512 EM 385-1-1 Chapters 16-22

Sections

16-8. General Requirements.

Operational Testing

Test mechanisms for load lifting, lowering, boom movements, swinging, travel, and all safety devices.
Ensure operational aids are functioning correctly during the testing process.

Load Testing

Conduct load tests under the guidance of a Qualified Person (QP) as per ASME standards and manufacturer's instructions, including maintaining the test load for specified durations.
For mobile and overhead cranes, operate through the full range of motions, adhering to the specific procedures for each type of crane.
Choose test load weights according to the crane type, ensuring it aligns with the manufacturer's recommendations or under approval of the USACE supervisor, KO, or COR.

Frequency of Load Testing

Perform load testing after any significant alterations, repairs, or component replacements, or when the crane is reconfigured or re-assembled.
Adhere to manufacturer's requirements for load testing frequency, documenting and providing information as necessary.
Maintain and provide reports detailing test procedures and confirming the adequacy of repairs, alterations, or maintenance.

Knowledge Check Choose the best answer for the question.

16-11. Conduct load tests under the guidance of a Qualified Person (QP) and Choose test load weights _____.

above maximum intended load requirements

per USACE limitations

according to the crane type

at 110% of loads being lifted

You forgot to answer the question!

EM 385-1-1 Paragraph 16-8 (t.–u.).

16-8. General Requirements. (t.–u.).

t.  Operational Testing. Operational testing must include the following:  (16-8.t)

(1)  Load lifting and lowering mechanisms.

(2)  Boom lifting and lowering mechanisms.

(3)  Boom extension and retraction mechanisms.

(4)  Swinging mechanisms.

(5)  Travel mechanisms.

(6)  Safety devices.

(7)  Operational aids.

u.  Load Testing. Load testing is considered a critical lift.  Develop a Critical Lift
Plan following the requirements of paragraph 16-7.d.  (16-8.u)

(1)  Load tests must be performed under the direction of a QP according to appropriate ASME standards and the manufacturer's instructions. At a minimum, the load test procedures must include the following:

(a)  For all cranes.  Hoist the test load for a minimum of five minutes to ensure that the load is supported by the crane and held by the hoist brake(s).  Lower the test load, stop lowering, and again hold the load for a minimum of five minutes above the ground with the brake(s).

(b)  For mobile cranes, to the extent possible while clearing physical obstructions, operate the crane through the full range of motions below as applicable:

(b-1)  Ensure there are no physical restrictions, the full range of its swing, with the test load.

(b-2)  Boom the crane up and down within the allowable working radius for the test load.  At the maximum radius, hold the load for a minimum of five minutes and ensure there is no movement of the load.

(c)  For overhead cranes, to the extent possible while clearing physical obstructions, operate the crane through the full range of motions below as applicable:

(c-1)  Travel to the extents of the trolley limits or end stops with the test load.

(c-2)  Bridge to the extents of the bridge limits or end stops with the test load.

Note. If the manufacturer is no longer in business and procedures are unavailable, a QP familiar with the type of equipment involved must develop and approve the procedures. Perform load testing according to paragraph 16-8.u.

(2)  Weight of test load.

(a)  For mobile cranes, the weight of the test load must be 100% to 110% of the anticipated load for the specified configuration.  Do not to exceed 100% of the manufacturer's load chart at the configuration of the test.  The actual anticipated load may be used as the test load, if approved by the USACE supervisor or accepted by the KO or COR.

(b)  For overhead cranes, use the test load weight recommended by the manufacturer.

(3)  Perform load testing at the following frequencies:

(a)  Before using a crane or hoisting equipment after altering, replacing or
        repairing a load bearing or load controlling part or component, brake, travel component, or clutch.

Note. Adding/removing counterweights is not considered load controlling/load bearing.

(b)  Every time a crane or hoisting equipment(s) is reconfigured or re-assembled after disassembly (to include booms).

Note. Attaching/detaching a jib attachment is not considered “reconfiguring or re- assembling” a crane and so does not require a load test.  Install or stow the jib following the manufacturer’s instructions and have a CP document this action prior to operation.

(c-1)  The employer must specifically research, identify and document the manufacturer’s required load-testing frequency for each USACE-owned/operated and/or Contractor owned/ operated crane or hoisting equipment.  Provide a copy of this information to the USACE supervisor/KO or COR.

(c-2)  Under conditions (a) and (b) above, a selective load test may be performed when the manufacturer requires determination of the weight of test load (that is, testing only those components that have or may have been affected by the alteration, replacement, or repaired).

(c-3)  Follow the manufacturer's specifications and limitations applicable to the operation of any crane and hoisting equipment.  Do not load a crane or hoisting equipment more than the manufacturer's rated capacity, except overhead and gantry cranes may be loaded up to 125% of the crane load rating for test purposes or planned engineered lifts. (See para 16-7.d and ANSI/ASME B30.2 or B30.16)

(c-4)  Where manufacturer's specifications are not available, the limitations assigned to the equipment must be based on the determinations of a registered engineer competent in this field, and such determinations must be documented and recorded.

(c-5)  Attachments used with crane and hoisting equipment must not exceed the capacity, rating, or scope recommended by the manufacturer.

(d)  Keep all reports that show test procedures and confirm the adequacy of repairs or alterations and provide copies upon request.