Overhead cranes play an important role in moving heavy loads safely and efficiently. When these systems fail, the consequences can be severe such as, interrupted production, damaged equipment, and most importantly, putting people at risk. One of the most effective ways to prevent these hazards is through load testing, which ensures that your crane can safely handle its rated capacity before putting it to use.
What is Load Testing?
Load testing is the process of evaluating an overhead crane’s ability to lift and move a specific weight safely. The test is designed to confirm that the crane’s structural components, hoisting mechanisms, and control systems all function correctly.
By applying a load test, typically 100% to 125% of the crane’s rated capacity, technicians can ensure the crane operates as intended and identify any weak points before they result in failures. When performed correctly, load testing verifies that every critical element of the crane has been stressed under real conditions to provide assurance that it will perform reliably in real, daily operations.
Benefits of Load Testing
- Confirms the crane can lift and transport loads at its rated capacity.
- Ensures the crane performs safely and consistently under operating conditions.
- Identifies weaknesses in the structure, hoist, or control system before they lead to failure.
- Creates a safer work environment for operators and nearby personnel.
- Reduces the risk of costly downtime by preventing accidents and equipment damage.
Compliance Standards
Beyond safety, load testing is also a compliance requirement.
- OSHA CFR 1910.179 mandates that new or modified overhead cranes must be load tested before use, with test loads not exceeding 125% of the rated capacity.
- ASME B30.2 requires new, repairs, or altered cranes to undergo load testing at 100-125% of rated capacity, with all functions tested such as lifting, lowering, and traversing.
- ASME B30.16 states that new hoists shall be load tested by the manufacturer with a load not less than 100% or more than 125% of the rated load.
- CMAA Specification 78 recommends periodic load testing at a minimum of once every four years along with records maintained for the life of the equipment.
Dangers of Ignoring Load Testing Requirements
- Structural failure due to undetected weaknesses.
- Falling loads can cause injury or damage to property.
- Accelerated wear and tear that shortens life of equipment.
- Costly downtime due to unplanned repairs or incidents.
- Regulatory penalties if standards are not met.
Why Engineered Systems?
At Engineered Systems, we provide both in-shop and on-site load testing to ensure your equipment meets all compliance and safety requirements. In-shop load tests are performed at our facility to verify accurate hoist performance. On-site load tests bring calibrated weights directly to your facility for crane performance and testing.
Our certified process ensures your crane is fully compliant with OSHA, ASME, and industry standards. Every test is thoroughly documented and accessible to authorized personnel.
Contact us for your next installation. With our skilled team and expertise, you can trust that your equipment will be safe and reliable, keeping your people safe and your operations running smoothly.
