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871 views49 pages

S Sans 19:20 018: The Mo e Inspe Bile CR Ection Ranes N, Testi NG An D Exam Minati Ion of

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© SABS.

This standard may reside on a LAN, WAN, intranet, internet or ECM server and is exclusively available to Eskom in accordance with copyright
exploitation agreement no. 014/009/21-038, valid until 2022-07-31. Only staff members employed by Eskom may make paper copies of the standard. No paper
copy may be photocopied or reproduced in any way.

ISBN 978-0-626--35765-8
SANS
S 19:20
018
Edition 2

SO
OUTH AFRIC
A CAN N
NATIO
ONAL
L STAN
NDAR
RD

The
e inspeection
n, testing and exam
minatiion of
mobile crranes

W
WARNING G
Th
his docum
ment refere
ences othher
documeents norm
matively.

Publishhed by the So
outh African Bureau
B of Sta
andards
1 Dr Lattegan Road Groenkloof
G  Private Bagg X191 Pretorria 0001
Tel: +27
7 12 428 7911
1 Fax: +27 12 344 1568
www.sa abs.co.za
 SABS S

This product is copyrighted by SABS, 1 Dr Lategan Road, Groenkloof, 0181, South Africa. All rights reserved.
© SABS. This standard may reside on a LAN, WAN, intranet, internet or ECM server and is exclusively available to Eskom in accordance with copyright
exploitation agreement no. 014/009/21-038, valid until 2022-07-31. Only staff members employed by Eskom may make paper copies of the standard. No paper
copy may be photocopied or reproduced in any way.

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SABS – Standards Division

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The SABS continuously strives to improve the quality of its products and services and would therefore
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SANS 19:2018
Edition 2

Table of changes
Change No. Date Scope

Foreword
This South African standard was prepared by National Committee SABS/TC 096, Cranes, in
accordance with procedures of the South African Bureau of Standards, in compliance with annex 3
of the WTO/TBT agreement.

This document was approved for publication in March 2018.

This document supersedes SANS 19:2007 (edition 1.1).

Reference is made in note 1(e) to 3.2 to the "relevant national legislation". In South Africa this
means the Framework Act, 2008 (Act No. 67 of 2008).

Reference is made in 3.3 and 3.4 and 3.8 to the "relevant national legislation". In South Africa this
means the Engineering Profession Act, 2000 (Act No. 46 of 2000).

Annex C forms an integral part of this document. Annexes A, B, D, E, F, G, H and I are for
information only.

Compliance with this document cannot confer immunity from legal obligations.

SANS 19:2018
Edition 2

Contents
Page

Foreword

1 Scope ..................................................................................................................................... 3

2 Normative references ............................................................................................................ 3

3 Definitions .............................................................................................................................. 3

4 Personnel carrying out inspection, testing and examination, and their responsibilities ........ 6

5 Facilities, information and equipment for inspection, testing and examination ..................... 6

6 Provisions for inspection, testing and examination of mobile cranes other than loader cranes 7
6.1 General ........................................................................................................................ 7
6.2 Daily inspections .......................................................................................................... 7
6.3 Frequent inspections .................................................................................................... 8
6.4 Periodic thorough inspections ...................................................................................... 9
6.5 Exceptional inspections ............................................................................................... 11
6.6 Major inspection ........................................................................................................... 11
6.7 Examination scheme approach .................................................................................... 13
6.8 Testing ......................................................................................................................... 13
6.9 Load test for jib arrangements ..................................................................................... 16
6.10 Rated capacity indicator/limiter (RCI/L) ....................................................................... 20
6.11 Post-test inspection ...................................................................................................... 21

7 Provisions for inspection and testing of mobile cranes mounted on water-borne craft ......... 22
7.1 General ........................................................................................................................ 22
7.2 Information ................................................................................................................... 22
7.3 Verification ................................................................................................................... 22
7.4 Anchoring ..................................................................................................................... 22
7.5 Rated capacity indicator/limiter (RCI/L) ....................................................................... 23
7.6 Inspection before testing .............................................................................................. 23
7.7 Stability margin............................................................................................................. 23
7.8 Test procedure ............................................................................................................. 23

8 Provisions for inspection and testing of loader cranes .......................................................... 24

9 Major or structural repairs or modifications ........................................................................... 28

10 Non-destructive testing .......................................................................................................... 28

11 Documentation ....................................................................................................................... 29
11.1 Reports ......................................................................................................................... 29
11.2 Records ........................................................................................................................ 30

Annex A (informative) Daily inspection checklist ...................................................................... 32

Annex B (informative) Frequent inspection checklist................................................................ 33

Annex C (normative) Lifting of persons - Inspection and testing of cranes and lifting and
lifting accessories ....................................................................................................... 34

SANS 19:2018
Edition 2

Contents (concluded)
Page

Annex D (informative) Examination scheme approach............................................................ 38

Annex E (informative) Beaufort scale ...................................................................................... 40

Annex F (informative) Sea state code ..................................................................................... 41

Annex G (informative) Applicable types of NDT ...................................................................... 42

Annex H (informative) Load testing certificate ........................................................................ 43

Annex I (informative) Logbook ............................................................................................... 44

Bibliography .............................................................................................................................. 45

2 © SABS

SANS 19:2018
Edition 2

The inspection, testing and examination of mobile cranes

1 Scope
This standard covers provisions for the inspection, testing and examination of mobile cranes in use.

2 Normative references
The following referenced documents, in whole or in part, are normatively referenced in this document and
are indispensable for its application. For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any amendments) applies.
Information on currently valid national and international standards can be obtained from the
South African Bureau of Standards.

ISO 4306-2, Cranes – Vocabulary – Part 2: Mobile cranes.

SANS 687, Inspection and testing of non-fixed load-lifting attachments.

SANS 1599-2, Cranes – Part 2: Power-driven mobile cranes.

SANS 4309/ISO 4309, Cranes – Wire ropes – Care, maintenance, installation, examination and
discard.

SANS 4310/ISO 4310, Cranes – Test code and procedures.

SANS 53411-6/EN 13411-6, Terminations for steel wire ropes – Safety – Part 6: Asymmetric wedge
socket.

3 Definitions
For the purposes of this document, the definitions given in ISO 4306-2 and the following definitions
apply.

3.1
competent engineer
person who has such theoretical knowledge of the design of mobile cranes as enables him/her to
assess the design of the crane in order to establish appropriate criteria for inspection and thorough
examination

SANS 19:2018
Edition 2

3.2
competent person

person who has both technical knowledge of and practical experience in the inspection, testing and
examination of mobile cranes
NOTE 1 Technical knowledge consists of the following:

a) knowledge of cranes: outline of cranes, type of cranes, structural parts and driving mechanism, mechanical
elements, safety devices and their accessories, brakes and clutches, wire ropes;

b) knowledge of electricity: electrical appliances, control systems and their maintenance;

c) knowledge of internal combustion engine and hydraulic system;

d) knowledge of material used for structural parts of cranes and the strength of structural parts of cranes and
wire ropes; and

e) knowledge of relevant national legislation (see foreword) and national standards related to cranes.

NOTE 2 Practical experience refers to the ability to inspect, test and examine crane parts in accordance with
the inspection and testing procedure which covers all aspects of this standard and to judge the conformity to
the criteria given in this standard

3.3
crane inspector
lift machine inspector
LMI
person responsible and competent to perform inspections and test according to acceptable
standards and legislation as specified in the relevant national legislation (see foreword)

3.4
crane operator
person who is licensed to operate a crane for the purpose of positioning loads or for the erection of
the crane as specified in the relevant national legislation (see foreword)

3.5
designated person
person who possesses relevant knowledge and experience in the field of overhead cranes and is
assigned by the employer to carry out any supervision or inspection on overhead cranes

3.6
creep
distance of vertical downward creep of the hook on a crane

3.7
creep rate
loader crane booms
distance, expressed as a percentage of the crane radius, that a load equal to the rated capacity
drops in 1 min on a fully extended crane

3.8
lifting
displacement of a load or person in a vertical direction

3.9
load radius indicator
device fitted to a crane that shows the radius at which the crane is operating and its corresponding
rated capacity

4 © SABS

SANS 19:2018
Edition 2

3.10
non-destructive testing
NDT
testing carried out on the structure and components of the crane to establish the presence, location
and extent of any defects that can affect the integrity of that structure

NOTE 1 NDT is also known as non-destructive examination (NDE).

NOTE 2 The techniques employed for non-destructive testing are such that they do not damage or alter the
material under test.

3.11
radius
horizontal distance between the point at which the centre of rotation of the crane meets the ground
and the vertical centre line passing through the load-lifting attachment

NOTE In the case of a non-slewing crane, the horizontal distance from the centre line of a load-lifting
attachment to the centre line of the nearest axle, bogie or track, measured at ground level, may be assumed to
be the radius for the purpose of this definition.

3.12
rated capacity
maximum load that can be safely handled by a crane at a specified position and under specified
conditions

NOTE The rated capacity was formerly known as "safe working load". It was also known as "working load
limit". In South Africa, the rated capacity is based on 75 %, 78 % and 85 % load charts.

3.13
rated capacity indicator/limiter
RCI/L
device that warns and helps prevent the crane from being overloaded

NOTE This was previously known as an "automatic safe load indicator" and "overload protection".

