness test
Bndentation ethods are )sed to -eri#y the hardness o# li#ting gear #ollo8ing heat
treatent or 8here e*)ipent is )sed in conditions that ight a##ect the heat
treatent. 'here are three basic ethods= Kickers> 0rinell and 3ock8ell.
0rinell is the ost coon in the li#ting e*)ipent ind)stry. Bt is a relati-ely siple
test that can be ade on the #inished ite. Bt re*)ires only basic training in order to
interpret the res)lts.
,.,., E2e#to*&'net$# 0$e o%e e)&*$n&t$on
'his is a #ast ethod o# detecting de#ects in long lengths o# 8ire rope. 'he rope is
passed thro)gh a agnetic #ield. 0reaks and dist)rbances in the agnetic #ield are
detected and a printo)t o# the #ield is gi-en. 'his calls #or a high degree o# training
and skill to interpret the res)lts.
"EE; 'echnical 3e*)ireents> Cla)se 3.5> calls #or non&destr)cti-e test e*)ipent
to be -eri#ied at appropriate inter-als in accordance 8ith the an)#act)rerAs
instr)ctions.
,.. Ot1e e-"$%*ent ne#ess&/ !"$n' &n e)&*$n&t$on
Coparators> s)ch as thread ga)ges> ay occasionally be needed to ens)re correct
identi#ication and pro#ile o# thread types and siEes> or as a siple go(no go ga)ge
4e.g. to check #or chain 8ear6.
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: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
Bn addition to load(#orce application and eas)ring e*)ipent> distance eas)ring
e*)ipent> and pro#ile eas)ring(coparison e*)ipent> the tester and e9ainer
8ill> #ro tie to tie> re*)ire other basic aids. ;dditional lighting> s)ch as a 8ander
light or torch> 8ill o#ten be necessary> along 8ith -is)al aids s)ch as a agni#ying
glass or dental irror.
Bn the case o# li#ting gear general> only the ost basic o# tools are generally
necessary. 'hese 8ill incl)de a haer> a set o# pin p)nches 4#or echanically
assebled chain slings6> dri#ts and arlin spikes 4#or 8ire ropes6> a set o# letter and
n)ber p)nches etc. Bn the case o# achines> spanners> scre8 dri-ers and circlip
pliers ay be re*)ired.
0asic cleaning e*)ipent> s)ch as a 8ire br)sh and cleaning cloth> ay also be
necessary> to reo-e r)st> dirt or debris 8hich ay obsc)re #a)lts> #la8s> de#ects or
arking.
.. T/%es o( test - &n! 01&t t1e/ te22 "s
Ha-ing considered the e*)ipent )sed d)ring an e9aination and test> this )nit no8
looks at the -ario)s tests a-ailable & and 8hat they ight tell )s. Soe o# these
8ere considered in )nit 1.6. 'hey are no8 p)t into conte9t.
..1 D$*ens$on&2 =e$($#&t$on
Ens)ring an ite is diensionally correct & eas)ring it & is )s)ally a #)nction o# the
initial -eri#ication to ens)re the ite is to the standard> speci#ication or dra8ing. Bn&
ser-ice ites are also eas)red> to deterine the ao)nt o# 8ear> b)ild )p or loss
o# corrosion in 8ire ropes and siilar atters> and ens)re they are 8ithin the
accepted liits.
Coparators and ga)ges are help#)l 8hen eas)ring 8ear or identi#ying threads or
thread 8ear.
..+ O%e&t$on&2 test
'his test has -ery liited application #or li#ting gear. Bt is ore appropriate to li#ting
achines. Bt is a siple test to ens)re the ite operates as intended. +)ring this
test the ite is operated thro)gh its noral #)nctions> )s)ally 8ith a light load or no
load. Bts )se is there#ore liited to ites o# li#ting gear that ha-e o-ing parts. For
e9aple> on a plate clap> to ens)re the Ca8s grip the plate and can be locked into
position. Bt is )sed both d)ring the initial -eri#ication and d)ring the in&ser-ice
thoro)gh e9aination.
.., L$'1t 2o&! test
'his test is not applicable to li#ting gear. Bt is #or ites that ha-e scre8 brakes or #all
arresting brakes that depend on the do8n8ard o-eent o# the load to operate
the> s)ch as a hand chain block. ; load o# bet8een 2F and 5F o# the W"" is
raised s)##icient height and then lo8ered. 'he operation is halted and the load )st
be s)stained by the brake.
