Section 1 Testing

1.1.1 Every lifting appliance is to be tested and thoroughly examined before being taken into use for the first time or after any subsequent alteration or repair which may affect the strength of the appliance, or at certain Periodical Surveys as indicated in Ch 12, 3 Survey requirements.

1.1.2 Where testing machines (e.g. dynamometers) are used to apply test loads, they are to be of a type approved by Lloyd’s Register (LR) as suitable for the intended purpose. The machine is to be calibrated biennially by a recognised authority and the accuracy is to be within ±2 per cent. Testing machines are not to be used for initial testing; and although acceptable to LR for periodical re-testing or following repairs, some National Authorities will not accept this form of testing.

1.1.3 Where test weights are used to apply test loads, the weights are to be certified as accurate to within 2 per cent.

1.1.4 Water bags may be used instead of certified weights for testing lifting appliances. Where used, these are to be of a type suitable and certified for the purpose. The volume of water is to be measured using a calibrated flow meter which has been certified as accurate to within ±2 per cent. As an alternative, use of calibrated load cells certified as accurate to within ±2 per cent for determining the test loads could also be accepted. The flow meters and load cells are to be re-certified biennially.

1.1.5 Suitable precautions are to be taken before commencing the test to ensure the stability of the ship throughout the load test and also in case of a failure of the load test. The adequacy of the supporting structure to bear the test loads is also to be ensured.

1.1.6 A risk assessment is to be carried out to evaluate the consequences of any failures during the load test and the identified risks are to be mitigated to acceptable levels. The system integrator in cooperation with the manufacturer of the crane and the designer of vessel shall prepare a Safety Statement in line with LR’s ShipRight Procedure Risk Based Certification (RBC) process and/or in line with the requirements of the National Administration (as applicable).

The risk mitigation may include the following measures;

1. the application of a testing concept that would identify components along the main load path which could be tested separately before assembly of the lifting appliance on board, where the extent of the separate testing is also to be based on the results of the risk assessment;
2. positioning of the test load (e.g. at the stern of the ship) in such a way that any single point failure (e.g. drop of load) will not lead to further failures (e.g. collapse of parts of the crane); and
3. consideration of the design of the ship and lifting appliance as a single system in such a way that any single point failure will not lead to further failures (e.g. capsizing of the ship, damage of the crane, possible interference with any onboard structure).

1.1.7 Measures are to be taken to ensure that the appliance can be controlled during the test and to avoid injury or damage which might occur in the event of failure under load.

1.1.8 Lifting appliances are generally to hold the test weights for at least 5 minutes, but this may be extended at the discretion of the Surveyor.

1.2.1 For the purpose of these requirements, loose gear is defined as including hooks, hook blocks, shackles, blocks, swivels, chains, rings and similar items not permanently attached to the lifting appliance. Lifting beams, spreaders, frames, grabs and similar items of equipment which are not an integral part of the lifting appliance are also considered as loose gear. Built-in sheaves and blocks and other items permanently attached to the lifting appliance are not considered as loose gear and the test on the complete system ‘as rigged’ will be accepted as the test on these items.

1.2.2 Every item of loose gear is to be proof load tested and thoroughly examined before being taken into use for the first time and prior to fitting to a lifting appliance or after any subsequent repair or alteration which may affect the strength of the item. The proof load applied to each item of loose gear is to be as required by Table 12.1.1 Proof loads for loose gear and associated Notes, and illustrated in Figure 12.1.1 Proof loads for loose gear.

1.2.3 For all blocks (single and multi-sheave), the proof load is to be taken as the resultant load and applied to the head fitting of the block during the test. Where the block is fitted with a becket, the load applied to the becket during the load test of the block will be accepted as the proof test on the becket.

1.2.4 Sheave blocks that are permanently attached to, or integral with, the hook are called cargo hook blocks and are to be tested with a proof load for multi-sheave blocks as indicated in Table 12.1.1 Proof loads for loose gear. The hooks are to be tested with a proof load for hooks as indicated in Table 12.1.1 Proof loads for loose gear.

Figure 12.1.1 Proof loads for loose gear

1.2.5 After proof testing, all parts of the blocks are to be thoroughly examined for deformations, cracks, flaws, or other defects and to check that head fittings can swivel and sheaves rotate freely.