3.14
testing

3.14.1
functional testing
operation of each motion of the crane without the application of a load in order to determine
whether the equipment performs as the manufacturer intended

3.14.2
performance testing
operation of each motion of the crane with the rated load applied in order to determine whether
the equipment performs to the manufacturer’s specification

3.15
thorough examination
examination by a competent person in such depth and detail as the competent person considers
necessary to enable him/her to determine whether the equipment being examined is safe to remain
in use

NOTE The thorough examination is not part of the maintenance regime for the equipment but provides
owners with information which could be used to determine the effectiveness of the regime.

SANS 19:2018
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3.16
user
person or organization that has control of both the lifting operation and the crane operator, and has
a responsibility to ensure that cranes and other equipment are properly maintained and thoroughly
examined by a competent person

4 Personnel carrying out inspection, testing and examination, and

their responsibilities
4.1 Inspection, testing and examination shall be carried out by a competent person.

4.2 After the competent person has identified defects which need to be rectified within a specified
timescale, he/she shall submit a report promptly to allow the user to take the necessary action
within the required period.

4.3 If the competent person sees that a crane is not safe for any reason, he/she shall notify the
user of the crane of this finding and also of any defects.

5 Facilities, information and equipment for inspection, testing and

examination
5.1 Facilities
The crane user shall ensure that the necessary facilities are provided to the competent person in
order enable him/her to conduct thorough examination of the crane. The facilities shall include the
following:

a) an appropriate area that is cordoned off in order to prevent access by persons who are not
directly involved in the examination;

b) crane operator;

c) person(s) who are available to remove covers or to open up parts of the crane; and

d) the preparation of parts or areas of the crane for non-destructive testing (NDT).

5.2 Information
A crane record book, containing all the relevant information shall be made available to the
competent person.

5.3 Measuring equipment

5.3.1 All measuring equipment shall have a valid calibration certificate and shall be accurate to
within  1,0 % of the measured value, and shall be undamaged and properly maintained.

5.3.2 All measuring equipment shall be calibrated annually.

5.4 Test weights

The following test weights shall be used:

a) weights of proven accuracy to within ± 1,0 %;

6 © SABS

SANS 19:2018
Edition 2

b) weights proven on a weighbridge, the weighbridge having been calibrated within the last
12 months; and

c) weights suspended from a calibrated weighing device, the weighing device having been
calibrated within the last 12 months. The weighing device shall be capable of weighing the test
load to within ± 1,0 %.

6 Provisions for inspection, testing and examination of mobile cranes

other than loader cranes
6.1 General
6.1.1 Inspections shall be conducted at a specified frequency in order to ensure that the crane is
kept in a safe and satisfactory condition. Inspections shall be conducted in accordance with the
requirements of this standard and shall be properly recorded.

6.1.2 The instructions shall be written in simple language and shall be made available to all
persons who conduct inspections.

6.1.3 Information on aspects such as rated capacities, alterations, maintenance repairs, renewals
and the operator’s instructions, shall be made available to the competent person if these are
necessary to carry out the thorough examination.

6.1.4 Where the manufacturer’s instructions for inspection and maintenance are available, they
shall be assessed by a competent person in accordance with the requirements of this standard. If
they are determined to be adequate and appropriate, they shall be applied during the crane's
inspection.

6.1.5 Where the manufacturer’s instructions for inspections are not available, or are deemed
inappropriate or inadequate by a competent person, the applicable provisions of this standard shall
apply.

6.1.6 Lifting accessories shall be included in the inspection regime. The requirements for non-fixed
lifting attachments are specified in SANS 687.

6.1.7 The following inspections shall be conducted:

a) daily inspections;

b) frequent inspections;

c) periodic thorough inspections;

d) examination scheme approach;

e) exceptional inspections; and

f) major inspections.

6.2 Daily inspections

6.2.1 Before the commencement of each work shift, the crane shall be given a visual inspection
and functional test to find evidence of deficiencies and that shall cover the following aspects:

a) the functioning of mechanisms, in particular the brakes (generally without load);

SANS 19:2018
Edition 2

b) the functioning of limiting and indicating devices; and

c) the observation of conspicuous defects including the ropes.

6.2.2 All safety-related problems shall be recorded, reported and resolved, before the crane is
used.

6.2.3 Such inspections and testing may be carried out by the crane operator and should include
the items listed in annex A.

6.2.4 The function tests shall be conducted without a load from the control station.

6.3 Frequent inspections

6.3.1 The frequency of inspection shall be based on the frequency and severity of use of the crane
and upon the working environment while it is in service.

6.3.2 The inspection shall be carried out by a designated person (for example, an experienced
technician) at intervals that do not exceed three months if the crane is in regular service. It shall not
be inferred that dismantling of any part is necessary during inspection, but opening of covers (for
example, limit switch covers), which are required for service and inspection purposes, shall be
allowed.

6.3.3 The following shall be inspected:

a) lubricants leaks, greasing;

b) hydraulic equipment leakage;

c) the visible deformation of hooks and latches, cracks and wear;

d) a visual inspection of connections and the corrosion of joints;

e) the wearing of the brakes, the thickness of brakes linings, adjustment, noise, etc.;

f) hydraulic and pneumatic hoses in particular those which are bent during operations;

g) the electrical installation for signs of deterioration and moisture accumulation; and

h) the condition of anchorage braces or guys that support the crane.

6.3.4 The inspection procedure shall include verification that the current logbook and operator’s
manual(s) are available on the crane and that this documentation is up-to-date.

6.3.5 A checklist of items, which should be included in the inspection is given in annex B.

6.3.6 A written report shall be furnished on completion of the inspection. The crane shall not be
returned to service until all safety-related malfunctions and problems have been corrected.

8 © SABS

SANS 19:2018
Edition 2

6.4 Periodic thorough inspections

6.4.1 General
6.4.1.1 Mobile cranes that are used to lift persons shall be examined by a crane inspector at least
once every six months, or at a shorter interval if so specified by the crane inspector and shall
include the lifting accessories in accordance with annex C.

NOTE Cranes lifting people should not be subjected to an overload test during the inspections which are
conducted every six months unless it is required by a crane inspector.

6.4.1.2 Mobile cranes that are not used to lift persons shall be examined by a crane inspector at
least once every twelve months.

6.4.1.3 After carrying out the periodic inspections, the crane inspector shall specify when the next
inspection shall be carried out, which may be less than, but not more than, twelve months later.

6.4.1.4 Before the inspections, the mobile crane shall be cleaned by appropriate means (for
example, pressure washed), to remove all spilt matter and dirt that would otherwise conceal the
structure or mechanisms and prevent an effective examination.

6.4.1.5 The examination shall be carried out in a logical sequence, for example, top to bottom, in
order to ensure that nothing is overlooked.

6.4.2 Items to check

6.4.2.1 Visually examine the crane structure, including the chassis, for signs of damage, distortion,
cracking and corrosion.

6.4.2.2 Visually inspect the superstructure and jib of the crane for corrosion, damage, cracks and
distortion.

6.4.2.3 Operate telescoping extensions on the crane and visually examine them for wear, security
and alignment.

6.4.2.4 Visually examine the fly jib and mounting attachment for corrosion, cracking, distortion and
wear. Check whether the hoist limit switch is in good working order.

6.4.2.5 In the case of lattice jib cranes, check the test certificate that covers all of the jib sections.

6.4.2.6 Visually examine all pivoting joints on the jib and the attachments of the crane for wear,
corrosion, security and evidence of lubrication.

6.4.2.7 Visually inspect the upper and lower hoist limit switches and check if they are in place and
free from damage and excessive wear.

6.4.2.8 Carry out a visual examination and functional check on the axle locking system for correct
operation, freedom from leaks, damage, corrosion and distortion, and for correct operation of all
indicators.

6.4.2.9 Visually examine the outrigger jacks and beams for wear, security, freedom of movement
and markings to show the correct extension for the beams. Extend the jacks and visually check
whether they move freely and smoothly and ensure that they do not creep when left supporting the
crane.

6.4.2.10 Visually examine the slewing mechanism and brakes for security and wear during
operation of the slew motion throughout its full range of movements and with the crane at maximum
reach.

SANS 19:2018
Edition 2

6.4.2.11 Visually examine the tyres for wear, damage, and inflated pressure.

6.4.2.12 Visually examine the crawler tracks for wear and adjustment.

6.4.2.13 Visually inspect all bolts and fastenings to ensure that they are not coming loose.

6.4.2.14 Examine all hydraulic cylinders for leakage, and for corrosion on the rods and alignment.
Visually check end fixings for wear, security and lubrication.

6.4.2.15 Visually examine all pipework on the crane for corrosion, damage, leakage, security and
fretting.

6.4.2.16 Visually examine all wire ropes to determine whether they are of the size and type
specified in the instructions and reeved in accordance with those instructions. Pay particular
attention to the end terminations. Requirements for wedge and socket terminations are specified in
SANS 53411-6.

6.4.2.17 Thoroughly examine the whole length of the wire ropes for signs of wear, damage, broken
wires and corrosion (see SANS 4309).

6.4.2.18 Visually check whether all pulleys or sheaves and rope drums are free from damage and
wear, whether the rope fits correctly on them and if they are effectively lubricated. Check whether all
idler pulleys or sheaves turn freely and ensure that all guards are undamaged and in place.

NOTE Plastics sheaves need special attention, as surface cracks might be deeper than indicated on the
surface and special solvents are required to establish the integrity of the sheaves.

6.4.2.19 Visually examine the hooks, and their attachments and safety catches, for wear, fretting,
distortion, corrosion and security.