'his is the ost onero)s test that can be applied to a brake> e.g. le-er hoist. ;s the
brake is the ost sa#ety critical part o# the )nit> it con#irs i# it is sa#e to operate.
1
: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
... S7L &n! !e(2e#t$on *e&s"e*ent
;gain this test is o# liited )se d)ring the e9aination o# li#ting gear. Bt is ore
appropriate to li#ting achines and str)ct)res. Bt ay be applied as part o# the initial
-eri#ication o# a li#ting bea or spreader> to deterine i# any peranent de#lection or
set has taken place.
'he ite is s)bCected to a load or #orce> either in a test achine 4eg spreaders6> or
by li#ting a li-e load 4eg r)n8ays and cranes6> 8hich is e*)i-alent to the SW" 4W""6.
'he de#lection )nder load is eas)red 4acc)racy I5F6 and recorded. 'he de#lection
)st be 8ithin the liits set by the appropriate standard. When the load(#orce is
reo-ed the ite is eas)red to see i# any peranent set has taken place and> i#
so> 8hether or not this is 8ithin the acceptable liits.
..3 Poo( 2o&! test
'his is a test 8hich is greatly is)nderstood. Bt erely con#irs that the ite is
capable o# s)staining the applied load at the tie o# the test. 'hat is> the ite is
strong eno)gh. +)ring the test a #orce e*)al to the W"" pl)s an o-erload> )s)ally
122F #or ost li#ting gear> 52F #or an)al achines and 25F #or po8er operated
achines and str)ct)res> is applied and then released. ;s #ar as li#ting gear general
is concerned> its )se is )s)ally restricted to ne8 coponent parts> 4eg chain
co)plers6> lengths o# chain> #abricated ites> 4eg li#ting beas and spreaders6> and
ites that rely on the action o# the load #or their e##ecti-e operation> 4eg plate
claps6. Bt is also )sed to -eri#y ne8ly #itted parts 8hen #abricated ites> 4eg li#ting
beas6> and load action reliant ites> 4eg plate claps6> ha-e been repaired. Bt
reains an iportant test #or str)ct)ral ites> 4eg r)n8ays6.
%any coon ites 8ere at one tie ro)tinely proo# load tested. 'his 8as despite
the #act that the res)lts 8ere )ncertain and the test co)ld daage> or shorten the
8orking li#e> o# per#ectly ser-iceable e*)ipent. Considering these liitations helps
to e9plain 8hy this test is being )sed less #re*)ently.
B# the test is to be eaning#)l and latent de#ects are to be detected> the )se o# alloy
steels in the an)#act)re o# chain and #ittings calls #or higher proo# loads than the
traditional 2 9 W"" pre-io)sly applied to chain slings. 0S E, $1$&2 gi-es a table o#
proo# loads to be applied to ne8ly an)#act)red grade $ chain 8hich e*)ates to 2.5
9 W"". Siilarly> the -ario)s standards #or the #ittings also call #or a proo# load o# 2.5
9 W"". Ho8e-er> in this case> this allo8s the radii o# the #ittings to be s)pported to
pre-ent the collapsing d)ring the test. .b-io)sly> d)ring a siilar test on a ade
)p chain sling it 8o)ld be ipossible to s)pport the radii and there 8o)ld e##ecti-ely
be point contact bet8een the ating s)r#aces. 7nder load> #ittings and aster&links
8o)ld distort and 8o)ld be daaged beyond #)rther )se. 0S E, $1$&4 #or Drade $
chain slings does not there#ore re*)ire echanically assebled slings to be proo#
load tested. Ho8e-er> the sa#ety o# the sling is reliant on its correct assebly> 8ith
all retaining and locking pins in place. ; thoro)gh -is)al e9aination> a#ter assebly
or 8hen in ser-ice> is essential.
'he sae is tr)e o# 8ire rope slings. 'he traditional proo# loading o# a #err)le
sec)red eye seldo detected incorrectly ade eyes. E-en an eye 8ith o-er siEe
#err)les 8o)ld hold the proo# load. 'here#ore the haronised standards #or 8ire
rope slings do not call #or proo# load testing> b)t 0S E, 13411&3 calls #or the #err)le
terination to be -eri#ied by eas)reent and thoro)gh e9aination.
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: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
Bn the case o# eyebolts> the old 0ritish Standard 42!$ reains in place and this
standard does call #or proo# load testing.