1.2.6 The proof load may be applied to a Ramshorn hook as indicated in Figure 12.1.2 Testing of Ramshorn hooks (Method A: Position for vertical test load) or Figure 12.1.3 Testing of Ramshorn hooks (Method B: Position for vertical test load), but in the latter case an additional load of half the proof load is subsequently to be applied as in Figure 12.1.4 Testing of Ramshorn hooks (Method B: Position for horizontal test load).

Figure 12.1.2 Testing of Ramshorn hooks (Method A: Position for vertical test load)

Figure 12.1.3 Testing of Ramshorn hooks (Method B: Position for vertical test load)

Figure 12.1.4 Testing of Ramshorn hooks (Method B: Position for horizontal test load)

1.2.7 Short and long link chain is to be subjected to a breaking test in addition to the proof test required by Table 12.1.1 Proof loads for loose gear. One sample of length 910 mm is to be taken from each length of chain measuring 185 m or less and is to withstand a breaking load of 4 x SWL for the chain.

1.2.8 Where the design of a lifting beam, frame, or similar item is such that the load can be lifted and supported in more than one manner, each arrangement is to be separately tested. Alternative testing proposals outlining how all components will be loaded above their maximum design load (but not above the required test load) will be specially considered subject to the Surveyor’s satisfaction. Hooks, shackles and blocks forming part of the lifting beam or frame are to be separately tested in accordance with Table 12.1.1 Proof loads for loose gear.

1.2.9 Where the loose gear is for use in an offshore, open sea or diving application, the selection of the component of loose gear should take account of the higher proof loads required by Notes 3 and 4 of Table 12.1.1 Proof loads for loose gear.

1.3.1 Steel wire used in the construction of ropes is to be subjected to breaking, torsion and reverse bend tests and to tests for quality and adhesion of the zinc coating in accordance with ISO 2232 Round Drawn Wire for General Purpose Nonalloy Steel Wire Ropes – Specifications or with an acceptable equivalent. Where required, similar tests may be carried out on wires taken from samples of completed ropes.

1.3.2 Steel wire ropes are to be tested to determine the breaking load of the rope. Tests in accordance with International or recognised National Standards may be accepted and, in this respect, attention is drawn to the following International Standards:

• ISO 2408 Steel wire ropes for general purposes – Minimum requirements.
• ISO 3108 Steel wire rope for general purposes – Determination of actual breaking load.

1.3.3 The breaking load is to be determined by one of the following methods:

1. Testing to destruction a sample cut from the completed rope.

2. Testing the individual wires to destruction, summating the results and deducting a percentage for laying up.

This percentage is to be not less than as given in Table 12.1.2 Percentage deduction for laying up. Manufacturers adopting this method of testing will be required to arrange for occasional tensile tests to destruction to be carried out on completed ropes.

1.3.4 Before a test sample is cut from the rope, it is to be securely seized or clamped so as to prevent any slacking of wires within the test length. The sample is to be of sufficient length to provide a clear test length in accordance with Table 12.1.3 Test length for steel wire ropes.

1.3.5 Up to 80 per cent of the nominal breaking load may be applied quickly. Thereafter, the load is to be applied slowly and steadily until the maximum load is attained. Tests in which a breakage occurs adjacent to the grips may be neglected.

1.3.6 Terminal connections, where used, are to be of a type acceptable to LR and manufactured to a recognised National or International Standard. Proprietary terminal connects not manufactured to a recognised National or International Standard will be specially considered.

Initial tests are to be carried out on various sizes of connections to show that the strength of the completed termination is not less than the following percentage of minimum breaking load of the original wire rope:

1. For metal and resin sockets, ferrules and ferrule-securing and swage sockets:
   • 95 per cent for ropes up to 50 mm diameter; or
   • 90 per cent for ropes exceeding 50 mm diameter.
2. For wedge sockets:
   • 80 per cent.

After completion, each terminal connection is to be proof tested to twice the SWL on the rope. However, for larger terminations where the safety factor on the rope is between 3,0 and 4,0, testing of the termination is not to exceed 50 per cent of the minimum breaking load strength of the rope.