6.4.2.20 Visually inspect the braking mechanism of the winch for wear, damage and adjustment,
and check whether it conforms to the instructions for the crane.

6.4.2.21 Check the oil and other fluids for the condition (for example, by debris monitoring) and
level of the fluid.

6.4.2.22 Check that all water is drained from air reservoirs; pneumatic systems and hydraulic
systems for safety devices and for deleterious effects.

6.4.2.23 Check any means of access for completeness and security of ladders, walkways and hand
rails or hand holds (or both).

6.4.2.24 Visually check whether the fixings for the crane operator’s seat, where fitted, and restraint
are all in place and secure.

6.4.2.25 Check the condition and markings whether of all control levers are marked with their
function and mode of operation.

6.4.2.26 Check whether there is a table displayed in the crane operator’s cabin showing the rated
capacities for the mobile crane for all crane operating conditions (free on wheels, free on cushion
wheels, all permitted outrigger positions, etc.).

6.4.2.27 Check whether warning signs and other important instructions are present and readable,
for example, the rating plate for load lifting.

6.4.2.28 Functionally test all controls for smoothness of operation and in order to determine
whether they are free from wear and other damage.

10 © SABS

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6.4.2.29 Operate the mobile crane to check whether all motions operate smoothly and effectively
without excessive play. Ensure that

a) the load-lifting attachment does not drop excessively after the motion has been stopped, and

b) all limiters and safety devices operate correctly, for example, boom length, boom angle, radius,
included load, maximum load that can be lifted and hook height, where applicable.

6.5 Exceptional inspections

6.5.1 Exceptional inspections shall be performed by a competent engineer.

6.5.2 Exceptional circumstances include the following:

a) a collision with other structures;

b) overload;

c) a safety device failure.

d) a fire;

e) an earthquake or seismic condition; and

f) extreme weather conditions.

6.5.3 Consideration shall be given to repair damaged components or change of the following:

a) load rating;

b) load bearing mechanical or structural components;

c) hoisting mechanism;

d) control station and system;

e) prime mover;

f) wire ropes or chains;

g) fixed and non-fixed load-lifting components; and

h) carrier.

6.6 Major inspections

6.6.1 The following categories of cranes shall be subjected to a major inspection and associated
maintenance:

a) cranes where the examination scheme approach regime has not been carried out and the cranes
have been in use for a period of ten years;

b) cranes that are to be re-commissioned or imported, and that do not have previous continuous
working records and maintenance records; and

SANS 19:2018
Edition 2

c) cranes that have been subjected to major inspections during their design working periods and
have been used after their design working period or are at the end of the deemed design life. The
deemed design life shall be determined by the competent engineer who would have supervised
the last major inspection.

6.6.2 The major inspection shall involve examination of the critical components that have been
identified by the manufacturer or a crane inspector. Where necessary, the crane shall be stripped
down and paint, grease and corrosion removed from critical components in order to allow a
complete and thorough inspection.

6.6.3 Particular attention shall be given to the following aspects:

a) past state of loading and utilization as compared to the crane's classification;

b) future intended state of loading and utilization as required by the user of the crane;

c) structural, mechanical, electrical, instrumentation, control and operational anomalies;

d) non-destructive testing of all nominated critical areas for evidence of cracking due to fatigue and
excessive stress;

e) components where maintenance records indicate repeated failures;

f) controls and emergency stop;

g) braking systems;

h) platform levelling systems;

i) platform, handrails and gate;

j) adequacy of safety instructions and manuals for operation and maintenance;

k) manufacturer’s safety upgrades; and

l) emergency retrieval system.

6.6.4 A written report shall be furnished on completion of the inspection. A competent engineer
shall assess the results and

a) specify the defects and wear that require attention in order to ensure its continued safe
operation, and

b) identify components that require particular attention in subsequent periodic inspections.

6.6.5 The crane shall not be returned to service until all safety-related malfunctions and problems
have been corrected.

6.6.6 Following the major inspection, the crane shall either be inspected as part of the periodic
inspection programme (see 6.4), or be reassessed by a crane inspector within five years. The
critical components that were identified by the assessment shall be inspected.

12 © SABS

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Edition 2

6.7 Examination scheme approach

The examination scheme approach to inspection and testing, if used, shall be based on regular
assessments of the mobile crane in accordance with its usage. The competent person shall take
into account the age, loading, environmental and duty cycle history of the crane, and any
examination intervals which have traditionally been accepted as appropriate for that or similar
equipment. Equipment that does not have a complete record of past usage shall be subjected to
periodic inspection (see annex D).

6.8 Testing

6.8.1 General

6.8.1.1 Mobile cranes shall be tested every twelve months by a crane inspector.

6.8.1.2 An inspection of the crane, in accordance with 6.4, shall be carried out before the test
commences.

6.8.1.3 The crane inspector shall check the rated capacity specified on the manufacturer’s
certificate of test, the load radius indicator and the table of rated capacities that is displayed in the
operator’s cab and those that are used by the RCI/L. The rated capacities shall all be identical.

6.8.1.4 The crane inspector shall verify that the crane is rigged in accordance with the instructions
in the manufacturer’s specifications for the crane.

6.8.1.5 At each successive calibration a different configuration shall be chosen so that eventually
all configurations are systematically covered.

6.8.1.6 A test load shall be applied to a crane by using test weights.

6.8.1.7 Tests shall not be undertaken when the crane or load cannot easily be seen because of
limitations on visibility (including inadequate lighting), or when it is heavily coated with ice or snow.

NOTE Mobile cranes have a large variety of support systems (for example, crawler tracks, tyres and
outriggers), jib configurations, counterweights and special attachments, all of which affect stability and
strength. The crane inspector should take account of all variations.

6.8.2 Variations of mobile cranes

6.8.2.1 Outriggers

Certain manufacturers provide duties for intermediate outrigger extension. The crane inspector shall
ensure that

a) the intermediate outrigger extension position is clearly and durably marked,

b) the manufacturer’s certificate indicates the correct rated capacities applicable to the intermediate
outrigger extension,

c) the duty charts give the specified intermediate extensions, and

d) provision is made in the RCI/L to accommodate the specified intermediate extension.

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6.8.2.2 Counterweights

Variations in counterweights affect the stability of the crane. The manufacturer’s duty charts specify
the ratings applicable for each counterweight. The crane inspector shall check whether the correct
counterweight is on the crane.

NOTE Mobile cranes can have additional counterweights and special rigs to enhance the lifting capacities.

6.8.2.3 Lifting free on wheels

6.8.2.3.1 Tyre pressure is a critical factor in retaining the desired stability margin of mobile cranes.
The pressure of the tyres of cranes under test shall be as specified in the manufacturer’s
specifications or instructions (or both).

6.8.2.3.2 Some crane manufacturers stipulate higher tyre pressure for free-on-wheels (static
condition fully mobile) duties than for road travel. Where the manufacturer permits lift-and-travel
duties that differ from the free-on-wheels duties, tests shall be carried out for both types of duty.

6.8.2.4 Lifting capacities

6.8.2.4.1 The load ratings marked on mobile cranes and shown on the manufacturer’s rated
capacity charts, i.e. the loads quoted, include the weight of the hook blocks, slings and lifting gear
and often other deductions, for example, stowed fly jib, shall be taken into account when the crane
is being tested and an allowance shall be made for the weight of suspended hook blocks, slings and
lifting gear. The exact weight of these items shall be ascertained.

6.8.2.4.2 Certain cranes can become unstable when working with long jibs and fly jibs if the jib
angle to the horizontal is reduced below the minimum angle given in the instructions. The hook
block shall always rest on the ground before any lowering of the jib beyond the maximum operating
radius commences.

6.8.3 Test site

6.8.3.1 Careful consideration shall be given to the condition of the site where the tests are to be
conducted. The recommendations that are provided in the operating instructions for the crane relate
to operations within the rated capacity. More stringent requirements apply when loads are being
applied for the purpose of testing.

6.8.3.2 Test sites shall not be located in areas which are known to be exposed to extreme weather
conditions.

6.8.3.3 Tests shall not be conducted over high-risk areas, for example a public highway, railway or
occupied buildings, in the flight path of airports or in the vicinity of overhead power lines. If, owing to
the requirements of usage, this is unavoidable, arrangements shall be made with the appropriate
authorities.

6.8.3.4 The site shall be of sufficient area and shall have unrestricted overhead clearance to allow
for the unobstructed movement of the crane and load during the test movement, for example
slewing, derricking and travelling.

6.8.3.5 The ground shall be well consolidated and shall be capable of withstanding the loads
applied to it. There shall be no hidden dangers such as cable ducts, drains, pipes, back-filled areas,
cellars or other subterranean hazards.

6.8.3.6 The ground shall be level as specified in the instructions. If the level of the ground is not
stated, the crane shall be levelled to a slope of not more than ± 1 %.

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6.8.3.7 All personnel who are not essential to the test shall be not be allowed to the area. The test
area shall be roped off and notices shall be posted prohibiting unauthorized entry. The site shall be
clear of plant and property which could inhibit the test.

6.8.4 Weather conditions

6.8.4.1 For cranes operating in situations where they are likely to be affected by the weather,
careful attention shall be given to this aspect.

NOTE Certain weather conditions such as electric storms, strong wind, heavy rains, ice, snow or an
excessive sea state can impose loads on a crane or adversely affect the safety of crane operations. Gusting
wind conditions can have an additional adverse effect on the safe handling of the load and on the safety of the
crane.

