Cranes are, without a doubt, among the most useful and essential machinery in the construction, mining, offshore, logistics, manufacturing, and maritime industries or any sector or situation where lifting heavy loads is a daily necessity.
They make building skyscrapers, moving or repairing large machinery, lifting, rescuing and recovering people, and loading and unloading ships, possible. Without them, performing such tasks would take much longer, involve greater risks, and require more human resources in the process.
And yet, even when cranes are designed and built to perform such activities, the tremendous forces they are subject to and the extremely heavy weights they carry, require them to be free from minor faults that, if left ignored, can lead to failures that can cost money and even lives.
This is why any business that owns, leases, or operates cranes, particularly those classified as registerable plant, must ensure their mobile cranes undergo periodic load testing to verify structural integrity, stability, and lifting capability.
Just like regular crane inspections, crane load testing is a basic equipment safety and compliance requirement. Routine crane load testing helps businesses reduce risks, prevent costly downtime, and stay compliant with industry regulations.
What Is Load Testing?
Crane load testing is a crucial safety measure that assures owners and operators that a crane can handle its rated capacity without issues. The process involves applying test loads, equal to or greater than the crane’s normal rated capacity, to assess its structural integrity and mechanical performance under stress.
In essence, load testing echoes the importance of preventive maintenance activities but is very specific and mandatory.
Importance of Load Testing for Registerable Plant
In Australia, certain types of machinery classified as ‘registerable plant’, must be registered with the relevant Work Health and Safety (WHS) regulator before being used on any workplace.
This requirement applies to various equipment, such as lifts, hoists, elevating work platforms (EWPs), and cranes. Registration helps ensure that these machines meet safety standards and operate within legal and engineering guidelines.
For cranes, the following types fall under registerable plant regulations:
- Mobile Cranes: Those with a rated capacity above 10 tonnes
- Tower Cranes: Includes both standard and self-erecting models used in high-rise construction
- Vehicle-Mounted Cranes: This includes vehicle-loading cranes and mobile cranes mounted on trucks, provided their capacity exceeds 10 tonnes
Why Is Load Testing Critical for Registerable Cranes?
Regular load testing of registerable cranes is essential for the following reasons:
- Meeting Regulatory Standards: Australian standards (such as AS 1418 and AS 2550) mandate load testing for safety compliance.
- Reducing Risks: Identifying potential equipment failures before they happen helps prevent workplace injuries, fatalities, and legal liabilities.
- Verifying Performance: Routine testing confirms that equipment can perform as expected under load conditions but does not replace regular maintenance.
- Ensuring Insurance Compliance: Many insurers require proof of load testing, and failing to meet these requirements could affect coverage.
- Providing Essential Documentation: Load-testing records are often needed for audits, certifications, and legal compliance.
By conducting regular load testing and maintaining proper documentation, businesses are able to demonstrate their commitment to workplace safety and regulatory compliance.
Regulatory Framework for Crane Load Testing in Australia
Australia has very strict regulations to ensure that cranes used in the workplaces meet the highest safety standards. These rules outline the responsibilities of crane owners, operators, and maintenance personnel, helping to prevent accidents and equipment failures.
Work Health and Safety (WHS) Regulations
The Work Health and Safety Act (WHS Act) serves as the primary basis for workplace safety laws across the country. Although the act doesn’t specifically mention load testing, it does require all registerable plant equipment, including cranes, to be safe for use. Compliance with relevant Australian Standards is a key part of meeting this requirement.
Several Australian Standards detail crane load testing requirements, including:
- AS 2550 Series – Safe Use of Cranes, Hoists, and Winches: Outlines general requirements for crane maintenance, inspection, and periodical testing.
- AS 1418 Series – Cranes, Hoists, and Winches: This covers design, construction, operational safety, and commissioning testing for different types of cranes and hoists.
- Manufacturer Specifications: Many crane manufacturers have additional load-testing requirements to maintain warranties and ensure safe operation.
Registerable Plant and Load Testing
Cranes classified as registerable plant must meet specific obligations under WHS regulations. Businesses, owners, and operators using these cranes are required to:
- Register their cranes if classified as a ‘registerable plant’ as per WHS regulations with the appropriate state or territory safety authority.
- Keep thorough inspection and testing records to document their compliance.
- Make sure load testing is conducted by qualified personnel with the necessary competency, training and expertise.
- Perform load testing after major repairs or modifications to confirm the crane’s safety after such procedures.
Failure to meet these requirements can lead to penalties, loss of registration, or even legal consequences if an accident occurs. By following proper load-testing procedures, businesses can protect their workers, extend equipment lifespan (although this is a subject of debate; more on this later), and maintain compliance with Australian safety laws.