1.3.7 Poured zinc and resin sockets do not require proof testing, provided:

1. The termination has been carried out by a competent person in accordance with a recognised procedure and material requirement.

2. The sockets are in accordance with a recognised Standard and are certified.

1.4.1 Fibre ropes are to be tested to determine the breaking load of the rope. Additional tests may be required, particularly in the case of ropes manufactured from man-made materials, in order to establish the suitability of the rope for its intended purpose.

1.4.2 Manufacture and testing are to be in accordance with international or recognised National Standards where appropriate.

1.4.3 The breaking load is to be determined by testing to destruction a sample cut from the completed rope. Alternative proposals will, however, be specially considered where a breaking test would be impracticable.

1.4.4 The minimum length of test sample is to be as given in Table 12.1.4 Testing of fibre ropes. The sample is to be subjected to an initial tensile load as given in Table 12.1.4 and checked for diameter and evenness of lay-up. The load is then to be increased evenly and continuously by stretching the sample at the rate given in Table 12.1.4 Testing of fibre ropes until the sample breaks. Tests in which a breakage occurs within 150 mm of the grips may be neglected.

1.5.1 Following any preliminary part load tests considered necessary to ensure correct assembly and freedom of operation, each derrick in the system is to be tested with a test load in accordance with Table 12.1.5 Testing of derricks and cranes. The test is to be carried out using certified weights suspended from the cargo hook or lifting attachment, according to a procedure agreed with the Surveyor.

1.5.2 During the test, hoisting and slewing operations are to be carried out at slow speed. The load is to be slewed as far as possible in both directions with the derrick boom at the lowest angle to the horizontal for which it has been approved, see Ch 2 Derrick Systems.

1.5.3 In addition to verifying the adequacy of the derrick and the support structure, the test is to demonstrate the adequacy of the winch brakes, controls and any overload cutout, safe load indicators, etc. The test is also to demonstrate that the test load can be held stationary when the winch drive is switched off, see also Ch 9 Machinery.

1.5.4 Where derricks have been approved for operation in union purchase, they are to be rigged and tested for working both port and starboard sides of the ship. The test is to be carried out for the headroom, runner angle and boom and guy positions for which the rig has been approved, with a test load in accordance with Table 12.1.5 Testing of derricks and cranes for the SWL of the system in union purchase operation.

1.5.5 Following the overload test, the derrick is to be operationally tested with its safe working load. The derrick is to be operated over its full range of positions at normal speeds and it is to be demonstrated that all parts of the system are free to take up their correct positions and that all ropes run freely and reel up correctly on the winch drums.

1.5.6 After testing, the derrick system is to be thoroughly examined for deformations and other defects.

1.5.7 Derrick cranes are to be tested in accordance with Ch 12, 1.5 Derricks and derrick cranes 1.5.1, with the addition that the derrick crane is to be luffed at slow speed to its maximum operating angle to the horizontal while bearing the full test load.

1.5.8 Where twin span tackles are fitted to derrick cranes of patent type, the manufacturer may be required to demonstrate during testing with the SWL that the derrick boom has adequate stability when in the maximum slewed position for both maximum and minimum luffing angles under the maximum approved angles of heel and trim of the ship.

1.6.1 Following any preliminary part load tests considered necessary to ensure correct assembly and freedom of operation, each crane or ROV handling system is to be tested with a test load in accordance with Table 12.1.5 Testing of derricks and cranes. The test is to be carried out using certified weights suspended from the cargo hook or lifting attachment, according to a procedure agreed with the Surveyor.

1.6.2 During the test the crane is to hoist, slew and luff the test load at slow speed. Gantry and travelling cranes together with their travelling trolleys, where appropriate, are to be traversed slowly over the full length of their track. ROV handling systems are to lift the test load through one complete operating cycle.

1.6.3 In the case of a variable load-radius crane, the tests are, generally, to be carried out for the appropriate safe working loads at maximum, minimum and an intermediate radius. Alternative proposals will, however, be considered.

1.6.4 Where the jib length may be increased by the insertion of additional lengths, the crane is to be tested for each jib length. Alternative testing proposals outlining how all components will be loaded above their maximum design load (but not above the required test load) will be specially considered subject to the Surveyor’s satisfaction.