6.8.4.2 The crane shall not be operated in wind speeds (or, in the case of water-borne craft, sea
states or significant vessel movement) that are in excess of those specified in the operating
instructions for the crane.

NOTE The limitations on wind speed for testing of the crane may be lower than the limitations for normal
operation, and in cases of doubt advice shall be sought from a design authority or competent engineer.

6.8.4.3 Information regarding the Beaufort scale of wind force is given in annex E.

6.8.4.4 Information regarding sea state codes is given in annex F.

6.8.5 Test procedure

6.8.5.1 Functional test

6.8.5.1.1 The functional test shall be performed without a load to confirm correct and smooth
operations and whether the equipment performs as the manufacturer intended.

6.8.5.1.2 Functional testing shall be carried out on all functions of the crane, including controls
(including any remote controls), contactors, brakes and safety devices. The adjustments of the
brakes and limit shall be checked and tests shall be carried out to determine whether they are
operating correctly.

NOTE 1 It might be necessary to include the lifting of a suitable load once these devices have been tested.

NOTE 2 For variations of configurations, the RCI/L readings should be confirmed with the crane manuals.

6.8.5.1.3 The equipment shall be free from wear and other damage.

6.8.5.2 Performance test

6.8.5.2.1 Performance testing shall be carried out after functional testing. The cranes shall be
operated through all its motions with the rated load having been applied and at the lowest possible
speeds.

6.8.5.2.2 Performance testing shall be carried out on all functions of the crane, including brakes
and safety devices to determine whether the equipment operates correctly and smoothly at the
rated speeds, and is free from wear and other damage.

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6.9 Load test for jib arrangements

6.9.1 General

6.9.1.1 The crane inspector shall test all of the jib and mast/tower configurations given in tables 1,
2 and 3 with a load equal to the rated capacity.

6.9.1.2 Where the crane has duties on outriggers, free on wheels, crawler tracks and lift and travel,
the crane inspector shall repeat the test for each permitted condition.

6.9.2 Long jib lengths

6.9.2.1 All loads and movement of loads shall be kept just clear of the ground.

6.9.2.2 The crane shall be set up the crane with the longest jib configuration (see designation A.3
in tables 1 and 2).

6.9.2.3 The load equal to the rated capacity shall be assembled as indicated for the maximum
radius at a reduced radius. The load shall be raised and derricked out very slowly until the
maximum radius is achieved.

6.9.2.4 The maximum rated capacity for the jib given on the test certificate at the maximum radius
of the jib shall be assembled and lifted.

6.9.2.5 If the same rated capacity is permitted at a lesser radius, the load shall be derricked in to
the minimum permitted radius.

6.9.2.6 The load shall be lowered to the ground and increased it to the value given in 6.9.2.3. The
overload shall be lifted clear of the ground and held for 10 min. Where possible, the derricking
motion shall be checked by first derricking in the smallest practicable distance and then derricking
out to the same position.

6.9.2.7 If the same rated capacity is permitted at a greater radius, the test load shall be derricked
out to the maximum permitted radius.

6.9.2.8 The load shall be slewed at the lowest possible speed in both directions through a small arc
to determine the ability of the structure to withstand lateral loadings.

6.9.2.9 The tests in 6.9.2.2 to 6.9.2.8 (inclusive) shall be repeated for each configuration of the jib
and mast/tower shown in tables 1, 2 and 3, except for the shortest length of jib in tables 1 and 2,
and with the minimum tower length in table 3, when this is appropriate.

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Table 1 — Test configurations for telescopic jib arrangements

1 2 3 4
Length of Length of extended
Arrangement mechanized manual telescopic Length of fly jib
telescopic section section
A) Mechanized A.1 Shortest – –
telescopic jib A.2 Intermediate – –
A.3 Longest – –
B) Mechanized B.1 Longest – B.1.1 At Shortest Longest
b
telescopic jib appropriate to minimum offset Shortest
with fly jib maximum fly jib
a B.1.2 At Longest
rating
maximum offset Shortest
B.2 Longest – B.2.1 At Longest
b
minimum offset Shortest
B.2.2 At Longest
maximum offset Shortest
C) Mechanized C.1 Longest C.1.1 Shortest –
telescopic jib C.1.2 Longest –
with manual
telescopic
sections
D) Mechanized D.1 Longest D.1.1 Shortest D.1.1.1 At Longest
b
telescopic jib minimum offset Shortest
with manual
telescopic D.1.1.2 At Longest
sections and maximum offset Shortest
fly jib
D.1.2 Longest D.1.2.1 At Longest
b
minimum offset Shortest
D.1.2.2 At Longest
maximum offset Shortest
a
If fly jib ratings for test configuration B.1 are similar to those for test configuration B.2, then B.1 is not
applicable.
b
If fly jib ratings at minimum offset are similar to those at maximum offset, then tests at minimum offset are
not applicable.

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Table 2 — Test configurations for strut jib arrangements

1 2 3
Arrangement Length of jib Length of fly jib
A) Jib A.1 Shortest –
A.2 Intermediate –
A.3 Longest –
B) Jib with fly jib B.1 Longest appropriate to B.1.1 At minimum offset b Shortest
a
maximum fly jib rating Longest
B.1.2 At maximum offset Shortest
Longest
b
B.2 Longest B.2.1 At minimum offset Shortest
Longest
B.2.2 At maximum offset Shortest
Longest
a
If fly jib ratings for test configuration B.1 are similar to those for test configuration B.2, then B.1 is not
applicable.
b
If fly jib ratings at minimum offset are similar to those at maximum offset, then tests at minimum offset are
not applicable.

Table 3 — Test configurations for mast/tower and jib arrangements

1 2
Arrangement Length of mast/tower
A) Mast/Tower with jib A.1 Shortest
A.2 Longest
B) Mast/tower with jib/flyjib B.1 Shortest
B.2 Longest

6.9.3 Short jib lengths

6.9.3.1 The cranes shall be set up either with the shortest jib or with the shortest tower with the
shortest jib.

6.9.3.2 The load equal to the rated capacity shall be assembled as indicated below for the
maximum radius at a reduced radius.

6.9.3.3 The load shall be slewed at the lowest possible speed in both directions through a small arc
to determine the ability of the structure to withstand lateral loadings and then through 360° where
the design permits.

6.9.3.4 The maximum rated capacity for the jib at the minimum radius shall be assembled and
raised until each tooth of the train gear has been subjected to the load. The crane shall be operated
through its permitted motions at the lowest possible speeds, including full circle slew.

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6.9.3.5 The rated capacity shall be lowered and increased to the value given in 6.9.3.2 to form an
overload test load. The overload test load shall be hoisted until each tooth of the train of gears has
been subjected to the overload, then lowered to 100 mm to 200 mm above the ground. Operate the
crane through its permitted motions at the lowest possible speeds.

NOTE 1 It is recognized that for certain types of cranes the structure does not permit full slewing with the load
just clear of the ground. In these cases it is necessary to rest the test load and to reposition the crane to
ensure that as much of the crane structure as possible is subjected to the test load.

NOTE 2 For the lengths of jibs (telescopic or strut) and fly jibs, see table 1 or table 2, as relevant.

6.9.3.6 The derrick brakes be tested shall be tested with the load given in 6.9.2.2 or 6.9.3.2 as
relevant, suspended no more than 100 mm above the ground by derricking in from the maximum
load radius the smallest practicable distance and derricking out and applying the derrick brake
immediately. Extreme care shall be taken during this test.

6.9.4 Jibs

6.9.4.1 The correct jib sections shall be used for the duty under consideration.

6.9.4.2 The crane shall be rigged in accordance with the instructions for the crane, for example, for
long jibs midpoint suspension (intermediate ties) might be required. It is also necessary to identify
precisely in which order the sections are fitted.

NOTE 1 Manufacturers may supply jibs for different duties from materials of different specifications, which
may not be apparent without careful checking.

NOTE 2 On many cranes there are a large variety of possible jib configurations.

6.9.5 Fly jibs

6.9.5.1 Fly jibs shall be erected and used in accordance with the instructions for the crane.

6.9.5.2 The fly jib, like the hook and block, has a maximum rated capacity. At small radii, the fly jib
shall not be overloaded. At larger radii, the load on the fly jib shall be reduced in accordance with
the lifting capacity of the main jib or fly jib combination.

6.9.5.3 When a load is lifted on the main hook with the fly jib fitted, the load on the main hook shall
be reduced to allow for the weight of the fly jib and fly hook. The maximum permissible angle of the
main jib to the horizontal shall not be exceeded when the fly hook is at its minimum radius, as there
is a danger that the jib might fall back owing to wind and dynamic loading.

6.9.5.4 Any necessary deductions and limitations in load value shall be in accordance with the
instructions.

6.9.5.5 Many fly jibs are capable of variation in length or angle of offset (or both). The tie ropes
shall be of equal length and shall be fitted in accordance with the instructions. The angle of offset (if
applicable) shall be checked by calculation or by measurement (or both).

6.9.6 Variable length jibs

6.9.6.1 When jib lengths are increased by the fitting of intermediate sections, the sections shall be
identified to ensure that they are correct for the model of crane, for example to avoid mismatch of
metric and imperial sections.

6.9.6.2 The identification of the jib sections tested shall be recorded on the test certificate.

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6.10 Rated capacity indicator/limiter (RCI/L)

6.10.1 General

6.10.1.1 The calibration check of the RCI/L shall be carried out

a) at intervals of not more than twelve months,

b) after the RCI/L has undergone repairs, and

c) as part of the annual overload test.

