When it comes to ensuring the safety and efficiency of crane operations, load testing stands as a critical and indispensable process. In China, as in many other countries, load testing is not just a best practice but a mandatory requirement governed by stringent regulations and industry standards. This comprehensive guide delves into the intricacies of crane load testing in China, highlighting its paramount importance in verifying the structural integrity, functionality, and safety mechanisms of cranes.

Readers can expect to gain a thorough understanding of the reference specifications and guidelines set by regulatory bodies and industry standards, such as those outlined by ASME and local Chinese regulations. The guide will cover the step-by-step procedures for conducting load tests, including determining load capacity, preparing and applying test loads, and the necessary pre-test and post-test procedures.

Additionally, this guide will explore the various applications of load testing, from certification and compliance to new crane installations, and the periodic inspections required to maintain crane safety and reliability. Whether you are a crane operator, a safety

Crane Inspection Protocols – China

Comprehensive Guide to Crane Inspection Protocols

Introduction

Crane inspection protocols are crucial for ensuring the safety, functionality, and compliance of cranes with various regulatory standards. This guide outlines the key aspects of crane inspections, including pre-inspection preparations, the inspection process, and post-inspection activities.

Pre-Inspection Preparations

Planning the Inspection

• Determine the frequency and scope of the inspection based on factors such as the type of crane, its usage, and the working environment.
• Review the crane’s maintenance history to identify potential hazards and areas that require special attention[2].

Gathering Necessary Resources

• Collect all necessary equipment and documentation, including inspection checklists, maintenance records, and relevant regulations or standards.
• Ensure that the crane is not in operation during the inspection[1].

Familiarization with Reference Specifications

• Familiarize yourself with the specific product reference specifications provided by the manufacturer. These specifications include information on load capacity, hoisting speed, trolley speed, lifting height, and other essential parameters[2].

The Inspection Process

Visual Inspection

• Start with a visual inspection to identify any signs of damage, wear, or defects on the crane’s structure, wires and ropes, hooks, chains, and other critical components.
• Look for signs of cracking, corrosion, misalignment, or loose connections[1][2].

Detailed Component Inspection

• Inspect load-bearing components, electrical systems, hydraulic systems, brakes, and other critical parts.
• Check safety devices such as limit switches and emergency stop buttons to ensure they are in place and functioning properly[1][4].

Functional Testing

• Conduct operational tests to ensure the crane is functioning correctly. This includes testing the hoisting, traveling, and rotating actions of the crane, as well as the horizontal traveling action of the trolley[3][4].

Load Testing

• Perform load tests to evaluate the crane’s capacity and performance under maximum load conditions. This typically involves applying a load equal to 1.25 times the rated load of the crane[3][4].

Non-Destructive Testing (NDT)

• Use NDT techniques such as magnetic particle testing, ultrasonic testing, radiographic testing, and dye penetrant inspection to evaluate critical crane components for defects or weaknesses that may not be visible to the naked eye[2][4].

Post-Inspection Activities

Documentation and Reporting

• Compile a detailed inspection report that includes a checklist, photographs, and recommendations for any necessary adjustments, repairs, or replacements.
• Maintain comprehensive maintenance records, including inspection reports, repairs, maintenance activities, and certifications[1][2].

Certification and Compliance

• Ensure that the crane meets all regulatory requirements and standards. This may involve obtaining a qualification certificate or mark from the inspecting organization[3].
• Display the qualification certificate or its photocopy in the cab of the crane or at obvious locations in the workplace[3].

Maintenance and Repairs

• Address any issues identified during the inspection promptly. This includes supervising repairs and ensuring that all safety devices are re-examined and functioning correctly[4].

Periodic Inspections

• Schedule periodic inspections as recommended by the manufacturer or local regulatory authorities. These inspections are crucial for maintaining the crane’s safe working condition and compliance with regulations[1][3].

OSHA Compliance and Other Regulatory Requirements

OSHA Inspections

• Conduct inspections to ensure compliance with Occupational Safety and Health Administration (OSHA) regulations in the United States. These inspections assess the crane’s compliance with proper maintenance, load capacity, and operational safety requirements[1].

Local and International Standards

• Ensure that the crane inspections comply with local and international standards such as ISO and other relevant regulations. This involves conducting inspections in accordance with all applicable regulations, standards, and engineering practices[2][4].

Training and Operator Competence

Training Programs

• Provide training for crane operators and maintenance personnel to ensure they understand the crane’s specifications, operation, and safety requirements.
• Training should be conducted in accordance with local and international standards[2][4].

Competent Personnel

• Assign a competent person to oversee the crane assembly, installation, and commissioning process. This person should have a detailed understanding of the crane’s operation and safety requirements[1].

Conclusion

Crane inspection protocols are essential for ensuring the safety and reliability of cranes. By following a structured approach that includes pre-inspection preparations, a thorough inspection process, and post-inspection activities, operators can maintain compliance with regulatory standards and ensure the safe operation of their equipment. Regular inspections, proper maintenance, and adherence to local and international standards are key to preventing accidents and ensuring the longevity of the crane.

Crane Load Test China Manufacturer Guide

Guide to Crane Load Testing: Ensuring Safety and Reliability

Introduction

Crane load testing is a critical procedure for verifying the safety and performance of overhead and gantry cranes. This guide provides a comprehensive overview of the importance, procedures, and best practices for conducting crane load tests.

