A crane that lifts every day can still hide a weak weld, a worn brake or a loose rope termination. A load test brings the crane up to its rating, and above it, under control, so that weakness shows before it shows in production. In India it is also a statutory requirement for lifting machines.
What a load test is
The crane lifts test weights while a trained team watches the structure, the brakes, the hoist and the controls. The test usually has two parts:
- Test at 100% of SWL: the crane lifts its rated load through its motions and holds it. Hoisting, travel, braking and limit switches are checked under load.
- Overload test at 125% of SWL: the crane lifts a load 25% above its rating, holds it, and the structure is checked for permanent deformation. Deflection of the girder is measured and compared with the permitted figure.
We record loads, deflection and function results reading by reading. Everything is done under the supervision of a competent person.
When a test is needed
- Before a new crane enters service.
- At the interval set by the Factories rules for your state.
- Before a critical lift, for example a turbine or generator rotor.
Form 10
Under the Factories rules, a competent person examines the crane and issues a report. In Gujarat this is Form 10.
The report records the crane, its SWL, the test load, the result and the next due date. Keep it where an inspector can find it.
Test weights
The test needs real weight. We bring calibrated and certified test weights, a cradle and lifting slings to your site, anywhere in India, up to 400 T on rental. For lifting beams and tackle, the same method applies: for a 225 T lifting beam we carried out an overload test at 1.25 times its SWL, witnessed by the customer and its inspection agencies.
Examples
- GE Vernova T&D, Vadodara: a 250/50 T double girder EOT crane with a 312.5 T test load.
- GSECL stations at Ukai, Wanakbori and Kadana: EOT cranes overhauled and certified.
- JK Paper, Songadh: two 45 T double girder cranes.
- Our own cranes are load tested in our works before dispatch.
How to prepare
Have the nameplate or drawings and the last certificate ready. Clear access for the weights, arrange power, plan a production window, and have a person from your side present.
Frequently asked questions
- Why 125%?
- The overload test shows the crane has a margin above its rating. It is a proof of strength, not a working load. Never lift 125% in production.
- Can we test with our own material?
- Calibrated test weights are the accepted way because the weight is known and certified.
- Who signs the form?
- The competent person or the authority named in your state's rules. We prepare the test report and support the statutory examination.
- How soon can you test?
- Tell us the date; we agree a plan after a short inspection.