OSHA 1926.552(c)(15) Construction Hoists

OSHA Safety & Health Regulations for Construction 1926.552(c)(15)

Following assembly and erection of hoists, and before being put in service, an inspection and test of all functions and safety devices shall be made under the supervision of a competent person. A similar inspection and test is required following major alteration of an existing installation. All hoists shall be inspected and tested at not more than 3-month intervals. 

The employer shall prepare a certification record which includes the date the inspection and test of all functions and safety devices was performed; the signature of the person who performed the inspection and test; and a serial number, or other identifier, for the hoist that was inspected and tested. The most recent certification record shall be maintained on file.

The use of water weights for proof load testing produce significant savings when certifying construction hoists. 

Specifications and installations are generally governed by OSHA 1926.552 and ANSI 10.4 standards. The requirements include a "drop test" as part of the final inspection and certification.

Traditionally tested using solid weights, the process is very cumbersome requiring the use of ancillary lifting equipment for hauling and staging the weights for testing.The bags when empty are packaged to a very light and small size. No support lifting equipment is required shaving a significant part of the cost, time, and labor when transporting and testing.

With Water Weights, the amount of water supplied to the bag is controlled from a manifold assembly running through a certified flow meter to achieve a variety of weights without having to load and unload the hoist car. 

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Title: Unit proof test and examination of cranes.

Occupational Safety & Health Administration (OSHA)

• Part Number:             1919

• Part Title:      Gear Certification

• Subpart:        H

• Subpart Title:            Certification of Shore-Based Material Handling Devices

• Standard Number:     1919.71

• Title: Unit proof test and examination of cranes.

1919.71(a)

    Unit proof tests of cranes shall be carried out at the following times:

1919.71(a)(1)

    In the cases of new cranes, before initial use and every 4 years thereafter.

1919.71(a)(2)

    In the cases of uncertificated cranes which have been in use, at the time of initial certification and every 4 years thereafter.

1919.71(a)(3)

    After important alterations and renewals and after repairs due to failure of, or damage to major components.

1919.71(b)

    Unit proof load tests of cranes shall be carried out where applicable with the boom in the least stable direction relative to the mounting, based on the manufacturer's specifications.

1919.71(c)

    Unit proof load tests shall be based on the manufacturer's load ratings for the conditions of use and shall, except in the case of bridge type cranes utilizing a trolley, consist of application of a proof load of 10 percent in excess of the load ratings at maximum and minimum radii, and at such intermediate radii as the certificating authority may deem necessary in the circumstances.1 Trolley equipped cranes shall be subject to a proof load of 25 percent in excess of the manufacturer's load rating. In cases of foreign manufacture, the manufacturer's specifications shall be subject to approval by the certificating authority as being equivalent to U.S. practice. The weight of all auxiliary handling devices such as, but not limited to, magnets, hooks, slings, and clamshell buckets, shall be considered part of the load.

    1 The manufacturer's load ratings are usually based upon percentage of tipping loads under some conditions and upon limitations of structural competence at others, as well as on other criteria such as type of crane mounting, whether or not outriggers are used, etc. Some cranes utilizing a trolley may have only one load rating assigned and applicable at any outreach. It is important that the manufacturer's ratings be used.

1919.71(d)

    An examination shall be carried out in conjunction with each unit proof load test. The accredited person, or his authorized representative, shall make a determination as to correction of deficiencies found. the examination shall cover the following points as applicable:

1919.71(d)(1)

    All functional operating mechanisms shall be examined for improper function, maladjustment, and excessive component wear, with particular attention to sheaves, pins, and drums. The examination shall include operation with partial load, in which all functions and movements, including, where applicable, maximum possible rotation in both directions, are performed.

1919.71(d)(2)

    All safety devices shall be examined for malfunction.

1919.71(d)(3)

    Lines, tanks, valves, drains, pumps, and other parts of air or hydraulic systems shall be examined for deterioration or leakage.

