Crane Proof Testing & LAG Revisions 2020 PDF

Crane Proof Load Testing &
New Survey Requirements on

Lifting Appliance Guide 2020
Jun 2020
EH Survey Offshore
© 2016 American Bureau of Shipping. All rights reserved
CONFIDENTIAL- FOR INTERNAL USE ONLY

Crane Load Diagram
• Crane proof load testing is to be carried to the highest
allowable loads in a controlled environment to ensure
the crane is able to withstand loads in service.
• A crane may have more than one proof load which
varies with the load radius.
• As the boom angle decreases from nearly vertical, the
amount of load the crane can hold is limited by
different parts of the crane such as the hoist wire,
crane foundation, and boom.
• Cranes with multiple proof loads will have a load
diagram which shows the SWL in increments of radius
or boom angle.
• Load chart is approved by ABS and is to be included
in the Register of Lifting Appliances.

2 | Crane Proof Testing & New Survey Requirement on LAG 2020
Failure Mode – Hoist Wire
Three basic failure modes of a boom type
crane:
1. Hoist wire (including loose gear such as
sheaves, blocks, hook, etc.)
• The hoist wire capability is typically the
limiting factor for loads held at the minimum
radius (maximum elevation).
• This limitation is constant across all radii
and is represented by a straight line on the
load diagram.
• The hoist wire must be tested by using the
highest possible load.

Failure Mode – Overturning Moment
2. Overturning moment
• The overturning moment is the torque
exerted on the crane foundation, the load
multiplied by the distance from the center of
rotation.
• This is typically the limiting factor in
intermediate radii.

Failure Mode – Boom Buckling / Suspension
3. Boom buckling/ suspension
• This is the compression force exerted on
the boom and the tension forces exerted
on the boom suspension system.
• This is typically the limiting factor at the
outer radii.
• The boom buckling must also be tested.

Simple Cranes
• Typical – cranes on bulk carriers, hose handling
crane, etc.
• The crane should be tested at the extreme
radius since this will subject the hoist wire and
loose gear to the maximum load.
• It will also subject the crane foundation and
boom suspension to the highest attainable loads.
• This crane should also be tested at the minimum
radius, with the boom all the way up, to verify the
boom cylinder does not buckle when fully
extended.
• Normally, a load diagram may not be provided
for this type of crane.

Complex Cranes
• For complex crane types, such as a knuckle
boom cranes found on many offshore
vessels, the load chart may be very
complex.
• To ensure correct load testing, follow the
radii and proof test loads as specified in the
approved proof test procedure (see next
slide).
• If it is an existing crane with no approved
load test procedure and there any
questions, contact ABS Engineering for
guidance

7 | Crane Proof Testing
Load Test Procedure
• For cranes contracted on or after 1 July 2016, Lifting Appliances Guide
requires that the designer submit a load test procedure to Engineering.
• The intent is for the designer to advise the range of radii and weights required
to fully test the crane.
• The procedure may state that three lifts, one with max load, one with max
overturning moment, and one at maximum boom buckling fully test the crane,
with a range of weights and radii that will test all failure modes.
• The procedure can be simple, with only general guidelines about how to test
the crane.
• The Lifting Appliance Guide requires that such cranes be tested in at
least 3 positions.

Proof Load Test Requirements
Crane is to be tested after onboard installation, Lifting Appliances Guide 2-7/5

Proof Load Test Requirements
• Proof test load calculation for heavy lift cranes same as for shipboard cranes.
• Proof load not to be less than the overload protection (shutdown) setting of the crane.
• For offshore cranes, Vertical Load (VL) = 0.75 × VAF × SWL
For the purpose of calculating test load, VAF ≥ 1.33
• Original Proof Load Test to be performed after onboard installation prior to first use,
and within a harbor or sheltered area or in very mild environmental conditions.
• Original proof load need not exceed the design load of the hoisting winch brakes
calculated as per 2-6/19.5.
• If a crane is provided with load charts for offboard and onboard lifts, the offboard
charts are to be used for determining the proof loads.
• Current for electrical winch operation during the test is to be taken through the
vessel’s cables. Shore current may be used when supplied through the main
switchboard.
Offshore Cranes with VAFs
• Vertical Amplification Factor (VAF) is a factor calculated to address the
dynamic and impact effects on the lifted load.
• Offshore cranes are designed to operate in sea states which add in inertial
loads from the crane and/or load moving up and down. Many components
must be able to resist this inertial load. This results in a higher safety factor,
and requires using additional weight at the initial test.
• The VAF is lower for cranes for operating with a lower motion (calmer seas or
used on larger vessel).
• The VAF is higher for cranes capable of operating in high motions (rough seas
or on a small vessel).