6.10.1.2 At each successive calibration, a different configuration of the mobile crane shall be
chosen so that eventually all configurations are systematically covered.

6.10.1.3 During the calibration check of the RCI/L the crane shall not be loaded beyond its rated
capacity for 75 %, 78 % and 85 % load chart.

6.10.1.4 The radius/angle at which the test load corresponds to the rated capacity for 75 %, 78 %
and 85 % load chart, shall be marked and the test load shall not be taken beyond that point.

6.10.2 Warning of approach to rated capacity

The RCI/L shall give a clear and continuous warning of approach to the rated capacity. The visual
and audible warning shall commence at 90 % of the rated capacity. The approach to rated capacity
warning shall continue to function until the percentage of load falls to below the value at which the
warning was initiated.

6.10.3 Warning of overload

The RCI/L shall give a clear and continuous visual and audible warning of overload. The visual and
audible warning shall commence at 100 % of the rated capacity. The overload warning shall
continue to function until the percentage of the load to the rated capacity falls to below the value at
which the warning was initiated.

6.10.4 Tolerances of indication

6.10.4.1 Proximity to rated capacity

The accuracy of indication shall be within ± 5 % when the entire load suspended from the crane is
equal to the rated capacity.

6.10.4.2 The radius of the load

The accuracy of indication of the displayed radius shall within a band determined from a graph of
rated capacity against radii, the graph being plotted from the values given on the certificate of test
for the crane. The displayed radius shall correspond to the rated capacity of the graph within ± 5%
of the rated capacity given by the actual radius (see figure 1).

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Figure 1 — Tolerance of SWL against radius

6.10.4.3 The angle of the jib

The accuracy of the indication of the displayed angle shall be within a band which is determined
from a graph of rated capacity against angles, the graph being plotted from the values given on the
certificate of test for the crane. The displayed angle shall correspond to the rated capacity on the
graph within ± 5 % of the rated capacity given by the actual angle.

6.10.4.4 Load of crane hook

The accuracy of the indication shall be ± 5 %.

6.11 Post-test inspections

After the completion of the testing, a thorough inspection shall be undertaken by a crane inspector
to determine whether the crane has withstood testing without signs of structural damage that could
affect the safety of the crane, such as

a) cracking,

b) permanent deformation,

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c) paint flaking, and

d) loosening of, or damage to, structural connections.

7 Provisions for inspection and testing of mobile cranes mounted on

water-borne craft
7.1 General
7.1.1 When mobile cranes are mounted on water-borne craft, it shall be considered a major
modification requiring the assembly of the crane and the vessel to be assessed, tested and
thoroughly examined as a floating crane.

7.1.2 Where applicable, all the requirements of this standard shall apply as well as the
requirements given in 7.2 to 7.8 (inclusive).

7.2 Information

7.2.1 Information shall be obtained regarding the amount of list and freeboard allowable under
both rated capacity and overload conditions (where applicable) from a crane inspector or authority
experienced in crane design and stability of water-borne craft.

7.2.2 In addition, confirmation shall be obtained from the crane manufacturer on how far the crane
is derated from land-based ratings whilst on the barge or pontoon. This is necessary to minimize
any excessive loads in the structure which would be applied when any part of the barge or pontoon
is at maximum list.

7.3 Verification
Before the mobile crane is tested, the following details shall be verified:

a) the calculated angle of heel and trim of the vessel when the crane is in operation, ensuring that a
minimum freeboard is maintained;

b) the crane manufacturer’s allowable rated capacity whilst the crane is working on the pontoon or
barge, taking account of information obtained from the assessment in clause 7;

c) the amount and position of any ballast required;

d) the depth of water below the keel of the vessel, to ensure that the vessel does not ground during
the test; and

e) the limiting weather and sea state conditions allowed by the crane designer, certifying authority
or other competent person.

7.4 Anchoring
If it is not possible to anchor the vessel to the shore, the vessel shall be anchored to a craft
alongside. The anchorage shall be sufficiently free to allow the vessel to take up a natural list in the
water.

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7.5 Rated capacity indicator/limiter (RCI/L)

7.5.1 The crane RCI/L shall be checked to ensure that the rated capacity reduction and any
increase in radius due to the list of the vessel have been taken into account.

7.5.2 The requirements of 6.10 shall apply.

7.6 Inspection before testing

7.6.1 The inspections required in 6.4, and the verifications given in 7.6.2 shall be carried out before
the application of any loads:

7.6.2 The verification of the

a) ties,

b) supports,

c) anchorages,

d) ballast counterweight, and

e) load radius configuration for the type of crane under test in accordance with the crane
instructions.

7.7 Stability margin

The stability margin for a crane/vessel combination shall be calculated by a competent person
familiar with the use of mobile cranes on vessels. The margin shall be such that the maximum
overturning moment of the crane does not exceed two-thirds of the restoring moment of the
crane/vessel combination.

7.8 Test procedure

7.8.1 General

7.8.1.1 As a general guide, the maximum list of a vessel under any conditions (including test
conditions) should not exceed 7° with adequate freeboard remaining, i.e. 300 mm. These angles of
list apply to vessels without cargo.

These listings are only permissible with the crane manufacturer’s agreement to the load radius
rating. The figures quoted in this subclause are an absolute maximum. For cranes designed in
accordance with SANS 1599-2, these figures shall be considerably reduced owing to lateral
strength considerations (see 7.2).

7.8.1.2 In the case of a grabbing crane mounted on a vessel, the weight of the grab and contents
shall not exceed 75 % of the hook load and a further 25 % reduction shall be made to allow for the
suction effects. The weight of the grab and contents shall, therefore, not exceed 56,25 % of the
water-borne hook load rating.

7.8.2 Application of loads

7.8.2.1 The crane inspector shall test the crane to the maximum rated capacity that is within the
required stability and strength margins for both the crane and vessel.

7.8.2.2 The requirements of 6.8 and 6.9 shall apply.

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8 Provisions for inspection and testing of loader cranes

8.1 General
The requirements of clause 6 shall apply where applicable.

8.2 RCI/L calibration check

8.2.1 Inspections of loader cranes should include confirmation that the RCI/L has been calibrated
to an accuracy within the tolerances given in 8.2.5 and 8.2.6.

8.2.2 This calibration is not necessarily part of overload testing. This calibration check should be
carried out at no more than twelve monthly intervals.

8.2.3 Calibration checks should include the suspension of calibrated weights on the crane, to
determine whether the RCI/L is accurate to within the tolerances in 8.2.5 and 8.2.6.

8.2.4 The usual format of loader cranes is a boom system consisting of a boom, an articulating jib
and a telescopic extension within the jib section. The horizontal reach of a loader crane with its
telescopic extension retracted is invariably less than 70 % of the reach of the crane with its
telescopic extension extended.

8.2.5 A load equivalent to the rated capacity10 % overload at maximum extension, lifted from the
ground with the jib fully extended and the telescopic section fully retracted is less than 90 % of the
rated capacity of the loader crane. With the load kept as close as possible to the ground, the radius
shall be increased until the indicator gives the approach to rated capacity warning.

8.2.6 The visual and audible warning should commence at 90 % of the rated capacity.

8.2.7 The visual and audible warning for overloading should commence at 100 % of the rated
capacity.

8.3 Items to check at periodic inspections

8.3.1 Visually inspect the crane structure for corrosion, damage, cracks and distortion.

8.3.2 Visually check the subframe attached to the lorry chassis for damage or signs of distortion,
cracking and corrosion.

8.3.3 Check all bolts and fastenings used to attach the crane to the subframe, and the subframe to
the lorry chassis, for tightness.

8.3.4 Visually inspect all pivoting joints on the crane for wear, corrosion, security and evidence of
lubrication.

8.3.5 Visually inspect the pipe connections between pump and crane, crane and oil tank, and oil
tank and pump, for chafing, leakage, damage, security and erosion.

8.3.6 Visually inspect all pipework on the loader crane for chafing, leakage, damage, security and
corrosion.

8.3.7 Visually inspect all hydraulic cylinders for alignment, and for leakage and corrosion on the
cylinder rods.

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8.3.8 Check the level and condition of the fluid in the oil tank.

8.3.9 Visually inspect the crane control valve for damage, leakage and security.

8.3.10 Check whether all control valve levers are marked with their function and mode of
operation.

8.3.11 Carry out a functional check on the hand brake interlock, to determine whether the power
take off disengages when the hand brake is released.

8.3.12 Operate telescopic extensions on the loader crane and examine them for wear, lubrication
and security.

8.3.13 Functionally test all controls (levers, buttons, etc.) for smoothness of operation and to
determine whether they are free from wear and any other damage to any linkage.

8.3.14 Check to ensure that all controls return to neutral when released.

8.3.15 Carry out a functional check of the height warning device which is used for the prevention of
collisions with bridges.

8.3.16 Check whether all manufacturers’ load plates are firmly attached and readable from the
control positions.

8.3.17 Deploy the stabilizers and check for wear, security and freedom of movement. Check
whether the cam locks and automatic latches on the beams (to prevent inadvertent extension)
function correctly and are free from wear, distortion and corrosion. Lower the leg jacks to make firm
contact with the ground and check to ensure that they do not creep during crane operations.

8.3.18 Check all means of access for completeness and for the security of ladders, walkways and
hand rails or hand holds.