Importance of Crane Load Testing

Crane load testing is essential for several reasons:
– Ensures Safety: It validates that the crane can safely handle its maximum rated load, protecting workers and facilities from potential accidents[2][3][5].
– Identifies Weaknesses: The test helps identify any structural or component issues that could compromise the crane’s safety and performance[1][3][5].
– Compliance with Regulations: Load testing is mandated by regulatory bodies such as OSHA and ASME to ensure compliance with safety standards[2][4].

Preparing for Crane Load Testing

Determining Maximum Load Capacity

Before conducting the test, determine the maximum load capacity of the crane by consulting its manual or contacting the manufacturer[1][4].

Inspecting the Crane

Perform a thorough inspection of the crane and its components to ensure all safety features are in proper working order. Check for signs of wear and tear, and verify that all motions align with control device markings[1][4].

Securing Testing Equipment

Prepare the necessary testing equipment, such as load cells and dynamometers, and secure them to the crane’s hook. Ensure the test weights are certified and appropriate for the test[1][2][4].

Conducting the Crane Load Test

Hoisting the Test Load

Hoist the test load to a distance to ensure it is supported by the crane and held by the hoist brake(s). This step confirms the crane’s ability to lift and hold the load[2][3][4].

Transporting the Test Load

Transport the test load using the trolley for the full length of the bridge and the bridge for the full length of the runway. This dynamic testing ensures the crane functions safely and properly as it moves[2][3][4].

Monitoring the Load

Monitor the load indicators throughout the lifting process. Take note of any fluctuations or irregularities. Hold the test load at the maximum capacity for a designated period to ensure the crane can support it without signs of strain or failure[1][3][5].

Lowering the Test Load

Slowly lower the test load to the ground and continue to monitor the load indicators for any anomalies[1].

Load Testing Procedures

Static Crane Testing

• Elevate the load to a height of 100-200 mm and hold it for about 10 minutes.
• Check for deformations of the crane bridge after lowering the load[3].

Dynamic Crane Testing

• Use a load that exceeds the normal carrying capacity by 10%.
• Include multiple lifting and lowering cycles to diagnose all working motions of the crane and hoists[3].

Best Practices for Crane Load Testing

Qualified Personnel

Ensure the test is conducted by qualified and experienced personnel familiar with the specific crane being tested. This minimizes the risk of accidents and errors during the testing process[1][4].

Following Manufacturer Guidelines

Adhere to the manufacturer’s guidelines and recommendations for load testing, as these are tailored to the specific crane[1][2][4].

Documentation and Reporting

Document and record the results of the load test for future reference and comparison. This provides valuable data for assessing the crane’s performance and identifying potential issues[1][4].

Post-Test Analysis and Reporting

Inspecting After Testing

After the test, inspect the crane for any signs of damage or deformation. This includes checking the bridge, trolley, and hoist mechanisms[3][4].

Maintaining Records

Keep detailed records of the load test, including the test load used, the results, and any observations. These records should be maintained for the lifetime of the equipment[2][4].

Conclusion

Crane load testing is a vital component of crane maintenance and safety protocols. By following the outlined procedures and best practices, you can ensure the reliability and safety of your crane operations, comply with regulatory requirements, and protect your workforce and facilities. Regular load testing helps in identifying and addressing potential issues before they lead to critical failures.

Crane test and crane inspection for overhead …

Overhead Crane Commissioning and Acceptance Guide

Introduction

Overhead crane commissioning and acceptance are critical processes that ensure the safe and efficient operation of overhead cranes. These procedures are essential for verifying the quality of the crane’s manufacturing and installation, as well as guaranteeing the safety of the crane during operation.

Pre-Commissioning Inspection

Before commissioning a newly installed or overhauled overhead crane, a thorough inspection is necessary. Here are the key contents of the crane inspection:

Power Supply and Initial Checks

• Cut off the power supply of the overhead crane before inspection.
• Check and ensure all fasteners are firm according to the crane drawings and technical specifications.

Rotating Devices

• Verify that all rotating devices are installed correctly and can rotate freely.
• Turn the wheel by hand to check the movement of the output shaft and the revolving of the driving organization, ensuring stable rotation without any blockage or sticking.

Brake System

• Ensure the overhead crane brake is accurate and reliable.
• Check that the two brakes installed for the running mechanism of the overhead crane are consistent with each other.

Lubrication

• Ensure all lubricating points are lubricated with the required lubricating oil according to the guidelines.
• Check that the oil amount on the reducer is within the prescribed scope.

Electrical Equipment

• Conduct a thorough inspection of the electrical equipment to ensure it is in good working condition.

Overhead Crane Operation Test

After the inspection and preparation, the overhead crane operation test can proceed. This test is divided into three main steps:

No-Load Test

• The no-load test includes:
• Crane trolley travelling test
• Overhead crane travel test
• No-load hook test
• This test ensures that the crane operates smoothly without any load.

Static Load Test

• Prepare a testing object that is 1.25 times the overhead crane’s rated capacity.
• Use a steel wire rope or belt to lift the load.
• This test verifies the crane’s ability to handle loads safely and within its rated capacity.

Movement Test

• Conduct the movement test to ensure the crane can move loads accurately and safely.
• This includes testing the crane’s travel, lifting, and lowering functions under load.