Offshore Cranes
Crane designed with lower VAF
Crane designed with higher VAF
SEU crane operating in a mild sea
CSDU crane operating in a rough sea

Original Proof Load Test
• To do the original proof load test, use VAF shown on the ABS approval letter for
the crane.
• If VAF < 1.33, there will be no additional load required, and the crane can be
tested at the usual 25% to 10% overloads. (See Example # 4 below)
• If VAF > 1.33, to find the proof load, do the following calculation:
Proof Load = (0.75 x VAF x SWL) + (required overload)
Required overload: up to 20 tf VL x 0.25
20-50 tf 5 tf
Over 50 tf VL x 0.1

Some Examples of Calculating Test Load for Original Proof Load Testing
Example # 1 Example # 2 Example # 3 Example # 4
VAF 1.5 1.75 2 1.25
SWL 10 Tons 30 tf 500 kN 5 Tonnes

VL VL= 0.75 x 1.5 x 10 VL= 0.75 x 1.75 x 30 VL=0.75x2x500 VL=0.75 x 1.33 x 5
VL= 11.25 VL= 39.375 tf VL=750 kN VL=5 Tonnes
Proof Load VL+ (VL x 0.25) VL + (5 tf) VL + (VL x 0.1) VL + (VL x 0.25)
Proof Load (11.25) + (2.8125) = 39.375 + (5) = 750 + (75) = 5 + (1.25) =
14.0625 Tons 44.375 tf 825 kN 6.25 Tonnes
Note use 1.33 to calculate,

as required by 2-7
Table 1 Note 2

Where can the VAF be found?
• Review Letters

Where can the VAF be found?
• Data Sheets / Load Charts

(reviewed by ABS Engg.)

Requirements during Proof Load testing
• The proof load to be lifted and held for at least five(5) minutes.
• To include a function test of all safety features, fail-safe and limiting devices, load-
moment and boom-angle indicators, and optional systems.
• To include hoisting and lowering of the main and auxiliary hook and boom; slewing
(swinging) and luffing with the proof test load on the hook, subject to any design
restrictions.
• For cranes with design restrictions:
- Offshore cranes with Proof Test loads calculated by VAF, if VAF > 1.33, Test load should only
be luffed and not hoisted nor slewed unless the manufacturer confirms that the crane design is
rated for it.
- If the crane is equipped with a built-in load limiting control,
-- not possible to hoist the required proof load, then only luffing or other means acceptable;
-- not possible to slew the required proof load, then slewing at SWL acceptable.
• Original Proof Test to be carried out using movable known weights
Testing Subsequent to the Original Test
• Subsequent tests (including a repeat of the proof load test when required within 30
days prior to delivery) for an offshore crane are the same as for a shipboard crane.
• If cranes is equipped with a built-in load limiting control, and not possible to lift the
required proof-load, it will be sufficient to lift the greatest possible load.
• In no case, the test load < SWL.
Note: When the load lifted is < proof test load required in 2-7/5.1, a notation is to be
made on the certificate that this load was the maximum possible load and
that the adjusting devices or relief valves were found sealed.

Lifting Appliance Guide 2020, Chapter 2, Section 7 Surveys
2-7/ 5.3.3 Post-test Examination after Proof Testing (1 June 2020)
After testing, to examine damage or permanent deformation caused by test.
In addition to the structural components, should visually examine at least the following items:
i) Foundation, where required as per 2-2/5.21
ii) Sheaves and rope guides
iii) Wire ropes including end connections
iv) Hoist machinery, brakes and clutches
v) Hooks. For offshore and heavy lift cranes, as well as cranes used for personnel lifting, the
hooks are to be also non-destructively examined using suitable crack detection methods
vi) Slewing assembly and bolting arrangements
vii) Boom heel pins and brackets

2-7/ 7 Initial Survey (1 June 2020)
2-7/ 7.1 Cranes with Slewing Rings (1 June 2020)
Prior to mounting of the crane, to witness flatness checks and surface finish requirements to verify
compliance with the manufacturer’s specifications:
………………….
• Shimming or surface leveling compounds NOT to be used to attain the required level flatness
• Bolt pretensioning (by bolt torque or by hydraulic tensioning device) procedure per the bearing
manufacturer’s instructions to be submitted for review
• At least 10% randomly selected bolts’ elongation to be measured to verify pretensioning
• A “Rocking Test” per the bearing manufacturer’s instructions is to be conducted after the crane
mounted, and the results are to be included in the Register of Lifting Appliances.