Inspection and Testing Frequency
Similar to other important equipment care and asset maintenance tasks, load testing is not a one-off event for some equipment, rather it needs to be performed at specific intervals to maintain safety and compliance.
Initial (Commissioning) Load Tests
Before using a new or refurbished crane, it must be subjected to a commissioning load test. This test ensures that:
- The crane or monorail meets design specifications and operates efficiently within its intended load capacity.
- Safety systems or features (e.g. limit switches and emergency stops) are working properly.
- The crane’s structural integrity and stability remain intact under stress.
Periodic Testing Requirements
Regular load testing is necessary to keep mobile cranes in peak working condition. The frequency depends on how often and under what conditions the crane is used:
- Annual Load Testing: Typically required for vehicle loading cranes and mobile cranes for verifying integrity of load indicator systems.
- Post-Repair or Modification Testing: Anytime a crane undergoes structural repairs or has any of its key components replaced, it must be tested before returning to service.
- 10-Year Major Inspections: After being in service for 10 years, a crane must be subject to a comprehensive evaluation of its condition, including full disassembly, load testing, and recertification to ensure long-term safety.
Types of Cranes and Their Load Testing Requirements
Each type of crane included in the registerable plant category has specific load-testing requirements based on its design and how and where it operates.
Monorails: Load testing for monorails verifies the integrity of the supporting structure, hoisting mechanisms, and travel path. Testing is typically required after installation, significant modifications, or repairs, and at regular intervals to ensure safe lifting performance and compliance with Australian Standards.
Mobile Cranes: Must be tested after assembly, major repairs, or modifications. Mobile crane load-testing requirements include assessing the boom extension, rotation, and real-world load conditions. Mobile crane load indicators are tested annually.
Tower Cranes: Load testing focuses on structural integrity, counterweight balance, and stability. These cranes are tested after installation, after reassembly, and at scheduled maintenance intervals.
Bridge and Gantry Cranes: Bridge and gantry crane load testing checks the hoisting mechanisms, brakes, bridge structure, rail alignment, and how loads are distributed across the crane span.
Vehicle-Mounted Cranes: Load testing ensures vehicle stability, the proper functioning of support outriggers, and safe weight distribution; required after modifications that might affect balance or weight distribution. The load indicator system is tested every 12 months or more frequently as required.
Cranes Handling Dangerous Goods or Molten Metal: Held to the highest safety standards, these cranes undergo rigorous testing to ascertain they can operate safely under extreme conditions, with a strong focus on their emergency shutdown features.
Crane Load-Testing Methods
Several testing methods are used to check a crane’s structural integrity and performance under different conditions.
- Static Load Testing: This test confirms that a crane can hold a load without movement, ensuring structural integrity. A weight, typically 100%, 110%, and 125% of the crane’s rated capacity, depending on the relevant test required, is lifted and held in place for a period of time. During the test, inspectors check for documents and any signs of deflection or instability.
- Dynamic Load Testing: Evaluates how the crane performs while moving loads. During the test, the crane lifts and moves a test load through its full range of motion. This test assesses the hoist speed, braking, and the crane’s travel function under load or its ability to handle operational stresses.
- Commissioning Load Testing: This test is designed to ensure that a newly installed or repaired crane is fit for use. The crane lifts its maximum-rated load at its weakest point to check deflection, brake performance, and movement capabilities. This test is required after the installation of a new crane or major crane repairs or modifications.
- Overload Testing: This test confirms that the crane can safely handle loads beyond its rated capacity, providing a built-in safety margin. During this test, the crane lifts a load between 110% and 125% of its rated capacity to verify it can withstand additional loading without failure, as required by the relevant Australian Standards.
- Deflection Testing: This test measures how much the crane structure bends under load. The crane lifts its maximum rated capacity, and inspectors measure the deflection to ensure it stays within safe limits. Note: Deflection testing is part of static load testing, but it can also be conducted separately to guarantee that deflection remains within acceptable limits.
- Emergency Stop Testing: Verifies that the crane’s braking system works in case of a power failure. The crane is tested under load to ensure it can stop safely if power is lost, simulating real-world emergency conditions.
These crane load-testing methods help maintain workplace safety and compliance with Australian Standards like AS 1418 and AS 2550.
The Load Testing Process
The crane load-testing process in Australia is a critical safety procedure designed to verify that cranes can safely handle their rated loads and comply with regulatory standards, such as those outlined in AS 1418 and AS 2550. It also aids in identifying potential mechanical issues or structural weaknesses.
Here’s a detailed explanation of the process:
1. Preparation for Load Testing
- Conduct a thorough pre-test inspection of the crane to confirm its rated load capacity and operational condition.
- Identify the test load, which is typically 100%, 110%, and 125% of the crane’s maximum rated capacity.