8.3.19 Visually check whether the operator’s seat and restraint, where fitted, are complete and
secure.

8.3.20 Check to ensure that there is a label visible from the operator’s seat displaying the travelling
height of the lorry loader.

8.4 Additional checks for loader cranes fitted with winches

8.4.1 Check whether the hoist rope is of the size and type specified by the manufacturer, and is
reeved in accordance with the instructions. Pay particular attention to the end terminations.
Requirements for wedge and socket terminations are specified in SANS 53411-6.

8.4.2 Visually check whether all pulleys or sheaves and drums are effectively lubricated, and free
from damage and wear, and that the rope fits correctly. Check whether all idler pulleys/sheaves turn
freely and all guards are in place and undamaged.

8.4.3 Thoroughly examine the entire length of the hoist rope for signs of wear, damage, corrosion
and broken wires. Requirements are specified in SANS 4309.

8.4.4 Visually inspect the hoist limit switches, when fitted, and check to ensure that they operate
correctly and are free from damage and excessive wear.

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8.4.5 Operate the loader crane to check whether all motions operate smoothly and effectively. The
creep rate shall be within the tolerance set by the manufacturer.

8.4.6 If a loader crane has a lifting capacity in excess of 3 t or a load moment in excess of
40 000 N•m it shall be fitted with a RCI/L loading control. Examine and test whether the RCI/L
loading control is in working order.

8.5 Testing

8.5.1 General

8.5.1.1 Load tests for loader cranes shall be carried out by a crane inspector at least once every
twelve months at a load of 100 % of the rated capacity.

8.5.1.2 A thorough examination of the crane according to 8.3 and 8.4 shall be carried out before a
test is performed.

8.5.1.3 The crane inspector shall check to ensure that the rated capacity quoted on the
manufacturer’s specification for the crane equates with the rated capacity plate on the crane and
the capacities given on the previous test certificate.

8.5.1.4 Hydraulic oil shall be at the normal operating temperature before testing commences.

8.5.1.5 The test can be considered successful if the lorry loader does not show cracking,
permanent deformation, paint flaking or damage as a result of the test or total instability to the
vehicle.

NOTE The purpose of the test is to check the integrity of the crane and its mounting, and to establish the
stability of the loader crane on an unloaded vehicle.

8.5.2 Levelling

All tests shall be carried out on firm level ground, with a slope that does not exceed ± 1 %.

8.5.3 Stabilizers

8.5.3.1 Stabilizers shall be fully extended to maximum spread, and with the vehicle tyres inflated to
the manufacturer’s recommended pressure.

8.5.3.2 Stabilizers shall be in firm contact with the ground, enough to provide adequate support for
the crane but not enough to take the load from the wheel and reduce the efficiency of the parking
brake.

8.5.4 Lifting capacities

The mass of all additional lifting equipment fitted to the loader crane shall be regarded as part of the
test load.

NOTE The load ratings shown on the crane’s load plate and given in the manufacturer’s rated capacities for a
given crane, indicate the gross loads.

8.5.5 Lifting of vehicle wheels and stabilizers

During overload testing it is acceptable for one or more stabilizers and wheels to lift clear of the
ground. However, at least one of the parking braked wheels shall remain in firm contact with the
ground.

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8.5.6 Test conditions

8.5.6.1 General

The test loading shall be carried out using an unloaded vehicle with no operator present in the cab,
if fitted, and shall be conducted in two stages in the following order:

a) overload test; and

b) dynamic functional test.

8.5.6.2 Overload test

The overload test is designed to ensure that a margin exists against structural failure of the lorry
loader, including all the anchorages to the vehicle, all vehicle structural parts, stabilizers and
hydraulic equipment. At each radius the load shall be slowly slewed through the full slewing arc.

8.5.6.3 Dynamic functional test

8.5.6.3.1 General

For dynamic and functional tests, the rated capacity indicator and all safety relief valves shall be set
at their correct values. These tests are designed to subject system hydraulics and structural
members to dynamic conditions and fluctuating loads. The tests also incorporate checks on each
powered function for movement through its full range of travel, and are carried out to confirm the
operation of load decelerating valves and the rated capacity indicator, when fitted.

8.5.6.3.2 Determination of the test load

The test load shall be determined in accordance with the following formula:

L = (KsP) + (0,1 Gb)

where

L is the test load;

Ks is the test factor (equal to 1);

P is the rated load;

Gb is the mass of the boom system referred to the point of load attachment.

8.5.6.3.3 Radii

The test shall be carried out at the following radii:

a) the maximum radius with any special extensions;

b) the maximum radius attainable with hydraulic outreach;

c) one intermediate radius, preferably corresponding to one of the ratings shown on the load plate;
and

d) the smallest practical radius given on the load plate.

SANS 19:2018
Edition 2

8.5.6.3.4 Procedure

8.5.6.3.4.1 Continue the dynamic test without interruption until the full range of movements and
positions throughout the speed range has been carried out.

8.5.6.3.4.2 Check the correct functioning of load decelerating valves by introducing sudden arrests
of the moving suspended load. Conduct tests in such a manner that, and in a place where, no
potential hazards exist.

8.5.6.3.4.3 Note the set points of the rated capacity indicator in terms of radius and load at which
the audible and visual warnings occur.

8.5.6.3.4.4 At the end of this continuous period of testing, check and record the temperature of the
hydraulic oil.

8.5.6.3.4.5 At the end of the test, ensure that the overload protection, if fitted, is reconnected at the
set point for operation. Note this in terms of radius and load after any necessary adjustments have
been made.

8.5.6.3.4.6 Set the main relief valve to lift the rated capacity at maximum hydraulic outreach.

8.5.6.3.4.7 Reseal all adjustable relief valves with tamper-proof seals.

9 Major or structural repairs or modifications

9.1 Equipment shall be thoroughly examined and tested after every major or structural repair or
modification.

9.2 Any testing shall be carried out in accordance with written instructions from the manufacturer
or other appropriate design authority.

9.3 In the event of any alteration or repair that could affect the stability of the crane, stability testing
shall be carried out in accordance with the original crane specification.

9.4 In the event of any alteration or repair that could affect the strength of the crane, overload
testing shall be carried out to ensure that all parts affected by the repair are subjected to the test
loads in accordance with the original crane specification, or SANS 4310 (or both).

NOTE It might be necessary to confirm the loads to be applied after such alterations or repairs with the
manufacturer or other design authority.

10 Non-destructive testing
During the thorough examination of a crane, the crane inspector might consider it appropriate to
apply NDT techniques to assess the integrity of components. These techniques can assist in the
detection of any material cracks or defects that might grow in service and ultimately lead to failure.

Annex G gives guidance to the different types of testing.

NOTE SANS 9712 contains guidance on the qualification and certification of NDT personnel and, unless the
operator is working to a detailed written procedure, he/she should be qualified to level two in accordance with
SANS 9712.

28 © SABS

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11 Documentation
11.1 Reports
11.1.1 After every thorough inspection (including when a crane is tested), a report shall be
prepared. The report shall contain at least the information given in 11.1.2 to 11.1.16.

11.1.2 The name and address of the employer for whom the thorough inspection was conducted.

11.1.3 The address of the premises at which the thorough inspection was conducted.

11.1.4 Particulars sufficient to identify the equipment, including, where known, its date of
manufacture.

11.1.5 The date of the last thorough inspection.

11.1.6 The safe working load of the lifting equipment or (where its safe working load depends on
the configuration of the lifting equipment) its safe working load for the last configuration in which it
was thoroughly inspected.

11.1.7 In relation to the first thorough inspection of lifting equipment after installation or after
assembly at a new site or in a new location, a statement to the effect that

a) it is such a thorough inspection, and

b) (if such be the case) the lifting equipment has been installed correctly and is safe to operate.

11.1.8 In relation to a thorough inspection of lifting equipment other than a thorough inspection to
which 11.1.7 relates

a) whether it is a thorough inspection,

1) within an interval of six months,

2) within an interval of twelve months,

3) in accordance with an examination scheme, or

4 after the occurrence of exceptional circumstances, and

b) (If such be the case) a statement to the effect that that the lifting equipment is safe to operate.

11.1.9 In relation to every thorough inspection of lifting equipment

a) identification of any part found to have a defect which is, or could become, a danger to persons,
and a description of the defect,

b) particulars of any repair, renewal or alteration required to remedy a defect found to be a danger
to persons, and

c) in the case of a defect which is not yet, but could become, a danger to persons

1) the time by which it could become such a danger,

2) particulars of any repair, renewal or alteration required to remedy it, and

3) the latest date by which the next thorough inspection shall be carried out.

SANS 19:2018
Edition 2

11.1.10 Where the thorough inspection included testing, particulars of any test such as

a) the date of the thorough inspection, and

b) the name, address and qualifications of the person making the report (crane inspector); and the
fact that he/she is self-employed or, if employed, the name and address of his/her employer.

11.1.11 The name and address of a person signing or authenticating the report on behalf of its
author.

11.1.12 The date of the report.

NOTE 1 Additional details might be needed for specific types of cranes.

NOTE 2 An example of a load test certificate is given in annex H.

11.1.13 The crane inspector shall ensure that the information provided in the report of thorough
inspection and certificate of test is the same as the rated capacities given on the duty charts for the
crane and the settings on the RCI/L.

NOTE The rated capacities established by the crane inspector and referred to in the current report of
thorough inspection and certificate of test could make it necessary to alter the charts on the crane and to
recalibrate the RCI/L.