Regular Inspections and Maintenance

In addition to the initial commissioning and acceptance, regular inspections and maintenance are crucial for the continued safe operation of overhead cranes.

Types of Inspections

• Initial Inspection: Conducted after a new crane is installed or an existing crane is modified or repaired.
• Pre-Shift Inspection: Daily visual and operational assessments conducted by the crane user.
• Frequent Inspections: Scheduled based on the crane’s usage and service class (e.g., monthly to weekly).
• Periodic Inspections: Conducted annually or quarterly, depending on the service class and usage[4][5].

Maintenance Schedule

• Maintain a routine maintenance schedule that includes tasks such as lubrication, checking fasteners, and inspecting electrical and mechanical components.
• Keep detailed records of all maintenance and repairs to aid in troubleshooting and ensure the crane operates at peak efficiency[3].

Compliance with Regulations

Ensuring compliance with local and national regulations is vital for the safe operation of overhead cranes.

OSHA Regulations

• Adhere to Occupational Safety and Health Administration (OSHA) regulations, which require regular inspections and load testing to ensure the crane is in good working order[2].

Canadian Regulations

• In Canada, follow the standards set by the Canadian Standards Association (CSA) and comply with federal and provincial regulations to ensure safe operation and maintenance of overhead cranes[3].

Training and Documentation

Operator Training

• Implement a comprehensive training program for crane operators to enhance safety and operational efficiency.
• The training should cover the complexities of operating overhead cranes and how to react appropriately under pressure[3].

Documentation

• Keep detailed documentation of all inspections, maintenance, and repairs.
• Maintain records of initial inspection reports, load test reports, and any modifications or repairs made to the crane[4].

Conclusion

Commissioning and accepting an overhead crane involves a series of rigorous tests and inspections to ensure the crane’s safety and efficiency. Regular maintenance, compliance with regulations, and thorough training programs are essential for maintaining a safe and productive working environment. By following these guidelines, you can guarantee the longevity and safe operation of your overhead cranes.

Crane Inspections and Inspections of Hoisting and Lifting …

Comprehensive Guide to Crane, Hoisting, and Lifting Equipment Inspections

Introduction

Ensuring the safety, reliability, and compliance of crane, hoisting, and lifting equipment is crucial for any operation involving these devices. This guide provides an in-depth look at the services and procedures involved in inspecting these types of equipment.

Why Inspect Crane, Hoisting, and Lifting Equipment?

Inspecting crane, hoisting, and lifting equipment is essential for several reasons:
– Safety: Ensures the equipment is in a safe working condition to prevent accidents and injuries.
– Compliance: Meets all applicable regulatory requirements and standards.
– Reliability: Maintains the operational capability and availability of the equipment.
– Uptime: Maximizes operational time and minimizes planned outages.

Types of Equipment Inspected

Inspections cover a wide range of material-handling and personnel-handling devices, including:

Material-Handling Devices

• Cranes
• Derricks
• Fork-lifts
• Truck-mounted cranes
• Shackles
• Hooks
• Elevating platforms
• Telehandlers

Personnel Handling Devices

• Elevators
• Escalators
• Ski lifts
• Cable cars
• Mobile elevating work platforms (MEWPs)

Inspection Services

The following services are typically included in a comprehensive inspection program:

1. Checking of Key Components

• Brakes
• Clutches
• Sheaves
• Wire rope assemblies

2. Design Studies and Calculation Reviews

• Ensures that the equipment’s design and calculations align with safety and operational standards.

3. Dynamic and Static Load Testing

• Tests the equipment under various load conditions to ensure it can handle the intended loads safely.

4. Inspection of Structural Load Bearing Members

• Includes sheaves, crane girders, rails, and columns of overhead cranes to assure structural integrity.

5. Line Level and Span Crane Gantry Surveys

• Ensures the crane’s gantry is properly aligned and level.

6. Non-Destructive Testing (NDT)

• Conducts NDT of load hooks for cracks and visual inspections for distortions.

7. Operational Tests

• Verifies that the equipment is functioning properly through operational tests.

8. Periodic Inspections

• Conducts regular inspections prior to use of mechanical, structural, electrical, and safety systems, as well as wire ropes and chains.

9. Re-examination of Safety Devices

• Ensures all safety devices are in good working condition.

10. Regulatory Compliance Assessments

• Verifies that the equipment meets all relevant regulatory requirements.

11. Remnant Life Assessment

• Evaluates the remaining lifespan of the equipment.

12. Repairs Supervision

• Oversees any necessary repairs to ensure they are done correctly.

Frequency of Inspections

The frequency of inspections varies based on the age and type of the crane:
– Mobile and Self-Propelled Cranes:
– Less than 6 years old: Every 3 years
– Between 6 and 10 years old: Every 2 years
– Over 10 years old: Every year
– Tower Cranes:
– Initial inspection before the start of service
– Every 2 years for cranes installed for extraordinarily long terms

Benefits of Professional Inspections

Using a professional inspection service offers several benefits:
– Expertise: Access to unrivaled expertise and experience in crane inspections.
– Compliance: Ensures compliance with all applicable regulations and standards.
– Safety: Ensures the safe and proper working condition of the equipment.
– Reliability: Maintains the operational capability and availability of the equipment.
– Training: Provides training for operators in accordance with local and international standards.