- Plan the test lift, including defining the path of movement, ensuring adequate clearance, and implementing necessary safety measures. This step considers certain limitations such as the height of lift (HOL), floor capacity, access constraints, and laydown areas.
- Brief all personnel involved in the test and ensure they are equipped with the appropriate safety gear.
2. Conducting the Test
- Gradually lift the test load slightly off the ground to verify initial stability, or if using a water weight and loadcell, fill to your nominated load.
- Lift the load to a predetermined height and hold it for a specific period to check for structural integrity and stability.
- If applicable, move the load through its operational range (e.g. traversing, hoisting, lowering) to test dynamic performance.
3. Monitoring and Key Parameters to Measure
- Closely monitor operational parameters during the test, including load-bearing capacity and stability, lifting speed, braking performance, structural behaviour (e.g., deflection or signs of stress), and mechanical integrity.
- Use visual inspections and monitoring equipment to collect performance data.
- Identify potential defects, wear, or signs of malfunction.
4. Evaluation and Post-Test Actions
- Analyse data and observations from the test to assess whether the crane meets operational safety requirements.
- Record results, including detailed measurements and issuing a certification report.
- Address any anomalies, issues, or repair needs identified during testing before returning the crane to regular service.
- Keep all results accurately documented as part of compliance records.
Benefits of Regular Load Testing
Based on the aforementioned discussion on crane load testing, we already know that it’s a process that’s intended to prevent accidents and equipment failure. For example, a mobile crane used in construction might develop stress fractures in its boom over time.
While load testing itself does not detect hidden damage, it confirms whether the crane can perform safely and as expected under real working conditions, thereby helping to reveal performance issues that could pose operational and safety risks during lifting operations.
In addition to preventing or reducing downtime and ensuring workplace safety, load testing also:
- Ensures compliance with regulations so businesses can avoid legal penalties and maintain operational compliance. Failing to comply with WHS regulations can lead to hefty fines and worksite shutdowns.
- Identifies Wear and Tear: Load testing helps highlight mechanical or operational issues that may manifest under stress. However, it does not prolong the equipment’s lifespan, and excessive or improper testing can contribute to material fatigue. That’s why it’s essential to follow correct testing protocols and rely on experienced professionals to minimise unnecessary strain while ensuring safety compliance.
- Builds credibility and trust as clients and stakeholders prefer working with companies that prioritise safety and compliance. A well-maintained and regularly tested crane fleet reassures customers and regulatory bodies that a business’s operations meet the highest standards.
AME Case Study: Load Testing for a New Processing Area
Project Overview
A recent project involved conducting a comprehensive load test on a newly built wet and dry processing area to ensure that the installation of monorails and cranes met the intended design specifications. The client required assurance that the equipment was installed correctly, functioned safely, and complied with Australian Standards before operations commenced.
Objective
The primary goal of the load testing was to:
✔ Verify that the drawings and specifications were adhered to.
✔ Ensure the installation was safe and secure for operational use.
✔ Confirm that the monorails and cranes were within the required tolerances set by Australian Standards.
Testing & Results
The cranes and monorails were tested under load to evaluate their structural integrity, load-bearing capacity, and overall performance. This rigorous testing process helped achieve the following:
- Enhanced Safety: Ensured that all personnel using the equipment were protected, reducing workplace risks.
- Regulatory Compliance: Confirmed that the equipment met the applicable Australian Standards, preventing future compliance issues.
- Operational Efficiency: With full assurance that the monorails and cranes were safe for use, the client avoided unplanned downtime due to non-compliant equipment.
Outcome
By completing this critical load testing process, the client gained confidence that their newly installed monorails and cranes were fit for purpose. The project successfully ensured the safety, compliance, and long-term reliability of the lifting equipment within the processing area.
Why AME Is Your Partner for Hoist, Crane, and Monorail Load Testing
There are many reasons why AME should be your partner of choice for crane load testing:
- Expertise: AME’s team of certified professionals has extensive experience in crane load testing and an in-depth understanding and mastery of compliance with all relevant Australian Standards and WHS regulations.
- Tailored Solutions: We customise load-testing plans for various crane types, from monorails to mobile, tower and gantry cranes. We adapt solutions that address your unique site requirements and logistical challenges.
- Advanced Equipment and Testing Methods: AME uses the latest testing tools for precise measurements and accurate results. We also apply both static and dynamic testing techniques.
- Comprehensive Support: Benefit from AME’s end-to-end services, including pre-test inspections, testing, and post-test reporting. We also assist with compliance documentation and certifications.
If you own, operate, or lease registerable cranes, staying ahead of the inspections and load-testing requirements is an investment in safety and reliability.
➜ Learn more about our Crane Load Testing Services.
Or get in touch with AME today!