No. 4MP-T81-01904 Rev.

2
CRANES USE & OPERATION PAGE 24 OF 30

Appendix 1
CRANE LOAD TEST PROCEDURE

1.0 PURPOSE
The purpose of this procedure is to establish a consistent generic approach for the function & load testing
of hydraulic and conventional crawler and wheel-mounted cranes on all Bechtel non-nuclear power
projects.

2.0 SCOPE
2.1 This procedure is applicable to cranes used for construction purposes, which have previously been
qualified for use. It is not intended to give direction to qualify new equipment.

2.2 This procedure does not address non-conventional lifting machinery such as custom cranes, telescoping
gantries, gin poles, etc. Such machinery shall be tested using specific procedures prepared by the
manufacturer or other competent person.

2.3 Refer to manufacturer operations and maintenance manuals, applicable jurisdictional codes, standards,
and regulations for any requirements (i.e., in the U.S. – applicable sections of ASME B30 series crane
standards). In the absence of local or regional standards, utilize applicable OSHA/ANSI regulations and
standards as guides. Contact BEO Rigging Operations for assistance in identifying and obtaining
applicable standards.

3.0 REQUIREMENTS
3.1 The work process for crane load testing is shown in Attachment 1-1 and Attachment 1-2, and as specified
below.

3.2 Function Test

a. Set up crane according to manufacturer’s recommendations in a suitable area, clear of obstructions.

b. Ensure all operation manuals and load charts applicable to the crane are properly located (in the cab
or within the general location of the crane – e.g., in the site cabin).
c. Perform a full crane inspection (see Attachments D, E or F) to assess the operational and mechanical
condition of the crane.
d. Barricade the test area and erect “no entry” signs with appropriate crane test warnings.
e. Perform checks of all operational and safety systems.
f. Each crane shall be operationally tested by the manufacturer and/or the owner/user to the extent
necessary to ensure compliance with the operational requirements. These operational functions
include the following:
• Load lifting and lowering mechanisms
• Boom lifting and lowering mechanisms
• Boom extension and retraction mechanism
• Swinging mechanism
• Travel mechanism
• Safety devices
g. If one manufacturer does not supply the complete production crane, such tests shall be conducted at
final assembly.

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3.3 Load Brake Test

3.3.1 Load brakes shall be tested and adjusted to manufacturer specifications prior to performing any
machine load test. The manufacturer’s specifications generally call for a single part line to be utilized
for these brake checks to prevent a multi-part line from masking any potential problems. The
Preliminary Brake Check Procedure using Single part line all hoisting drums is as follows:

a. On Hydraulic Cranes with spring applied/hydraulically released brakes:

1. Check brakes in accordance with manufacturer recommendations found in service manuals
or published bulletins.
2. Determine the maximum load rating for the brakes.
3. Determine the maximum safe working load of the wire rope installed on the crane.

The lower of the two capacities above will be the limiting factor in planning the
test.

4. Determine the test weight needed, taking into account all loading the brakes will be subjected
to.
5. This test must be carried out at a boom length and radius well within the rated capacity of the
crane.
6. Lift the load approximately 6 inches off the ground.
7. Move the hoist control to the neutral position allowing the brake to set.
8. Hold the load with the brakes only.
9. The load should remain suspended with the brakes set according to manufacturer
specifications for a period of five minutes.
10. If required, replace or repair braking system to comply with manufacturer’s specifications.

b. On conventional friction type cranes:

1. Adjust friction brakes in accordance with manufacturer recommendations found in the service
manuals or published bulletins.
2. Determine the maximum load rating for the brakes.
3. Determine the maximum safe working load of the wire rope installed on the crane.

The lower of the two capacities above will be the limiting factor in planning the
test.

4. Determine the test weight needed taking into account all loading the brakes will be subjected
to.
5. This test must be carried out at a boom length and radius well within the rated capacity of the
crane.
6. Lift the load approximately 6 inches off the ground.
7. Apply the brake.
8. Hold the load with the brakes only.

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9. The load should remain suspended with the brakes set according to manufacturer
specifications for a period of five minutes.
10. If required, re-adjust or repair the brake to comply with manufacturer’s specifications.

3.3.2 Locate suitable test weight. The weight must either be a stamped certified weight or weighed with a
certified and/or calibrated dynamometer or scale. If local jurisdictional codes, standards, or
regulations are more stringent, and require a "certified weight", then one must be used.