11.1.14 All certificates of test shall be endorsed with the information necessary to ensure that
there is no ambiguity as to crane rigging at the time of test. This applies to all possible variables, for
example, jib length, rope reeving, track width, short or long crawlers, counterweights, blocked, free
on wheels and jib locking pins.

11.1.15 Where for any reason the crane inspector considers it necessary to restrict the use of a
crane (for example, where site limitations prevent the testing of the full range of movements of the
crane), the restrictions shall be noted on the report of thorough inspection and certificate of test,
and the use of the crane shall be subject to these restrictions. A notice of these restrictions shall be
posted in the cab of the crane.

11.1.16 Where for any reason the crane inspector deems it necessary to change the rated
capacities, the markings and tables of rated capacities on the crane shall be amended to reflect
these restrictions, and they shall be recorded on the certificate of test. The RCI/L shall be set to
perform in accordance with the new rated capacities.

11.2 Records
11.2.1 A continuous working record, including logbook and service/maintenance history of the
significant events concerning the safety and operation of the crane, shall be kept by the user and be
readily available (see annex I). They may be in any suitable format. These records shall be
transferred with ownership of the crane.

11.2.2 The minimum records that shall be retained in the logbook are copies of

a) the last major inspection,

b) the last periodic thorough inspection,

c) the last test,

d) the last frequent inspection, and

e) the complete daily pre-operation reports for not less than the last 90 d of operation, or since the
last frequent inspection whichever is the greater.

30 © SABS

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11.2.3 Action taken or repairs carried out to rectify malfunctioning or damaged components.

11.2.4 Each log entry shall be signed by the responsible person making the entry and should
contain details of that person’s identification and qualifications.

11.2.5 The checks, adjustments, replacement of parts, repairs and inspections performed and all
irregularities or damage concerning the unit’s safe use shall be recorded.

11.2.6 In addition, all complete reports for all inspections shall be maintained and made available
for examination as required.

NOTE Any system that records these events and is readily available to the operator and inspector should be
accepted as meeting the intent of this clause.

SANS 19:2018
Edition 2

Annex A
(informative)

Daily inspection checklist

1 2 3
Component Visual inspection Functional test
Pendant and cab controls x x
Emergency controls and retrieval system – x
Visual and audible alarms – x
Personal protective equipment x –
Air, hydraulic and fuel system leaks x –
Cables and wiring for security and
x –
damage
Loose and missing parts x –
Brakes – x
Tyres, wheels x –
Placards, decals, warnings, control
markings and presence of operating x –
manuals on the crane
Slew brake function where fitted – x
Safety switches and interlocks x
Structural defects or damage x –
Correct operation of drive and speed
– x
functions, including speed-limiting devices

32 © SABS

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Annex B
(informative)

Frequent inspection checklist

The frequent inspection should include the following items:

a) all functions and their controls for speed, smoothness of operation and limits of motion;

b) all emergency and safety devices including interlocks and emergency lowering devices;

c) pendant and cab controls including the provisions for overriding of addition controls;

c) all chain and cable mechanisms for adjustment wear and damage;

d) lubrication of all moving parts, inspection of filter element(s) and fluid levels;

e) visual inspection of structural members and welds;

f) visual inspection, and measurements as necessary, of critical components such as brakes,

gears, fasteners, pins, shafts, wire ropes, sheaves, locking devices, all guardrails and guarding,
all attachments and connections, electrical contactors and all ancillary equipment;

g) signage, including warning signs, decals and control markings;

h) wear and damage to wheels and rails; and

i) corrosion.

SANS 19:2018
Edition 2

Annex C
(normative)

Lifting of persons — Inspection and testing

of cranes and lifting accessories

C.1 General
Cranes and other equipment used to lift persons and the personnel work platform shall be
thoroughly examined either at least every six months or in accordance with a written scheme of
thorough inspection.

C.2 Crane
C.2.1 Check to ensure that the crane has an RCI/L with an appropriate duty for personnel lifting
(i.e. half the rated capacity for lifting other loads).

C.2.2 Check to ensure that the crane is equipped with a motion-control system that brings motion
to rest automatically when the controls are released.

C.2.3 Check to ensure that the crane is equipped with an appropriate anemometer or other device
to monitor in-service wind speeds. This is intended to ensure that personnel work platforms are not
used in wind speeds in excess of 7 m/s.

C.2.4 Check to ensure that any crane equipped with a winch has power lowering. Cranes with
free-fall ability shall not be used to lower and raise persons unless the free-fall facility has been
locked out.

C.2.5 Check to ensure that load-bearing hydraulic cylinders are fitted with load-hold valves (over-
centre valves) to stop movement in the case of hose rupture or pipe fracture. Cranes only equipped
with simple check or hose rupture valves shall not be used for the lifting of persons.

C.2.6 Carry out a functional check to determine whether the crane control system is able to
provide a smooth transition of the work platform. The control shall be such that the work platform
can proceed gently and the working speed shall not exceed 0,5 m/s during all motions.

C.2.7 Check to ensure that means are provided so that, if the power supply or control system
fails, the work platform can be positioned to enable access/egress without risk.

C.2.8 Measure the wire rope used for hoisting and lowering the work platform. The wire rope shall
have a diameter of at least 8 mm.

C.3 Work platform

C.3.1 Visually check to ensure that storage accommodation for equipment, including any
emergency egress equipment (for example safety harness, lanyard), is provided in the work
platform.

C.3.2 Visually check to ensure that the work platform is marked with the number of persons that
may be carried and the maximum load that may be carried.

34 © SABS

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C.3.3 Check to ensure that no doors in the work platform open outwards and that doors can be
securely fastened.

C.3.4 Visually check to ensure that the work platform has hand rails, mounted in positions that do
not trap hands, to provide security for persons.

C.3.5 Visually check to ensure that the work platform sides are such as to prevent persons or
materials from falling from the work platform.

C.3.6 Visually check to ensure that any attachment points for safety devices such as harnesses
are secure and undamaged.

C.3.7 Visually check any safety devices such as harnesses and lanyards for integrity and
completeness.

C.3.8 Visually examine the structure of the work platform. It shall be free from damage, corrosion,
cracks and other imperfections.

C.3.9 Visually check any mechanism provided to ensure that the floor of the work platform
remains horizontal. It shall be free from damage, leaks, corrosion and wear.

C.3.10 Visually check the work platform for a unique identification mark and record this on the
report of thorough inspection.

C.4 Report of thorough examination

The report of thorough inspection shall state that the crane and work platform have been thoroughly
examined for the purpose of lifting persons.

C.5 Bosun's chair

C.5.1 Visually examine both primary and secondary suspension points. They shall be free from
damage, corrosion, cracks and other imperfections.

C.5.2 Visually examine the seat structure for damage, security and contamination.

C.5.3 Visually examine the seat belt(s) for damage, contamination, security of their fixings and
correct operation.

C.6 Harnesses
C.6.1 Visually examine the harness for signs of cuts, abrasion, damaged stitching or
contamination.

C.6.2 Check the harness for correct operation of all buckles, adjusters, fasteners, etc.

C.6.3 Visually examine both primary and secondary suspension points. They shall be free from
damage, corrosion, cracks and other imperfections.

C.6.4 Check the age of the harness to determine whether it is within the age range recommended
by the manufacturer.

C.6.5 Check the harness for the correct capacty.

SANS 19:2018
Edition 2

C.7 Pre-use checks

C.7.1 Crane
Before using the crane for lifting persons and suspended work platform, check to ensure that the
following requirements have been complied with:

a) the hoist ropes are free of kinks and other obvious defects;

b) a means has been provided to prevent the work platform attachment from becoming detached
from the hook;

c) multiple part lines are not twisted around one another;

d) there is no slack in the wire ropes; and

e) all ropes are properly seated on drums and on sheaves.

C.7.2 Work platform

C.7.2.1 The work platform, suspension system, attachment points and any work platform motion
controls shall be checked before use by the appointed person/crane supervisor. The checks are to
identify conditions that have been specifically indicated by the work platform manufacturer, or crane
inspector, as potentially creating a hazardous operating condition.

C.7.2.2 The checks shall cover at least those items listed in C.8, and the form shall be signed by
the appointed person or crane supervisor. Any conditions found to be unsatisfactory shall be
corrected before persons are lifted.

36 © SABS

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Edition 2

C.8 Personnel carrier — Pre-use check

Inspector: Date:
Platform ID:
Marking Satisfactory Unsatisfactory
Platform (all information legible)
Make of platform
Date of manufacture
Safe working load
Number of people licensed to carry
Certificate issued by Department of Labour
Last inspection/examination
Suspension system
Structure
Load-supporting welds/bolts
Load-supporting members
Barrier from toe board to intermediate rail
Hand rail
Fall protection device
Anchorage points
Gate-locking mechanisms
Platform flooring
Suspension attachment points
Attachment mechanisms
Pins/eyes
Wire rope/chain
Master links and shackles
Special-purpose items (e.g. overhead protection, platform controls)
1
2
3
4
General comments:
Weather conditions and lighting:
Appointed person/crane supervisor:

Name
(print)…………..................………………Signature…………………............................……Date……................

SANS 19:2018
Edition 2

Annex D
(informative)

Examination scheme approach

D.1 The examination scheme shall include a written schedule of the steps required to periodically
assess the condition of items included in the examination, for example, condition monitoring. The
scheme is intended to ensure that the equipment remains safe to use and includes information on
the required frequency of examinations.