Conclusion

Inspecting crane, hoisting, and lifting equipment is a critical aspect of maintaining safety, compliance, and operational efficiency. By leveraging professional inspection services, operators can ensure their equipment meets all necessary standards, reducing the risk of accidents and downtime.

Lifting Equipment Inspection & Certification – China

Given that the specific website you mentioned is not accessible in the search results, I will create a comprehensive guide based on the general best practices and detailed information from the other sources provided.

Lifting Equipment Inspection Guide

Introduction

Lifting equipment inspections are crucial for ensuring the safety and compliance of workplaces that utilize such equipment. This guide outlines the key components, procedures, and best practices for conducting thorough and effective lifting equipment inspections.

Types of Lifting Equipment

Lifting equipment includes a variety of devices such as:
– Cranes
– Forklifts
– Hoists
– Pallet jacks
– Boom lifts
– Scissor lifts
– Chain hoists
– Winches
– Slings and chains

Each type of equipment has its own specific inspection requirements and intervals.

Visual Inspection

Check for Visible Damage

• Inspect for any visible signs of damage, such as cracks, dents, bends, or corrosion.
• Look for loose or missing bolts, nuts, pins, or other fasteners.

Inspect Load-Bearing Components

• Check hooks, shackles, slings, and chains for signs of wear.
• Ensure that all load-bearing components are in good condition and free from damage.

Wire Rope/Chain Inspection

• Inspect wire ropes or chains for broken wires or links, kinks, or flattening.
• Check for proper lubrication and cleanliness.
• Verify that terminations (e.g., splices, end fittings) are secure and undamaged.

Hook and Attachment Points

• Examine hooks for deformation, cracks, or wear beyond acceptable limits.
• Ensure that latch mechanisms are functional and properly engaged.
• Inspect attachment points on the equipment for wear or damage.

Operational Checks

Test Controls and Mechanisms

• Test controls and mechanisms to ensure they operate smoothly and effectively.
• Verify that safety devices, such as limit switches and overload protection, are functioning correctly.

Test Safety Features

• Test emergency stop buttons and other safety features to ensure they are operational.

Documentation and Record-Keeping

Review Maintenance Records

• Review the equipment’s logbook or maintenance records to ensure it has been regularly inspected and serviced.
• Confirm that the equipment has undergone any required certifications or inspections by regulatory bodies.

Reporting Defects

• Document all inspection findings, including any defects or issues identified.
• Take appropriate corrective actions as needed and report serious defects immediately to the dutyholder.

Load Capacity and Rating

Check Load Rating

• Ensure that the equipment’s load rating is suitable for the intended task.
• Verify that the load capacity markings are clear and legible.

Electrical and Hydraulic Components

Electrical Components

• Inspect power cords, plugs, and sockets for damage or wear.
• Test electrical connections and circuits for proper functioning.
• Check for signs of overheating or electrical faults.

Hydraulic Systems

• Inspect hydraulic hoses, fittings, and seals for leaks or damage.
• Check fluid levels and quality.
• Test hydraulic controls for responsiveness and smooth operation.

Environment and Surroundings

Assess Working Environment

• Assess the working environment for potential hazards, such as overhead obstacles, uneven terrain, or inclement weather conditions.
• Ensure adequate lighting for safe operation.

Operator Training and Awareness

Confirm Operator Competence

• Confirm that operators are adequately trained and competent to use the lifting equipment.
• Remind operators of safe lifting practices and procedures.

Emergency Preparedness

Verify Emergency Equipment

• Verify the availability and functionality of emergency response equipment, such as fire extinguishers, first aid kits, and rescue gear.
• Ensure that emergency procedures are clearly posted and understood by all personnel.

Regulatory Compliance

Meet Regulatory Requirements

• Ensure that the equipment meets all relevant regulatory requirements and standards.
• Check for any updates or changes in regulations that may affect the safe operation of the equipment.

Thorough Examinations

Definition and Purpose

• A thorough examination is a systematic and detailed examination of the equipment and safety-critical parts, carried out at specified intervals by a competent person.
• This examination must include a written report detailing the examination date, the date when the next thorough examination is due, and any defects found.

When to Conduct Thorough Examinations

• Before use for the first time, unless the equipment has a Declaration of Conformity less than one year old and was not assembled on site.
• After assembly and before use at each location for equipment that requires assembly or installation.
• Regularly, while in service, especially if the equipment is exposed to conditions that cause deterioration.
• Following exceptional circumstances such as damage, failure, or major changes.

Intervals for Thorough Examinations

• Every 6 months for lifting equipment and accessories used to lift people and all lifting accessories.
• Every 12 months for all other lifting equipment.

Inspection Frequency

In-Service Inspections

• Conduct visual assessments of the equipment prior to each use to look for any wear or damage and verify the weight limit tag is visible and legible.

Periodic Inspections

• Conduct more thorough examinations of the equipment at specified intervals (e.g., every 6 or 12 months).
• Consider factors such as the amount of use, intensity of the job, and working conditions when determining inspection frequencies.

Conclusion

Regular and thorough inspections of lifting equipment are essential for ensuring workplace safety and compliance with regulatory standards. By following this guide, you can ensure that your lifting equipment is in good working condition, reduce the risk of accidents, and maintain a safe working environment.