2-7/ 7.2 All Cranes (1 June 2020)
i. The critical welds of crane pedestals or kingposts including transition pieces between the pedestal
and crane slewing ring are to be subjected to NDT prior to proof testing:
● 100% volumetric NDT of all critical butt welds
● 100% surface NDT on both sides of critical fillet welds
ii. A load rating vs. boom angle chart on durable material and easily visible to the operator shall be
securely fixed. Where more than one boom length, or more than one rating applicable to a boom
(e.g., static rating and dynamic rating), a chart should be supplied for each.
iii. Telescoping boom crane to demonstrate extending sequence of telescoping boom is from the
thickest boom sections first.
iv. At least 10% random surface NDT on both sides of critical welds, such as circumferential welds, in
the pedestal, kingpost, and transition pieces is to be carried out after proof load testing.

2-7/ 7.2 All Cranes (1 June 2020)
v. For cranes certified for lifting of personnel, all applicable requirements for personnel lifting of
Section 2-9 are to be examined and verified. All safety devices and features are to be tested and
personnel emergency recovery is to be demonstrated.
vi. Cranes installed on a new construction vessel or offshore unit, within 30 days before delivery, a
load test in accordance with 2-7/5 is to be carried out.
vii. Initial survey is to include confirmatory testing of the dynamic braking by cycling the luffing, hoisting
and folding drives, as applicable, at their rated load and corresponding maximum speeds, over a
sufficient range of motion for at least 5 minutes.
viii. Upon satisfactory completion of survey and testing after installation, a Register of Lifting
Appliances is to be issued which contains the in-plant certificate and reports.

2-7/ 9 Annual Survey (1 June 2020)
iii) For offshore and heavy lift cranes, as well as cranes used for personnel lifting, the
hooks are to be also NDE using suitable crack detecting inspection methods.
ix) Verification that the maintenance and inspection program for ropes is being
followed (Refer to 2-7/13 and 2-11/7.13).

2-7/ 11 Retesting Survey (1 August 2018)
11.1.2 Requirements Upon Completion of Proof Load Testing (1 June 2020)
Upon completion of proof load testing, in addition….
Critical welds of the pedestal and deck connections are to have random NDE conducted to
the satisfaction of the attending Surveyor.

2-7/ 13 Maintenance and Inspection of Wire Ropes (1 June 2020)
The crane owner or operator is to establish and document a wire rope maintenance and inspection
program taking into consideration the crane type, frequency of usage, history of maintenance, wire rope
manufacturer’s recommendations and crane manufacturer’s recommendations.
Note: For additional guidance on wire rope maintenance and inspection, refer to API RP 2D, ISO 4309,
or equivalent recognized national or international standards.
The crane owner or operator is to examine the wire rope, including end connections, at annual surveys
as a minimum. Inspection and maintenance records are to be maintained on board the vessel by the
crane owner or operator and are to be made available to the Surveyor during surveys.
All running wire ropes are to be visually inspected at each Annual and Retesting Survey. Wire rope
inspection and discard requirements during surveys are to be in accordance with Section 6 of ISO 4309
(Discard Criteria) or equivalent recognized national or international standards.
In addition to the above, ropes used for subsea lifting are to meet the maintenance and inspection
requirements of 2-11/7.13.3 of this Guide.
Thank You.
Always be Safe.
© 2016 American Bureau of Shipping. All rights reserved CONFIDENTIAL- FOR INTERNAL USE ONLY

Crane Proof Testing & LAG Revisions 2020 PDF

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Crane Proof Load Testing &

New Survey Requirements on

© 2016 American Bureau of Shipping. All rights reserved

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

Crane designed with higher VAF

SEU crane operating in a mild sea

CSDU crane operating in a rough sea

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

VAF 1.5 1.75 2 1.25

SWL 10 Tons 30 tf 500 kN 5 Tonnes

Note use 1.33 to calculate,

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

• Data Sheets / Load Charts

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

• At least 10% randomly selected bolts’ elongation to be measured to verify pretensioning

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

CONFIDENTIAL- FOR INTERNAL USE ONLY

Upon completion of proof load testing, in addition….

CONFIDENTIAL- FOR INTERNAL USE ONLY

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