Every new and altered crane requires some rated load tests as per IS 3177. This requirement goes hand in hand with ensuring that the overhead cranes perform efficiently and that all fatalities are avoided. The basic requirements are mandatory to remain compliant as per IS’s safety code.
Let us have a look at some of these requirements and understand their importance in industrial applications.
What is a load test?
A certified and rated load test implies that test loads must not exceed 125 percent of the rated load except when the manufacturer recommends it. Reports of load tests are then placed in proper files for appropriate perusal and ready availability of appointed personnel.
Why is the load test so important?
While considering operational and facilitation safety, we cannot afford to overlook any part of the maintenance process and equipment inspection. An integral part of this equipment inspection includes testing equipment before using it in several operations. Leading crane manufacturers & service providers worldwide are committed to providing quality testing and maintenance services, and industries must acquire their services diligently.
Cranes are an integral part of every factory floor. They are responsible along with other equipment such as hoists and monorails, for lifting and rigging heavy loads in the workplace. Every workplace needs to ensure that its cranes are working in their optimum conditions to extract maximum productivity. Hence factories need to install new cranes once in a while or perform vital modifications on the installed ones.
As per IS guidelines, interpretation-rated load tests of every new and altered crane are mandatory before they are initially used. This ensures that any impending issues in repair or errors in installations are revealed during the load tests and tended to before the crane is operated in its entirety. This also implies that every employer must comply with the standards described by IS and by no means can utilize the ANSI standard based on a de minimus condition.
Regulations from OSHA
The most important thing is, it is a mandatory process. If you are in charge of the facility, you have to know the most significant reason. You have to meet the requirements of OSHA (Occupational Safety and Health Administration).
According to OSHA, you have to conduct three types of inspection. You have to do it on overhead crane equipment.
The first one is the initial inspection. It is mandatory to perform this inspection of your new equipment. After that comes the frequent inspection. You have to perform it regularly. It can be weekly as well as monthly. It will depend on the equipment's service class. Finally, you have to opt for periodic inspection. You should carry out this inspection semi-annually, manually, or quarterly. It will also depend on the service class of the equipment.
You can discover problems and bottlenecks
You should know that preventing injuries is not the only purpose of load testing. It can provide pivotal insights to the personnel of manufacturing and industrial facilities. To be precise, they will notice the functional performance of the crane and fathom the potential bottlenecks that are happening regularly.
With the help of this process, you can determine the hidden issues. Those issues are responsible for the slow functioning of the cranes. Plus, it is capable of pointing out the weaknesses in the overhead crane's performance. You will understand whether it needs any repairs or not. Also, you can discern the necessity of buying new lifting equipment.
Avoid emergencies
Another vital importance of load testing is preventing emergencies. Or it may lead to unwanted accidents. Without load testing, it will be hard for the operators to understand the developing malfunction. If it becomes too late, the possibility of failure will increase.
Cranes are capable of taking heavy loads daily. Therefore, the possibility of wearing and tearing is pretty high. To be specific, it will happen in the hoists and cranes. If you follow the load tests capabilities of OSHA, you can pinpoint all the functionality issues. Or else, issues can create hazards and will bring injuries to your employees. So, you have to address them and correct them as soon as possible.
You can maintain the overhead crane equipment
Load testing is an eye-opener to managers. It urges the managers to incorporate maintenance procedures into their schedules.
While doing load testing, you will get enough time to examine the performance and functionality of the crane. You can consider it to be the best opportunity to make sure to carry out routine maintenance regularly. It will also ensure the adequacy of maintenance.
It enhances productivity
Productivity is an essential part of an organization, and load testing will enhance that. Due to this process, managers can find out the areas where they have to implement changes. Hence, facilities will become more productive.
There can be some minor errors in the equipment. To find out those errors, nothing can be better than load testing. You can repair those errors, and your equipment will become more competent. Once it becomes more efficient, productivity will surge up.
All of us know that productivity improvement is essential. With the help of it, you can improve the bottom line of your manufacturing or industrial operations. It will be necessary for the long-run development.
Some testing standards of OSHA
OSHA provides some testing standards that you have to meet.
- You should appoint a designated person who is capable of operating. The person must be qualified and possess professional knowledge. He or she must have specific training along with experience.
- Some tests will determine the hoist-limit device's trip setting. You have to test it using an empty hook that will travel from increased speed to maximum speed.
- You must test new and altered cranes before using them. There are certain functions that you have to check. For instance, you have to check hoisting, lowering, trolley travel, bridge travel, safety devices, locking, and limit switches.
- You have to locate the upper limit device's actuating mechanism. In this way, you make your device trip for every condition. Also, it will ensure insufficient time to avoid the load block or hook's contact with cranes or trolleys.
So, these are the importance of load testing overhead cranes. It will guarantee the safety of your workers. Moreover, it will improve the overall productivity of your company. You don't have to come across any severe accidents if you conduct load testing. So, take a look at those reasons and do your work according to that.
Rated load tests specifications
- For New and existing equipment: OSHA guidelines state that all new gantry and overhead cranes installed or constructed after 31st Aug 1971 meet the concerned design specs of the American National Standard Safety Code for Overhead and Gantry Cranes.
- For modifications made: An overhead crane may be modified and later re-rated if the modifications and the structure supporting them goes through proper checks based on the new rated load. Qualified personnel or engineer or the equipment manufacturer ought to perform these checks. The crane must be inspected, and the new rated load must be displayed as per OSHA guidelines.
Conclusion
There needs to be an inspection of the installations and the alterations made on the cranes to ensure they have been done correctly. Any disregard on this front would lead to inefficiency in operation and worse still, fatalities during these operations. Hence a load test is very crucial in assuring all alterations are in their proper place, and the crane can be operated without the possibility of any mishaps.