Crane operation and load testing

Guide to Crane Safety Inspections and Operations

Introduction

Crane safety inspections and proper operation are crucial for ensuring the safety of personnel, preventing equipment damage, and complying with regulatory requirements. This guide outlines the key aspects of crane safety inspections, maintenance, and operation based on OSHA regulations and industry best practices.

Types of Crane Inspections

Frequent Inspections

Frequent inspections are conducted on a regular basis, typically daily or pre-shift, to check components that are subject to daily wear and tear. These inspections include:
– Checking wire rope for twists, kinks, or damage
– Ensuring all limit devices are functioning properly
– Testing crane motions to match control labeling directions
– Verifying the hook is free of visual defects and the safety latch is working correctly
– Checking for loose, damaged, jammed, or missing parts and oil leaks[2][3].

Periodic Inspections

Periodic inspections are more comprehensive and are performed at intervals defined by OSHA, depending on the crane’s activity, severity of service, and environment. These inspections include:
– Examining deformed, cracked, or corroded members
– Checking for loose bolts or rivets
– Inspecting sheaves and drums for cracks or wear
– Evaluating worn, cracked, or distorted parts such as pins, bearings, shafts, gears, and rollers
– Assessing brake system parts, linings, pawls, and ratchets for excessive wear
– Testing load, wind, and other indicators for inaccuracies
– Inspecting powerplants for improper performance or noncompliance with safety requirements
– Checking chain drive sprockets and chain stretch
– Evaluating electrical apparatus for signs of pitting or deterioration[1][5].

Inspections for Cranes Not in Regular Use

• Idle for 1-6 Months: Cranes idle for over a month but less than six months must be inspected according to OSHA Frequent Compliance Inspection requirements before being placed back in service.
• Idle for Over 6 Months: Cranes idle for over six months require a complete inspection conforming to both OSHA Frequent and Periodic Compliance Inspection requirements before being placed back in service.
• Standby Cranes: Standby cranes must be inspected at least semi-annually according to OSHA requirements[1][4].

Pre-Operation Safety Checks

Daily and Pre-Shift Checks

Before operating a crane, several key checks must be performed:
– Test run the crane to ensure no obstructions will interfere with its travel motions.
– Verify that all motions match the control labeling directions.
– Check the wire rope for proper seating and any signs of damage.
– Ensure all limit devices are functioning correctly.
– Test the upper limit switch and other safety devices[2].

Environmental and Operational Checks

• Ensure the operating area is clear of other people, cranes, moving equipment, and hazards.
• Check for adequate lighting and ensure the floor/ground is free of dangerous holes, bumps, or slippery spots.
• Verify that all safety labels and direction/capacity labels are in place and easily visible.
• Ensure loads do not exceed the rated capacity and that all necessary warnings and signs are in place[3].

Preventive Maintenance

Establishing a Preventive Maintenance Program

A preventive maintenance program based on the crane manufacturer’s recommendations is essential. This program should include:
– Regular inspections and maintenance as recommended by the manufacturer.
– Addressing any deficiencies or unsafe conditions disclosed by inspections before resuming crane operation[5].

Maintenance Procedures

Before starting any adjustments or repairs:
– Move the crane to a location that minimizes interference with other operations.
– Ensure all controllers are in the off position and the main or emergency switch is open and locked.
– Place warning or “out of order” signs on the crane and in visible locations.
– After repairs, ensure all guards are reinstalled, safety devices are reactivated, and maintenance equipment is removed[5].

Load Testing and Other Special Inspections

Load Testing

Load testing verifies that the crane can lift and move the rated load through all designed motions. This test should be conducted at intervals not exceeding 12 months and must meet local statutory requirements. An observer from the Mechanical Engineer Chamber or an accredited third-party company should attend the test[4].

Initial Inspection

An initial inspection is required before a new crane is taken into use, or if a crane is taken into use after being out of operation for a long period, moved to another location, or if there has been a major modification in crane structure or components[4].

Slings and Accessories Inspection

This inspection focuses on non-maintainable load lifting attachments and accessories attached to the crane hook. It identifies deficiencies and deviations from local statutory safety and health regulations[4].

Operator Training and Compliance

Operator Training

Crane operator training is crucial for safe and compliant operation. Training should cover the functionality of all new cranes and provide participants with the knowledge to reduce operator errors that may lead to downtime[2].

Compliance with Regulations

Regularly scheduled crane inspections help companies comply with local regulations and highlight safety and production issues. Compliance inspections satisfy regulatory requirements established by governmental authorities such as OSHA. It is important to note that annual compliance inspections alone do not ensure full compliance; additional preventive maintenance, repairs, and other evaluations are necessary[4].

By following these guidelines, crane operators and maintenance personnel can ensure that overhead cranes are operated safely, efficiently, and in compliance with regulatory standards. Regular inspections, preventive maintenance, and proper training are key components in maintaining crane safety and productivity.

Regulations for Safety Inspection of Hazardous Machines …

Regulations for Safety Inspection of Hazardous Machines and Equipment

General Principles

Article 1: Enactment

These regulations are enacted pursuant to the provisions of Paragraph 4 of Article 16 of the Safety and Health Act.

Article 2: Terminology

Unless otherwise defined in these Regulations, the terminology relating to dangerous machines and equipment shall be as specified in the relevant stipulations of occupational safety and health.