When e9aining an in&ser-ice hand chain block> #or e9aple> the strength is already
kno8n. S)bCecting it to an o-erload 8ill not there#ore re-eal anything that is not
kno8n. Ho8e-er> it 8ill p)t additional stress on the 8orking parts and shorten their
8orking li#e.
..8 >e&5$n' 2o&! test<*$n$*"* 6e&5$n' 2o&! test
'his is a test that can be applied to any prod)ct as a type test to pro-e the design> i#
the designer so 8ishes> and to establish that the desired #actor o# sa#ety has been
achie-ed prior to series an)#act)re. Bts )se> ho8e-er> needs to be controlled.
7s)ally it is only applied to saples #ro series prod)ction ites. .# co)rse> it is not
a test that 8o)ld be applicable to str)ct)res or in&ser-ice ites> as the ite is
o-erloaded beyond #)rther )se or destroyed.
'he te9tile sling standards 0S E, 1412&1 and 0S E, 1412&2 are e9aples o#
standards re*)iring this type o# test. Selected saples o# #lat 8o-en 8ebbing slings
and ro)ndslings to these standards are re*)ired to be loaded )p to ! 9 W"" 8itho)t
#ail)re. B# this is s)ccess#)l> there is no need #or the test to contin)e to destr)ction>
altho)gh the tested saple is scrap.
Changes ha-e also taken place in the 8ay that 8ire rope is -eri#ied. Bn the past> a
saple o# the rope 8as loaded to destr)ction and the act)al breaking load 8as
recorded on the 8ire rope certi#icate. 0S E, 123$5 calls #or a di##erent regie> 8ith
the ini)> or speci#ied> breaking #orce being gi-en on the certi#icate> not the
act)al breaking load. 'his can be -eri#ied in di##erent 8ays=
4a6 by loading a saple )p to the ini) breaking load> or>
4b6 calc)lation o# the ini) aggregate breaking #orce #ro a saple o# the
8ire.
;gain there is no need to contin)e to destr)ction i# the test is s)ccess#)l.
..7 4&!ness test
Bn the ain> this test is )sed by an)#act)rers o# steel coponent parts> 4eg chain
connectors6> and li#ting gear> 4eg shackles6> d)ring prod)ction to -eri#y the
e##ecti-eness o# the #inishing heat treatent.
Bts )se #or in&ser-ice e*)ipent is restricted to C)st one or t8o specialist applications>
8here the e*)ipent ay ha-e been a##ected by heat 8hich ight a##ect the steel. B#
the e*)ipent has been s)bCected to a teperat)re abo-e the original tepering
teperat)re> it 8ill ha-e been so#tened. B# it 8as s)bCected to -ery high teperat)res
and then s)dden cooling> it 8ill ha-e becoe hard and brittle.
'he 0rinell hardness test 40S E, 122236 is the ost coon )sed in the li#ting
e*)ipent ind)stry. ; hardened steel ball is pressed into the s)r#ace o# the aterial
by a standard #orce. 'he diaeter o# the res)lting indentation is then eas)red.
3e#erence is ade to tables 8hich are calc)lated to copare the diaeter o# the
indentation to the diaeter o# the ball )sed and gi-e the hardness n)ber. 'he
0rinell hardness n)ber> signi#ied by the pre#i9 H0> or acceptable range o# n)bers>
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: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
is gi-en in the -ario)s prod)ct standards. 'ypically> #or ites o# grade 4 4or %6> an
H0 n)ber o# 152&21! is re*)ired.
..: L$-"$! %enet&t$on #&#5 !ete#t$on
'here are se-eral li*)id penetration ethods a-ailable> the ost coon being the
)se o# t8o or three aerosol spray cans o# li*)id. "i*)id penetration crack detection
can be applied to #erro)s and non&#erro)s etal coponents. 'hese tests are
ho8e-er liited in that they 8ill only re-eal the position o# cracks and do not help to
assess the depth. ,either do they re-eal #a)lts belo8 the s)r#ace o# the aterial>
s)ch as lainations and blo8 holes.
;ltho)gh liited> it is a pop)lar test #or li#ting gear> 8here no s)r#ace cracks are
peritted. Bt is coonly )sed to check the 8elds on #abrications s)ch as li#ting
beas> crane str)ct)res and siilar ites. 'his test is -ery siple> readily portable>
and calls #or the ini) o# training in order to interpret the res)lts.