1919.71(d)(4)

    Loose gear components, such as hooks, including wire rope and wire rope terminals and connections, shall be checked with particular attention to sections of wire rope exposed to abnormal wear and to sections not normally exposed for examination. The provisions of 1919.24 shall apply in wire rope examinations. Cracked or deformed hooks shall be discarded and not reused on any equipment subject to the provisions of Part 1918 of this chapter and this Part 1919.

1919.71(d)(5)

    Rope reeving shall comply with manufacturer's recommendations.

1919.71(d)(6)

    Deformed, cracked, or excessively corroded members in crane structure and boom shall be repaired or replaced as necessary.

1919.71(d)(7)

    Loose bolts, rivets, or other connections shall be corrected.

1919.71(d)(8)

    Worn, cracked, or distorted parts affecting safe operation shall be corrected.

1919.71(d)(9)

    Brake and clutch system parts, linings, pawls, and ratchets shall be examined for excessive wear and free operation.

1919.71(d)(10)

    Load, boom angle, or other indicators shall be checked over their full range for any significant inaccuracy. A boom angle or radius indicator shall be fitted.

1919.71(d)(11)

    It shall be ascertained that there is a durable rating chart visible to the operator, covering the complete range of the manufacturer's capacity ratings at all operating radii, for all permissible boom lengths and jib lengths, with alternate ratings for optional equipment affecting such ratings. Necessary precautions or warnings shall be included. Operating controls shall be marked or an explanation of controls shall be posted at the operator's position to indicate function.

1919.71(d)(12)

    Where used, clamshell buckets or other similar equipment such as magnets, etc., shall be carefully examined in all respects, with particular attention to closing line wires and sheaves. The accredited person may supplement such examination by requesting any operational tests as may be appropriate.

1919.71(d)(13)

    Careful examination of the junction areas of removable boom sections, particularly for proper seating, cracks, deformities, or other defects in securing bolts and in vicinity of such bolts.

1919.71(d)(14)

    It shall be ascertained that no counterweights in excess of the manufacturer's specifications are fitted.

1919.71(d)(15)

    Such other examination or supplemental functional tests shall be made as may be deemed necessary by the accredited person under the circumstances.

Mooring System Load Cells

Tension Tether Measurement load cells used in the monitoring of underwater anchor tethers on oil & gas offshore platforms. Designed for a 25 year sub-sea life cycle because once installed they cannot be removed if failure arises. The continued and reliable operation is critical to the integrity of an oil rig's mooring system especially in locations where high seas and hurricane forces can be expected.

To ensure compliance, they undergo rigorous in-house and third party examination and testing at each critical stage of the manufacturing process. This process commences with the Engineers Design study considering the different elements such as; loading forces, materials of construction, sealing arrangements, pressure compensation.
Once approval of the design study is granted, the process continues with NDT examination of the raw
material for the billet, often procured from a bespoke forging or limited production run. The testing and examination continues throughout the process with one of the final tests being the hydro test where the load cell is submerged in water for an extended period at a pressure above the operational depth.

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European Crane Manufacturers Position Paper on Overload Testing

Mobile crane manufacturers have moved to end the practice of overload testing except after major repairs and overhauls.

The European manufacturers’ association FEM (Fédération Européenne De La Manutention) has published a position paper warning that overloading cranes will reduce their lifespan. Mobile cranes should not be overloaded even if the rated capacity limiter (overload prevention device) is left switched on.

FEM says that overload testing “should only be performed in case of modification or repair of load-bearing parts or in case of a general overhaul. National regulations in some countries may require periodic testing with overload and/or overload testing prior to the execution of lifting jobs every time the crane configuration is changed.”
It adds: “Structural failures may be the result of cracks from overloading and/or fatigue and such defects will not be identified by an overload test. Thus overload testing may give a false sense of security to owners and users.

“To ensure the integrity of the structure, thorough examinations after each overload situation and prior to the execution of lift jobs are recommended. Such examination is a visual inspection combined with functional tests (including the safety devices) and may require non-destructive testing such as magnetic particle or ultrasonic testing. Any malfunction or observation during the inspection needs to be assessed by a competent person to decide whether the lift can be safely executed or whether an immediate repair/modification is needed.”
The full position paper can be seen on the FEM website.

694 Ton Overhead Crane Test with Water Weights