Article 3: Scope of Application

These Regulations shall apply to the dangerous machines with the capacity as stipulated. The inspection of domestic (homemade) hazardous machines/equipment shall be subject to this regulation, the Occupational Safety and Health Act, and relevant national, international, or association standards endorsed by the central governing authority.

Inspection and Certification

Article 10: Strength Calculation and Assembly Drawings

• The strength calculation basis for the major structural components of fixed type cranes must be described in detail using mathematical formulas as per relevant regulations.
• Assembly drawings must include specific items such as strength calculation basis and other structural details.

Article 12: Completion Inspection

• Upon completing the installation of fixed type cranes or altering their location, the Employer must submit an Application Form for Completion Inspection along with necessary documents, including:
• Qualification Certification for the type inspection of manufacturing facilities.
• Area drawings and a fundamental summary of the installation location.
• Specification of Fixed Type Cranes.
• Strength calculation basis and assembly drawings.

Simulated Load Test

• If the load test or stability test cannot be carried out due to the location or other reasons, the Employer must entrust the Manufacturer to fill up the Application Form for the Simulated Load Test.
• The inspecting organization shall issue the Report for the Results of the Simulated Load Test.
• Fixed type cranes qualified in the simulated load test are exempted from the load test or safety test before the completion inspection.

Reporting and Compliance

Article 3: Reporting Alterations

Any alteration of the equipment or personnel must be reported to the local inspecting organization.

Article 12: Submission of Documents

The Employer must ensure all required documents are submitted to the inspecting organization for approval before any manufacturing or modification work is carried out.

Certification and Qualification

Qualification Certificate

The inspecting organization shall issue the Qualification Certificate of Type Inspection for Manufacturing Equipment for qualifiers in the type inspection.

Periodic Inspections

Article 132: Periodic Inspection of Pressure Vessels

The periodic inspection of pressure vessels shall be carried out more than one time per year.

Compliance with International Standards

Article 3: Compliance with International Standards

Hazardous machines/equipment that are either directly imported or locally designed and manufactured must comply with international standards based on contractual agreements. These machines/equipment are also subject to the stipulations of the same standards relevant to material selection, mechanical properties, construction methods, and inspection methods.

Conclusion

The Regulations for Safety Inspection of Hazardous Machines and Equipment are comprehensive and stringent, ensuring the safety and compliance of hazardous machinery in Taiwan. They outline detailed procedures for inspection, certification, and reporting, and emphasize the importance of adhering to both national and international standards. Employers and manufacturers must carefully follow these regulations to ensure the safe operation and maintenance of hazardous machines and equipment.

Requirements for rated load tests for new or altered cranes.

The website you mentioned does not directly lead to a specific document, but based on the provided sources, here is an in-depth guide to OSHA standard interpretations, particularly focusing on the topics that might be relevant for the date range and content of 2009.

OSHA Standard Interpretations: An Overview

What are OSHA Standard Interpretations?

OSHA standard interpretations are official letters and documents that explain how OSHA standards, regulations, and requirements apply to specific circumstances. These interpretations help employers, employees, and other stakeholders understand their obligations and compliance requirements.

Key Interpretations from 2009

Application of OSHA’s De Minimis Policy

Chimney Construction Work

• On August 24, 2009, OSHA issued an interpretation regarding the application of its de minimis policy to certain chimney construction work. This interpretation addressed the requirements of 29 CFR 1926.452(o)(3) and various subsections of 29 CFR 1926.552(c), such as (c)(1), (c)(4), (c)(8), (c)(13), (c)(14)(i), and (c)(16).
• The de minimis policy is used to determine whether a violation is so minor that it does not warrant a citation. This interpretation provided guidance on how this policy applies to specific safety standards in the construction industry[1].

Penalty Adjustment Factors

Amendments to OSHA’s Penalty Policy

• On August 21, 2009, OSHA issued an interpretation related to amending the penalty adjustment factors under 29 CFR 1903.
• This interpretation explained the changes to how OSHA calculates penalties for violations, providing clarity on the factors that influence the severity of penalties imposed on employers[2].

Management of Organizational Change

Process Safety Management

• On March 31, 2009, OSHA provided an interpretation on the management of organizational change under the Process Safety Management (PSM) standard, 29 CFR 1910.119.
• This interpretation detailed how employers should manage changes within their organizations to ensure compliance with PSM requirements, emphasizing the importance of proper procedures and training[2].

Compliance with Bloodborne Pathogens Standard

Medical and First Aid Procedures

• On February 27, 2009, OSHA issued an interpretation on compliance with the Bloodborne Pathogens Standard, 29 CFR 1910.1030.
• This interpretation clarified various aspects of the standard, including the administration of medical treatment, the use of personal protective equipment, and the handling of sharps and other contaminated materials[2].

Hazard Communication Standard

General Requirements

• OSHA’s Hazard Communication Standard (HCS) requires employers to train employees to recognize chemical hazards and take necessary precautions.
• Employers must ensure that employees understand the hazards of the chemicals they work with, how to read and understand Safety Data Sheets (SDS), and how to use personal protective equipment[3].

Training and SDS

• The HCS mandates that employers provide comprehensive training to employees on chemical hazards, including how to identify hazardous chemicals, understand SDSs, and follow safe handling procedures.
• Employers must also ensure that SDSs are readily available to employees and that chemical labels comply with OSHA regulations[3].