1.6.5 Where it is not practicable for the crane to raise the full test load, as may be the case for hydraulic cranes, a reduced test load may be accepted, but in no case is this to be less than 1,1 x SWL. Although acceptable to LR, this test at reduced load may not be acceptable to some National Authorities.

1.6.6 Following the overload test, the crane is to be loaded with its safe working load and operated over its full range of speeds in order to demonstrate the effective operation of the crane, the accuracy of overload and safe load indicators and the effectiveness of limit switches, etc.

1.6.7 Following the overload test, the ROV handling system is to be operated with its SWL over its complete operating cycle to demonstrate the effective operation of the handling system, the accuracy of overload and safe load indicators and the effectiveness of limit switches, etc.

1.6.8 Where the crane has been approved with hoisting factor of more than 1,6, the test loads indicated in Table 12.1.5 Testing of derricks and cranes are to be increased by the ratio of F _h/1,6, where F _h is derived from Ch 4, 3 Offshore cranes.

1.6.9 Where the ROV handling system has been approved with hoisting factor of more than 1,7, the test loads indicated in Table 12.1.5 Testing of derricks and cranes are to be increased by the ratio of F _h/1,7, where F _h is derived from Ch 4, 4 Submersible handling systems.

1.6.10 After testing, the crane or ROV handling system is to be thoroughly examined for deformations and other defects.

1.7.1 For the purpose of these requirements, the term ‘manned submersible handling systems’ includes the handling of manned diving systems.

1.7.2 Upon completion of preliminary tests necessary to ensure correct assembly and freedom of operation, each lifting appliance used for raising, lowering or transferring manned submersibles is to be subjected to the following tests:

1. A ‘static’ load test equivalent to 1,5 SWL. In the case of cranes or A frames, this load is to be lifted at the maximum and minimum radii or inboard/outboard positions and at an intermediate position.

2. A ‘dynamic’ load test equivalent to 1,1 SWL. This test is to demonstrate that the hoist brake system is capable of stopping the load whilst being lowered at maximum speed to simulate a power failure.

3. An ‘operational’ load test equivalent to 1,25 SWL. This test is to be carried out over the full range of operation of the lifting appliance.

1.7.3 Where the manned submersible handling system is approved with hoisting factor of more than 1,7, the test loads indicated in Ch 12, 1.7 Manned submersible handling systems 1.7.2 are to be increased by the ratio of F_h.swh/1,7, where F_h.swh is derived from Ch 4, 4 Submersible handling systems.

1.7.4 If testing to values in excess of those defined in Ch 12, 1.7 Manned submersible handling systems 1.7.2 and Ch 12, 1.7 Manned submersible handling systems 1.7.3 is envisaged, a review of the manned submersible handling system should be undertaken to ensure that overstressing does not occur.

1.7.5 For the purpose of these requirements, the safe working load of the appliance is to be taken as the greater of:

1. The maximum in-air weight of the manned submersible, lifting frame and rope when it is at water surface; or

2. The total submerged weight of the manned submersible, lifting frame and rope when it is at its maximum operating depth.

1.7.6 Following the overload test, the manned submersible handling system is to be operated with its SWL over the complete operating cycle to demonstrate the effective operation of the system, the accuracy of overload and safe load indicators and the effectiveness of limit switches, etc.

1.7.7 After testing, the manned submersible handling system is to be thoroughly examined for deformations and other defects.

1.7.8 Further tests in accordance with LR’s Rules and Regulations for the Construction and Classification of Submersibles and Diving Systems may be required and reference is made to that publication. Where compliance with National Authority Regulations is required, specific reference should be made to the Regulations in case any additional or more onerous test requirements are appropriate.

1.8.1 The testing of the appliance is to be carried out in accordance with the requirements of Ch 12 Testing, Marking and Surveys as applicable.