Common sense must prevail when choosing a "suitable test weight". It should have
readily available pick points and not be of a geometry that would require special rigging
fixtures and calculations to determine the center of gravity. If a piece of equipment is
used as a “test weight”, it should be rigged such that the slings and rigging will not
damage the equipment.

3.3.3 Use certified rigging (i.e., slings, shackles, spreaders, etc.) for all loads. Refer to BESH Core Process
CP-223, Cranes and Lifting Operations for general guidelines and sling use, as well as rigging
equipment inspection and techniques.

3.3.4 While it is not required, documentation of crane load tests using photographs has proven to be an
effective medium to communicate what transpired.

3.4 Rated Load Test

3.4.1 A rated load test is to be conducted by, or under the direction of, a qualified person:
• Prior to initial use (when manufactured)
• Following maintenance on cranes in which load sustaining parts have been altered, replaced, or
repaired
• When required by legislation
• When required by contractual conditions

The replacement of the rope is specifically excluded from this requirement. However, a functional
test of the crane under a normal operating load should be made prior to putting the crane back in
service.
CAUTION: The crane shall not be loaded to more than 100 percent of its rated chart capacity
without prior written approval from the crane manufacturer. If a 110 percent load
test is required by the project, then manufacturers’ approval and test plan shall be
obtained.
3.4.2 Rated load tests will, by their nature, always be “critical” lifts according to Standard Work Process
Procedure 4MP-T81-01903, Construction Rigging Work Operations. They must be planned and
executed in the same manner as any other critical lift, requiring a written lift plan and review and
approval by a Bechtel CRE.

3.4.3 Determine/confirm deductions from the gross capacity chart for the following:
• Manufacturer approved attachments
• Load block
• Overhaul ball
• Wire rope
• Rigging

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 No. 4MP-T81-01904 Rev. 2
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3.4.4 Determine test load required based upon available weights and load charts to achieve 100 percent
capacity.

3.4.5 Refer to in-cab load charts and select a radius at which the total test load will be 100 percent of gross
capacity.

For cranes with automatic safe load indicators and alarms, in order to achieve a 100
percent lift, the LMIs may need to be overridden. The systems are generally equipped
with override switches to aid in the performance of these load tests.

3.4.6 The load test procedure is:

1. Measure the test radius and place a suitable marker.
2. Position the test load inside the test radius well within the capacity of the crane as configured.
3. Lift the test load and allow it to stabilize.
4. Maintain the load no more than one foot from the ground.
5. Boom down to the predetermined test radius with the guidance of a ground signalman.
6. Measure the height of the test weight from the ground.
7. Apply all brakes and shut down the engine.
8. Observe the load for five minutes to check for load drift.
9. Restart the crane and swing the test load 360 degrees if permitted by the load chart work area
diagram.
3.4.7 If corrective maintenance or repairs are required during the execution of the load testing, the PEMOT
are responsible to assure corrective actions are performed.

3.4.8 If any load sustaining parts are altered, replaced, or repaired during the execution of any correction
actions (maintenance or repairs) ,then a load test will be required.

3.4.9 All repairs and maintenance shall be recorded and placed in the equipment file.

3.4.10 At the completion of a successful load test, all results shall be recorded and placed in the Equipment
file. Refer to Attachment B for a sample Load Test form.

3.4.11 Written reports shall be reviewed and filed by an appointed or authorized person, showing test proce-
dures and confirming the adequacy of repairs or alterations.
3.5 Project Specific Load Testing
Should the project or customer have a specific load test requirement, this load test shall not exceed 100
percent of the Crane or Lifting Device load chart capacity. These test needs are usually a result of a
Heavy or Critical lift where a "pre-lift" verification of the crane is mandated by the project. These types of
project-specific load tests are in addition to the required "rated load tests" previously discussed.
If a 110 percent load test is required, manufacturers’ approval must be obtained.