Conclusion

OSHA standard interpretations are crucial for understanding the specific requirements and applications of OSHA regulations. These interpretations help in ensuring compliance and maintaining a safe work environment by providing detailed guidance on various aspects of workplace safety and health.

By reviewing these interpretations, employers and employees can gain a deeper understanding of their responsibilities and the steps necessary to adhere to OSHA standards, thereby reducing the risk of workplace injuries and illnesses.

Crane Inspection And Certification China Manufacturer Guide

Guide to Crane Inspection and Certification

Introduction

Crane inspection and certification are crucial for ensuring the safety and efficiency of crane operations. This guide outlines the key requirements, procedures, and certifications involved in crane inspection.

Eligibility and Experience Requirements for Crane Inspectors

• To become a certified crane inspector, one must be at least 18 years of age.
• Applicants must have a minimum of 2,000 hours of documented work experience within a five-year period related to maintaining, inspecting, servicing, repairing, or modifying cranes[1][4][5].

Training and Education

• Formal training is essential, and inspectors must undergo training every two years. This training includes learning about safety measures, proper use of tools, and how to operate cranes safely[4][5].
• Training courses, such as those offered by Konecranes, include hands-on experience, written evaluations, practical evaluations, and the ability to present findings[5].

Certification Process

Types of Certifications

• Certifications are available for various types of cranes, including:
• Articulating Crane Inspector (ACI)
• Mobile Crane Inspector (MCI)
• Tower Crane Inspector (TCI)
• Overhead Crane Inspector (OCI)[1].

Steps to Become Certified

• Submit a completed Experience Form and relevant documentation at least two weeks prior to submitting the exam candidate application[1][4].
• Pass the written examinations, which include a Core Examination and specialty examinations for specific crane types[1].
• Currently CCO-certified operators are not required to take the corresponding operator exam if they maintain their certification status in good standing[1].
• Comply with the National Commission for the Certification of Crane Operators (NCCCO) Substance Abuse Policy and Code of Ethics[1].

OSHA Inspection Requirements

Types of Inspections

• OSHA mandates three types of inspections:
• Daily/Shift Inspections: Visual inspections before each shift to check for deficiencies. No documentation is required, but using a checklist is recommended[3].
• Monthly Inspections: More detailed inspections to identify any maladjustments, defective parts, or deformations[3].
• Annual/Comprehensive Inspections: Conducted by a qualified person to test the global structure integrity of the crane[3].

Who Should Inspect the Crane?

• Inspections must be performed by a “competent individual” who can identify hazards and take corrective measures. For annual inspections, a “qualified person” such as a certified crane inspector, a registered professional engineer, or a qualified third-party inspector is required[2][3].

Inspection Checklists

• Inspectors must check critical crane components, including:
• Control mechanisms
• Pressurized lines
• Hydraulic system
• Hooks and latches
• Wire rope and reeving
• Electrical apparatus
• Tires
• Ground conditions
• Cab windows
• Safety devices[2][3].

Conducting Crane Safety Inspections

Initial Inspection

• An initial inspection must be done prior to the first use of the crane, including a functional test and a load test. This inspection is repeated every four years[2].

Frequent and Periodic Inspections

• Frequent inspections occur daily to monthly, focusing on the crane’s function and proper operation.
• Periodic inspections occur bimonthly, quarterly, or yearly, with a focus on the crane’s structural integrity and overall condition[2].

Certification Validity and Renewal

• Certification is valid for five years. Inspectors must pass the necessary exams within 12 months of passing the first exam. If additional designations are added within the final 24 months of the certification period, the inspector is exempt from recertifying for the new designation after five years[1][4].

Additional Resources and Services

• Third-party inspection services, such as those provided by the Crane Inspection & Certification Bureau (CICB), can ensure neutrality and adherence to all safety regulations, especially for high-risk jobs[3].
• Companies like Konecranes and Southeast Rigging offer training courses, inspection services, and rigging products to support crane safety and compliance[5][4].

By following these guidelines and ensuring compliance with OSHA standards and NCCCO certifications, crane inspectors can help maintain safe and efficient crane operations.

Overhead Crane load testing project video

Overhead Crane Load Testing: A Comprehensive Guide

Importance of Load Testing

Load testing is a critical procedure for ensuring the safety and reliability of overhead cranes. It verifies that the crane can safely handle its maximum rated load and identifies any potential issues or weaknesses in the crane’s structure or components. This process is essential for complying with safety regulations and standards.

When to Conduct Load Testing

• New Cranes: Load testing is required before the initial use of any new overhead crane to ensure it meets design specifications and safety standards[3][4][5].
• Altered or Repaired Cranes: Cranes that have been modified, repaired, or re-rated must undergo load testing to validate their new or altered capacities[3][4][5].
• Periodic Testing: Existing crane systems should be load tested once every four years to maintain safety and compliance[2][3][4].

Pre-Test Procedures

Inspection of the Crane

• Conduct a thorough inspection of the crane and all its components before the test. Check for signs of wear and tear, ensure all safety features are in proper working order, and verify that the crane is aligned correctly[1][5].

Site Preparation

• Ensure the working environment is safe and prepared. This includes checking the crane rail surface, ensuring electrical insulation and grounding are proper, and having firefighting and medical rescue equipment on hand[5].

