Section 3 Fabrication of certified lifting appliances

3.1.1 The fabrication and inspection of lifting appliances subject to certification is to comply with the requirements in this Section and the appropriate Sections of this Code.

3.1.2 The requirements in Ch 11, 1.1 Scope, Ch 11, 1.2 General material requirements and Ch 11, 1.3 General requirements for fabrication apply to certified lifting appliances.

3.1.3 The requirements of the Rules for the Manufacture, Testing and Certification of Materials, July 2022, or an agreed National or International Standard, are to be followed for the applicable fabrication and welding requirements not covered in this Section.

3.2.1 All standards related to welding procedures, qualification of welders, Non-Destructive Examination procedures, Non-Destructive Examination personnel qualifications and Non-Destructive Examination acceptance criteria are to be agreed with the surveyor prior to the commencement of work.

3.2.2 Welding procedures are to be in accordance with the Rules for the Manufacture, Testing and Certification of Materials, July 2022, or an agreed National or International Standard. All welding procedures are to be qualified by testing and approved by the Surveyor.

3.2.3 All welders are to be qualified to the satisfaction of the Surveyor in accordance with the Rules for the Manufacture, Testing and Certification of Materials, July 2022 or other equivalent National or International Standards.

3.2.4 Following welding, visual inspection is to be carried out by qualified inspectors to ensure that the welds are in accordance with the approved plan and comply with agreed acceptance criteria. Surveyors will conduct visual examination spot checks to confirm the overall quality of the welds against the approved plan and agreed acceptance criteria.

3.2.5 Non-Destructive Examination is to be carried out by qualified Operators using procedures approved by Level 3 NDE personnel and accepted by the surveyor and according to the minimum requirements given in Ch 12, 3.2 Initial Survey of new installations 3.2.4 to the Surveyor’s satisfaction.

3.2.6 In addition to visual inspection, welds are to be non-destructively examined to verify their soundness. All Non-Destructive Examinations (NDE) are to be carried out to a written procedure that is representative of the item under inspection and they are to be based upon a National or International Standard. Personnel carrying out NDE or interpreting the results of NDE are to be qualified to the appropriate level of a nationally recognised scheme such as ISO 9712 Non-destructive testing – Qualification and certification of NDT personnel, ACCP (ASNT Central Certification Program (American Society for Nondestructive Testing (ASNT))) or an employer-based scheme such as SNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing. Where employer-based schemes are applied, personnel qualification to these schemes may be accepted if the written practice is acceptable to LR. Level 1 personnel are not permitted to interpret results to Codes or Standards.

3.3.1 Check tests may be required at the discretion of the Surveyor unless the material is sourced from an LR approved manufacturer, see Ch 1, 1.6 Materials and fabrication 1.6.6.

3.3.2  In general, the manufacturer’s chemical analysis will be accepted but may be subject to occasional independent checks if required by the Surveyor.

3.3.3 When mechanical check tests are required, the specified tests are to be carried out by competent personnel using calibrated machines which are maintained in a satisfactory and accurate condition.

3.4.1 In all cases, the removal of defects, and repair by welding where appropriate, is to be carried out to the satisfaction of the Surveyor.

3.4.2 Surface imperfections may be removed by mechanical means as agreed with the Surveyor. After such treatment, the dimensions are to comply with an agreed National or International Standard and the area is to be confirmed to be free from defects. The work is to be completed to the satisfaction of the Surveyor.

3.4.3 For steel castings, flame scarfing or arc-air gouging may be used, provided that preheating is used where necessary and the surfaces of the resulting depression are subsequently ground smooth. The complete removal of all defects is to be confirmed by suitable Non-Destructive Examinations and the area is to be suitably prepared for welding.

3.4.4 Repair by welding is not to be carried out without the agreement of the Surveyor. Agreement of the Surveyor is to be obtained before the work is commenced.

3.4.5 The complete removal of all defects is to be proved by suitable non-destructive examinations and the area is to be suitably prepared for welding.

3.4.6 Welding is to be carried out using a qualified and approved procedure which is to include the selection of suitable welding consumables. Preheating and post-weld heat treatment may be necessary due to the particular chemical composition or dimensions of the weld repairs. The repairs are to be carried out by qualified welders under adequate supervision.