1.8.2 Testing with overload: Notwithstanding the requirements in Ch 12, 1.6 Cranes and ROV handling systems 1.6.1 and Table 12.1.5 Testing of derricks and cranes, the test load for the appliance shall be taken as follows:

SWL ≤ 20t: 1,50 x SWL

20t < SWL ≤ 50t: SWL + 10t

SWL > 50t: 1,20 x SWL

1.8.3 Testing with SWL: Notwithstanding the requirements in Ch 12, 1.6 Cranes and ROV handling systems 1.6.7, the crane shall be tested with 1,1 times SWL instead of 1,0 times SWL.

1.8.4 Each of the primary and secondary brakes shall be statically tested to at least 1,5 times SWL and dynamically tested to at least 1,1 times SWL.

1.9.1 The test requirements for mechanical lift docks are given in Ch 5 Shiplift and Transfer Systems.

1.10.1 Attention is drawn to the existence of statutory requirements of certain National Authorities for the testing of lifts, particularly of passenger lifts.

1.10.2 Each lift is to be tested with its applied or rated load, see Ch 6 Ro-Ro Access Equipment and Ch 7 Lifts, to demonstrate the satisfactory operation of the lift and all control and safety systems.

1.10.3 In addition, after installation or following any major repair, renewal or alteration, each lift is to be subjected to the following tests:

1. For all lifts, the brake is to hold the lift with a proof load of 1,25 times the applied or rated load.

2. The lift is to be operated through one complete round trip with a proof load of:

   1. Passenger lifts: 1,1 times the applied or rated load.

   2. Cargo or vehicle lifts: in accordance with Table 12.1.6 Test load for cargo or vehicle lifts.

1.10.4 Vehicle ramps which may be raised or lowered while loaded are to be tested as for vehicle lifts.

1.10.5 Vehicle ramps which are raised or lowered only when unloaded are to be tested after installation and following any major repair, renewal or alteration as follows:

1. The brake is to hold the ramp in its most unfavourable position while the ramp is subjected to a load of 1,25 times its self-weight.

2. The ramp is to be placed in its working position and subjected to a test load as given for vehicle lifts in Ch 12, 1.10 Lifts and ramps 1.10.3.(b).

3. The ramp is to be operated through one complete operating cycle, unloaded, using the terminal stops only.

1.11.1 Re-testing of loose gear is to be carried out in the following circumstances:

1. In the absence of an appropriate certificate indicating that the item has previously been tested;

2. Following any repair or alteration which may affect the strength of the item;

3. If the item’s unique identification mark has become illegible;

4. As required by the National Administration.

1.11.2 The re-test of loose gear is to be in accordance with Ch 12, 1.2 Loose gear.

1.11.3 Re-testing of derrick systems, derrick cranes, cranes, and ROV handling systems is to be carried out in the following circumstances:

1. Following any structural repair, alteration or re-erection of the appliances;

2. At every fifth Annual Thorough Survey, or in accordance with the requirements of the National Administration.

1.11.4 These tests need not be as extensive as the initial tests, but it must be demonstrated that the test load can be raised and lowered. It is preferable also for the derrick or crane to be slewed and luffed during the re-test, but this may be waived at the discretion of the Surveyor.

1.11.5 Re-testing of union purchase rigs is not essential, provided the derrick has been re-tested in single working and special attention is paid to the condition of the preventer guy eyeplate attachment to the deck.

1.11.6 Derricks and cranes having a safe working load not exceeding 15 t may be re-tested using a spring or hydraulic weighing machine, provided:

1. The machine has an accuracy within ±2,0 per cent and the load is applied for at least five minutes with the indicator remaining constant;

2. The derrick boom is placed in the most onerous certified operating position;

3. The support point for the machine is adequately strengthened to avoid overstressing of the supporting structure; and

4. This method of test is acceptable to the appropriate National and Port Authorities.

1.11.7 Lifting appliances used for raising, lowering or transferring manned submersibles or other diving systems are to be re-tested annually in accordance with Ch 12, 1.7 Manned submersible handling systems. Re-testing will also be required following any structural repairs, alterations or re-erection of the appliance.

1.11.8 Lifts and ramps are to be re-tested at every fifth Annual Thorough Survey, depending on the requirements of the National Administration, and also when repairs or alterations have been carried out affecting the strength of the item. The re-test is to be in accordance with Ch 12, 1.10 Lifts and ramps 1.10.3.