Preparation of Load Blocks

• Prepare the load blocks according to the specified parameters. For example, the load blocks should be marked and prepared to represent 100% to 125% of the rated load capacity[5].

Conducting the Load Test

No-Load Test

• Operate all mechanisms independently and then together, including one-way and two-way movements, to check for smooth operation, unusual noises, vibrations, or looseness. Also, check the reliability of the brakes and the tightness of the bolts[5].

Static Load Test

• Lift the test load slowly and at the slowest speed and acceleration to avoid load shock. Lift the load about 200-300 mm above the ground and hold it for 10 minutes. This test should be conducted at least three times with an overload of up to 125% of the rated capacity[5].

Dynamic Load Test

• Hoist the test load to ensure it is supported by the crane and held by the hoist brake(s).
• Transport the test load by means of the trolley for the full length of the bridge.
• Transport the test load by means of the bridge for the full length of the runway in both directions.
• Lower the test load and stop and hold it with the brake(s)[4].

Monitoring and Recording

Load Indicators

• Monitor the load indicators throughout the lifting process and take note of any fluctuations or irregularities. Ensure the crane can safely support the load without signs of strain or failure[1].

Documentation

• Document and record the results of the load test for future reference and comparison. This includes recording the test load, the performance of the crane, and any issues identified during the test. Maintain these records on file for the life of the equipment[1][3][4].

Safety Considerations

Qualified Personnel

• Ensure the test is conducted by qualified and experienced personnel who are familiar with the specific crane being tested. This minimizes the risk of accidents and errors during the testing process[1].

Safety Equipment

• Ensure that all necessary safety equipment is available and ready for use. This includes firefighting equipment, medical rescue equipment, and other safety measures to respond promptly in case of an accident[5].

Post-Test Procedures

Inspection After Testing

• After the load test, inspect the crane again to ensure there are no signs of damage or strain. Check the crane’s components, such as the hooks, brakes, and structural elements, for any anomalies[1][5].

Maintenance and Repair

• Address any issues identified during the test. Perform any necessary repairs or maintenance to ensure the crane is in good working condition before it is put into operation[1].

Compliance with Standards

OSHA Standards

• Follow OSHA standards, specifically CFR 1910.179, which requires load testing for new, altered, and repaired cranes. Test loads should not exceed 125% of the rated load unless recommended by the manufacturer[3][4].

ASME Standards

• Adhere to ASME standards such as ASME B30.2, B30.16, and B30.17, which detail load test requirements for overhead and gantry cranes, including the need for periodic inspections and testing[3][4].

By following these guidelines, you can ensure the safety and reliability of your overhead crane, comply with relevant regulations, and maintain optimal performance of your equipment.

Frequently Asked Questions (FAQs)

What is the purpose of load testing for cranes in China?

Load testing for cranes in China is a critical process designed to ensure the safe and efficient operation of the crane. The primary purpose is to verify that the crane can handle its maximum load capacity safely and efficiently. This involves subjecting the crane to a predetermined load to assess its structural integrity, functionality, and safety mechanisms. Load testing is essential for certification and compliance with local regulations and safety standards, such as those set by OSHA or ANSI, and it helps identify any manufacturing defects or installation errors that could compromise the crane’s operation[1][2][4].

How is a load test conducted for cranes in China?

The load test for cranes in China involves several steps. First, the maximum load capacity of the crane is determined from the manufacturer’s documentation or load charts. A load test weight equivalent to this capacity, often 1.25 times the rated load, is prepared and securely attached to the crane’s hook or lifting mechanism. The crane is then subjected to this load, and its performance is observed over a specified period, usually several hours, to simulate actual working conditions. The test includes incremental loads applied to various parts of the crane, such as the hoist, trolley, and boom, to evaluate its stability and endurance. The crane must hold the test load without signs of structural failure or excessive deflection[1][2][3].

What are the key reference specifications for crane load testing in China?

The key reference specifications for crane load testing in China are established by regulatory bodies, industry standards, and manufacturers’ recommendations. One common standard is the American Society of Mechanical Engineers (ASME) standard B30.5, which provides detailed instructions on load testing procedures. Additionally, local regulations and standards, such as those outlined in the Laws & Regulations Database of the Republic of China (Taiwan), specify that load tests should be performed with a test load weighing 1.25 times the rated load of the crane. These specifications cover the procedure, criteria, and safety factors to be considered during the testing process[1][3][4].

How often should crane load tests be performed in China?

Crane load tests in China are typically required at specific intervals and under certain conditions. For new crane installations, load testing is mandatory before the crane is put into service to verify its performance capabilities and ensure compliance with safety standards. Regular load tests are also required annually or semi-annually, depending on the usage and type of crane. For example, heavy or severe load tests should be conducted semi-annually or quarterly to ensure the crane’s continued safe operation. Additionally, any significant modifications or repairs to the crane may necessitate a new load test[2][4][5].

What documentation and records are required for crane load testing in China?

For crane load testing in China, detailed documentation and records are essential. All load testing reports must be filed and accessible to the personnel in charge. These reports include the results of the load test, any observations or issues noted during the test, and confirmation that the crane meets the required safety standards. The documentation should also include information about the test loads used, the duration of the test, and any inspections or maintenance performed before and after the test. This documentation is crucial for compliance with regulatory requirements and for maintaining the certification of the crane[2][3][4].