'he principle o# the -ario)s ethods is )ch the sae. 'hey )se lo8 -iscosity
li*)ids 8hich #lo8 -ery easily and penetrate s)r#ace cracks. Bn the ost siple o#
these tests> the area to be checked is sprayed 8ith a backgro)nd> )s)ally 8hite. ;
second spray is )sed 8hich 8ill r)n o## the backgro)nd> b)t 8ill penetrate and gather
in the cracks. 'his li*)id is o# a di##erent colo)r and so re-eals the crack as a
colo)red line.
; siilar ethod )ses a peranent agnet to attract the arker #l)id into the crack.
Bts )se is there#ore liited to agnetic aterials. Ho8e-er> this test )st not be
con#)sed 8ith agnetic particle crack detection.
..? M&'net$# %&t$#2e #&#5 !ete#t$on
'his ethod o# crack detection 8ill re-eal both s)r#ace cracks and indicate the
position o# #iss)res 8ithin appro9iately 12 o# the s)r#ace. ;s the ite )nder
in-estigation has to be agnetiEed> its )se is liited to #erroagnetic aterials and
a #e8 non&#erro)s etals> s)ch as nickel and t)ngsten.
Sall ites and coponents s)ch as shackles are agnetiEed by passing the
thro)gh a coil. For larger ites> s)ch as li#ting beas> electrodes are attached to the
ite co-ering the area )nder in-estigation. 'he ite is then sprayed 8ith a sol)tion
o# s)spended iron #ilings. ; crack or iper#ection near the aterialAs s)r#ace 8ill
distort the agnetic #ield and attract the iron #ilings. 'he crack is then re-ealed by an
acc))lation o# particles along the line o# the crack and s)b&s)r#ace de#ects by an
acc))lation in the area o-er the #a)lt. ;s cracks are only detectable 8hen the lines
o# agnetic #orce are at a signi#icant angle to the crack> sall ites are rotated and
t)rned d)ring the test. For larger ites> the electrodes are attached at -arying
positions.
For ease o# identi#ication> an )ltra -iolet light is o#ten )sed. 'his reacts 8ith the
sol)tion and re-eals the iron #ilings as a black line. .ther systes )se a backgro)nd
spray 8hich allo8s the #ilings to be readily seen.
;s the ite has been hea-ily agnetiEed it is iportant that it is de&agnetiEed a#ter
the test to pre-ent the collection o# agnetic particles 8hich 8o)ld daage the ite
8hen it 8as p)t into ser-ice.
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: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
'his test calls #or siple training and the res)lts are easily interpreted. Bt is 8idely
)sed #or larger in&ser-ice ites that are s)sceptible to cracking> s)ch as #ork tr)ck
ars> and d)ring series prod)ction o# #orgings.
..1@ R&!$o'&%1/ (X-&/s) #&#5 !ete#t$on
'his ethod o# crack detection 8ill locate a #a)lt any8here thro)gh the section 8hich
is 5&rayed. Ho8e-er> it 8ill only locate the #a)lt in one plane. Bt 8ill not re-eal its
depth> )nless a #)rther 5&ray is taken in the opposite plane. Bt is an e9pensi-e
operation and calls #or -ery high sa#ety eas)res to be #ollo8ed. ;s a general r)le it
re*)ires the e*)ipent to be e9ained to be taken to a specialist location. Bt is
ainly )sed 8hen e9aining prod)ction ites 4eg the 8elds o# links6> or 8hen
in-estigating a #ail)re.
'he article being 5&rayed is s)bCected to radiation> )s)ally #ro a gaa ray so)rce>
8hich passes thro)gh the ite and #alls onto photographic #il. When de-eloped>
the #il gi-es a pict)re o# the internal str)ct)re o# the ite in the plane o# the
radiation. ;s the radiation 8o)ld daage body tiss)e the area )st be #)lly shielded
to pre-ent stray radiation and contact 8ith persons. 'he so)rce o# the radiation is
norally an isotope 8hich )st also be handled care#)lly to a-oid h)an contact.
'his is a specialist test> )s)ally carried o)t )nder laboratory conditions. Bt calls #or
great care in interpreting the res)lts.
..11 E!!/ #"ent #&#5 !ete#t$on
'his ethod o# crack detection is s)itable #or )se on thin sections> gi-ing the best
res)lts #or aterials o# less than 25 thickness. Bts )se #or li#ting gear general is
there#ore -ery liited.