4.0 ATTACHMENTS
4.1 Attachment 1-1 – "Load Test Process" Flow Chart
4.2 Attachment 1-2 – "Load Test" Flow Chart
4.3 Attachment 2 – "Example" Load Test Form

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suppliers, and may not be used, reproduced or disclosed without Bechtel’s prior written permission. All rights reserved.
 No. 4MP-T81-01904 Rev. 2
CRANES USE & OPERATION PAGE 28 OF 30

Attachment 1-1
Load Test Process

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suppliers, and may not be used, reproduced or disclosed without Bechtel’s prior written permission. All rights reserved.
 No. 4MP-T81-01904 Rev. 2
CRANES USE & OPERATION PAGE 29 OF 30

Attachment 1-2
Load Test

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suppliers, and may not be used, reproduced or disclosed without Bechtel’s prior written permission. All rights reserved.
 No. 4MP-T81-01904 Rev. 2
CRANES USE & OPERATION PAGE 30 OF 30

Attachment 2
LOAD TEST FORM (Example)
" Sa m ple "

LO AD TE ST
E q u ip m en t N u m b er : 1 4 - 0 00 0 S eri al N u m be r: 4 1 00 7

M ake M a nito w oc M od e l 4 1 0 0w S e r 1 1

O p e ra tor s S ign a tu re J oe O p er ato r D ate 7 /1 7 /20 0 0

E xa m ine rs Sig na tu re S am Ex a m in er D ate 7 /1 7 /20 0 0

W itn e s s Sig n atu re W ya tt W itne s s D ate 7 /1 7 /20 0 0

T est N otes
C rane C on f igu rat ion & Ope ra tio n D e sc rip tion
G ross L oad C hart R a ting s Test R a dius & L oa d P erc en tag e Ove r C h a rt R ating
190 F eet o f # 22 B o om , 4 1 /2
De g ree o ff-set in stalled 40 ,4 0 0 @ 9 5F t. R ad iu s 4 0 ,4 00 @ 95 F t. R a d ius 1 00 .0
30 F eet o f #1 23 jib at 20 D e gree
o ff- set.

200 T o n L oa d Block G r os s R a tin g fr om C r ane

l oad ch art

15 T o n Cap acity B all 40 ,4 0 0 lbs @ 95 ft R a d ius

re p res en ts 1 0 0% cran e ch a rt

No tes o n L if t:

L iftin g o f th e t est lo a d o n m ain lo ad li ne W h ip li n e w as te sted to B S o f th e lin e.

D es cr ibe th e T es t for ex am ple on m ai n load b loc k or w hi p l in e

B r ake Te st res u lt N o te s:

B r ake fu n ctio n m e ets r eq u ire m en ts, w e h eld th e tes t l o ad o n th e b ra kes w ith n o evid e n ce o f d ri ft d o w n o f th e lo a d .

D e sc rib e if l oad li ne b ra ke s h el d l oad w i thuo t an y c r eep dow n for a g iv en perio d "s ay " 5 m inu tes .

D e s cr ip t io n o f D ed u ct i o n s D ed u ct i o n s f ro m G ro s s C a p a c it y D e d u c t io n s fro m G ro s s C a p a ci t y

U S P ounds K ilo g ra m s

L oad B lo c k W eigh t D ed u c tio ns 5 ,5 0 0 2 ,4 9 5

H ea d ache B a ll W e igh t D e duc tio n s 1 ,0 0 0 454 D edu ct ion s tha t are p ar t of t he
ac tual loa d th e c ra ne w i ll ha ve
L oad Lines W eig h t D ed uct ion s 1 ,1 0 0 499 durin g the tes t
Jib W eigh t D ed u ct io ns 2 ,5 0 0 1 ,1 3 4
Jib S to w ed - Jib E rec ted (H yd C rane s) 0 0
R o oste r S h ea ve A ss em b ly C alc ul ate T o tal D educ ti ons 0 0
R igg in g W eig ht D edu ct io n s fro m G r os s l oad C hart R a tin g. 300 136
Ot he r W eig h t D ed uct io n s 0 0
Ot he r W eig h t D ed uct io n s 0 0
To tal d e du c tio ns 10 ,4 0 0 4 ,7 1 7

C o m bined T es t W eig ht & D ed u ct io ns T ota l T e st L oad L b s. To ta l T e st Lo ad K g s.

W eigh t of T e st B lock 30 ,0 0 0 1 3 ,6 0 8 D ed uc tio ns p lus T es t W e igh t

repres ent s to tal tes t lo ad
D ed u ct io ns From Gro ss L o a d C h a rt R atin g
10 ,4 0 0 4 ,7 1 7
T otal Te st Lo ad 40 ,4 0 0 1 8 ,3 2 5

S ign a tu re O p e ra to r D a te

S ign a tu re In sp ecto r D a te Sig n atu re w itn e ss D a te

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©Bechtel Corporation 2009, 2005, 2000. Contains information that is confidential and proprietary to Bechtel or its affiliates, clients or
suppliers, and may not be used, reproduced or disclosed without Bechtel’s prior written permission. All rights reserved.