D.2 The competent person shall prepare an examination scheme which might require the co-
operation of the equipment manufacturer and user. For example, the manufacturer might provide
limiting criteria based on the crane design, number of load cycles, load spectrum, critical parts and
exceptional circumstances (such as shock loading). These criteria should not be based on time
alone.

D.3 The competent person should take into account the limiting criteria from the crane supplier
when devising an examination scheme in accordance with the relevant national regulations for
lifting equipment.

NOTE Data-logging equipment greatly facilitates the collection of information concerning crane usage for
comparison with the crane design criteria. The data-logging equipment needs to be fitted to the mobile
cranewhen it is new to ensure that a complete record of all the usage of the mobile crane is maintained.

D.4 For mobile cranes and other equipment subject to an examination scheme, a calibration
check shall be carried out on the RCI/L at least once every twelve months.

D.5 An examination scheme shall contain at least the following information:

a) The name and address of the owner.

b) The name, qualifications and address of the person drawing up the scheme and certifying that it
is suitable and sufficient. If the competent person is not working on his/her own account, the
name of the organization employing him/her and his/her position in that organization.

c) The make, model and unique identification number of the crane.

d) any information used in drawing up the scheme. This might include the instructions, or specific
information from the designer on the design life of the structure and mechanisms;

e) Details of any data-logging system fitted, including a listing of the parameters monitored and the
means by which data retrieval, monitoring and storage are achieved.

f) Details of the environment in which the crane might be used during the period covered by the
scheme.

g) Identification of those parts of the crane requiring thorough examination and the probable
reasons for the deterioration, for example wear and corrosion.

h) Frequency of thorough examination for those identified parts which might include time, loading or
duty cycle limits and which might vary for different parts of the equipment.

i) Method of thorough examination of those identified parts that require thorough examination,
which might include the degree of dismantling required, any preparation to be carried out by the
user before the examination, NDT techniques, timed replacement, etc.

38 © SABS

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Edition 2

j) An indication of the resources required to carry out the inspection. This might include crane
inspector(s), workshop facilities, specialist NDT and metallurgical facilities, etc.

k) Any changes to the condition of the equipment, or to operational or environmental parameters

that would require a review of the scheme by the competent person. These may include damage
to the structure, change of use from general use to heavy-duty work, or moving from an inland
location to a marine environment.

l) The date of drawing up the scheme and the date at which any routine review is required.

D.6 The examination scheme shall determine whether all mechanisms function correctly and are
free from defects and whether the crane is safe for further use.

D.7 If it is not possible to comply with any of the requirements of the examination scheme, the
crane shall be subjected to a specified period inspections.

SANS 19:2018
Edition 2

Annex E
(informative)

Beaufort scale
Table E.1 gives information regarding the wind conditions for the Beaufort scale.

Table E.1 — Beaufort scale wind conditions

1 2 3 4 5

Beaufort Description Wind speed Wind speed

Specifications for use on land
number of wind km/h m/s
0 Calm Calm; smoke rises vertically >0≤1 > 0 ≤ 0,3
1 Light air Direction of wind shown by smoke >1≤5 > 0,3 ≤ 1,4
2 Light breeze Wind felt on face; leaves rustle; > 5 ≤ 12 > 1,4 ≤ 3,3
ordinary vanes moved by wind
3 Gentle breeze Leaves and small twigs in constant > 12 ≤ 19 > 3,3 ≤ 5,3
motion; wind extends light flag
4 Moderate breeze Raises dust and loose paper; small > 19 ≤ 28 > 5,3 ≤ 7,8
branches are moved
5 Fresh breeze Small trees in leaf begin to sway; > 28 ≤ 38 > 7,8 ≤ 10,6
crested wavelets form on inland
waterways
6 Strong breeze Large branches in motion; whistling > 38 ≤ 50 > 10,6 ≤ 13,9
heard in telephone wires; umbrellas
used with difficulty
7 Near gale Whole trees in motion; inconvenience > 50 ≤ 62 > 13,9 ≤ 17,2
felt when walking against wind
8 Gale Breaks twigs off trees; generally > 62 ≤ 75 > 17,2 ≤ 20,8
impedes progress
9 Strong gale Slight structural damage occurs > 75 ≤ 87 2 > 20,8 ≤ 24,2
(chimney pots and slates removed)

40 © SABS

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Edition 2

Annex F
(informative)

Sea state code

Table F.1 gives information regarding the condition of the sea and the associated sea state code.

Table F.1 — Sea state code and sea conditions

1 2 3
Significant wave height
Code Description of sea
m
0 Calm (glassy) 0
1 Calm (rippled) >0 ≤ 0,10
2 Smooth (wavelets) > 0,10 ≤ 0,50
3 Slight > 0,50 ≤ 1,25
4 Moderate > 1,25 ≤ 2,50
5 Rough > 2,50 ≤ 4,00
6 Very rough > 4,00 ≤ 6,00
7 High > 6,00 ≤ 9,00
8 Very high > 9,00 ≤ 14,00
9 Phenomenal > 14,00

SANS 19:2018
Edition 2

Annex G
(informative)

Applicable types of NDT

G.1 Magnetic particle examination

In this technique, a magnetic field is induced in the area under examination whilst the surface is
flooded with ferrous particles suspended in a liquid. Any cracks or defects cause a discontinuity in
the magnetic field, which in turn causes the ferrous particles to cluster over the defect, indicating its
presence by a dark line. This technique is only suitable for magnetic materials (most structural
steels and some stainless steels), and only detects surface defects and large defects just below the
material surface. Further guidance is given in SANS 9934-1, PD 6513 and EN 10228-1.

G.2 Dye penetrant

In this technique, the surface of the material is flooded with a liquid dye which penetrates into any
surface cracks or defects. After a specified period, the dye is cleaned off and the surface is sprayed
with an absorbent "developer" which draws the dye from any defects, indicating the presence of the
defect. The technique is often employed on non-ferrous materials such as aluminium alloys, but can
only locate surface defects. Further guidance is given in SANS 3452-1 and EN 10228-2.

G.3 Ultrasonic examination

In this technique, pulses of high-frequency sound waves are transmitted from the surface of the
material into its interior. Any defects or discontinuities cause the sound waves to be reflected back
to the surface where they can be detected and, by the measurement of the time delay from the time
of transmission, an estimate of the defect’s depth below the surface can be made. The technique
can be used for a wide range of materials, and detects both surface and subsurface defects.
However, it requires both a skilled operator and specialist equipment, and would normally be carried
out by a specialist firm. Further guidance is given in ISO 16823.

42 © SABS

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Edition 2

Annex H
(informative)

Load testing certificate

Certificate No. …………….

Certificate of Test of Mobile Crane

1 Name and address of owner of crane and its
location
2 Make of crane
3 Type of crane and nature of power (e.g. Scotch
derrick-manual; Tower derrick-electric;
Mobile telescopic-hydraulic)
4 Date of manufacture of crane
5 Identification (e.g. maker's serial number, owner's
identifying mark)
6 Make and type of rated capacity indicator
7 Date of previous test of crane
8 Date of previous thorough examination of crane
9 Safe working load or loads (i) (ii) (iii) (iv)
Length of jib Radius Rated Test
capacity load
In the case of a crane with a variable operating m m kg kg
radius (including a crane with a derricking jib or with
interchangeable jibs of different lengths), the safe
working load at various radii of the jib, jibs, trolley or
crab should be given. Test loads at various radii are
given in column (iv). In the case of a safe working
load which has been calculated without the
application of a test load, "NIL" is entered in that
column.
10 Maximum radius at which the jib or jibs may be
worked (in metres)
11 Defects noted and alterations or repairs required
before crane is put into service (If none, enter
"None")

I hereby certify that the above item described in this Certificate was thoroughly inspected and tested on

………............................... and that the above particulars are correct.

NAME (print)…………….................………….......…..
Qualification……………......................…………………………….

Signature………………................………….......……..Date of
Certificate…………………………......................………..

Name and address of person, company or association by whom the person conducting the test and
examination is employed.
.............................................................................................................................................................................
............................................................................................................................................................................

SANS 19:2018
Edition 2

Annex I
(informative)

Logbook

I.1 The logbook or register should have at least the following information:

1 2 3 4 5
Date Activity Name Designation Signature

I.2 The activities should include

a) frequent inspections,

b) periodic thorough inspection,

c) load tests,

d) major inspections,

e) exceptional inspection,

f) repairs, and

g) modifications.

NOTE Daily inspection records should be included if defects were identified.

I.3 Documentation confirming the activities should be sequenced.

44 © SABS

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Edition 2

Bibliography
EN 10228-1, Non-destructive testing of steel forgings – Part 1: Magnetic particle inspection.

EN 10228-2, Non-destructive testing of steel forgings – Part 2: Penetrant testing.

ISO 16823, Non-destructive testing. Ultrasonic testing. Transmission technique.

PD 6513, Magnetic particle flaw detection – A guide to the principles and practice of applying
magnetic particle flaw detection in accordance with BS 6072.

SANS 3452-1/ISO 3452-1, Non-destructive testing – Penetrant testing – Part 1: General principles.

SANS 4305, Mobile cranes – Determination of stability.

SANS 4308-1, Cranes and lifting appliances – Selection of wire ropes Part 1: General.

SANS 9712/ISO 9712, Non-destructive testing - Qualification and certification of personnel.

SANS 9934-1/ISO 9934-1, Non-destructive testing – Magnetic particle testing – Part 1: General
principles.

______________

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