0y placing a sall 8ire coil near the test piece and then passing an alternating
c)rrent thro)gh the coil> an alternating agnetic #ield is created. 'his> in t)rn>
ca)ses a c)rrent in the test piece. 'his e##ect is kno8n as electroagnetic ind)ction
and the c)rrents ind)ced in the test piece are kno8n as eddy c)rrents.
/ro-iding the test piece is consistent> the c)rrent #lo8ing in the coil 8ill reain
)nchanged 8hen the coil is passed o-er the test piece. Ho8e-er> i# there is a crack
or ip)rity> the c)rrent 8ill change. 0y onitoring the c)rrent in the coil it is possible
to detect #la8s in the test piece 8hich are not other8ise -isible.
'his is an e9pensi-e specialist test. 'he test e*)ipent is sei&portable and so
tests can be ade in s)itable locations. Bt calls #or e9tensi-e training and e9perience
to per#or the test and interpret the res)lts.
..1+ U2t&son$# #&#5 !ete#t$on
'his ethod o# crack detection enables the siEe and location o# #a)lts to be
identi#ied. Bt is )s)ally )n8arranted #or ost ites o# li#ting gear> b)t is soeties
)sed to detect #a)lts in -ery large li#ting beas and siilar ites.
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: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!
; probe containing a *)artE crystal is passed o-er the s)r#ace o# the test piece. 'he
crystal transits and recei-es high #re*)ency -ibrations 8hich are apli#ied and
recorded as a 8a-e#or on a cathode ray oscilloscope t)be. ; de#ect 8ill be
re-ealed as an interediate echo on the screen> its depth being proportional to
horiEontal distance. Kario)s ethods o# placing the probe are )sed depending on
the siEe and location o# the #a)lt.
;gain this is an e9pensi-e specialist test. 'he test e*)ipent is sei&portable and so
tests can be ade in s)itable locations. Bt calls #or e9tensi-e training and e9perience
to per#or the test and interpret the res)lts.
..1, E2e#to*&'net$# 0$e o%e e)&*$n&t$on
'his ethod is )sed to detect broken 8ires and corrosion in 8ire ropes. Bt is ost
s)itable #or long lengths o# rope> s)ch as crane ropes.
'he rope is passed thro)gh a t)b)lar detector head 8hich sat)rates the rope in a
agnetic #ield. ;ny 8ire breaks or signi#icant changes o# 8ire section 8ithin the rope
ca)se a dist)rbance o# the agnetic #ield. 'his is detected and sho8n on a
contin)o)s paper printo)t.
;s rope can be #ed thro)gh the detector head in a contin)o)s r)n> this a #ast test
s)itable #or long lengths o# 8ire rope. Bt calls #or s)itable training and e9perience to
interpret the res)lts.
3. A#t$ons (o22o0$n' &n e)&*$n&t$on
Follo8ing an e9aination> the #irst thing the tester and e9ainer )st do is prepare
a report. 'his is regardless o# 8hether or not the ite has passed the e9aination.
'he in#oration to be gi-en in the report is detailed in Sched)le 1 to "."E3 4see
)nit 1.16. Bn soe cases this report ay be sipli#ied to a check list or siilar> #or
s)bission to the copany o##ice #or the report to be prepared #or the client.
For in&ser-ice e*)ipent> i# the e9aination re-eals one or ore de#ects 8hich
present an iediate or iinent risk o# serio)s or personal inC)ry> a copy o# the
report )st be sent to the en#orcing a)thority 4)s)ally the HSE in the 7?6. ;
prosec)tion ay #ollo8 i# this is not done. 'his is a d)ty placed on the person
aking the e9aination. ;ltho)gh yo)r copany ay ha-e a proced)re #or doing
this> it is yo)r legal responsibility to ens)re it has been done.
Con#2"s$on
+ependent on the types o# ite yo) are dealing 8ith> yo) 8ill already be #ailiar 8ith
soe o# the tests o)tlined abo-e. Soe o# the are carried o)t by the tester and
e9ainer in the 8orkplace or on site as a atter o# daily ro)tine. .thers are
specialist tests> only 8arranted in special circ)stances or in partic)lar prod)ction
sit)ations.
;s a tester and e9ainer yo) sho)ld be a8are o# all o# the tests that are a-ailable to
yo) and 8hat they 8ill tell yo). When the -ario)s ites o# li#ting e*)ipent are
considered in detail> 8e 8ill assess 8hich o# the are applicable.
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: "i#ting E*)ipent Engineers ;ssociation 2211 < 7nit 1.!