Load Testing & Inspection
NDT methods, proof load testing, dynamic load testing, and inspection protocols for in-service and commissioning testing. Statutory requirements vary by jurisdiction.
Proof Load Test
Application of a test load greater than the rated SWL to demonstrate structural integrity without permanent deformation. Required by most codes at commissioning and after significant repair or modification.
Key Features
- Witnessed by Competent Person / AIA
- Test load = 100–125% SWL (IS 13416: 125% for cranes)
- Includes dynamic testing of all motions
- Load cells and dynamometers for accurate test load
- Certificate of test issued
- NDT checks before and after proof load
Typical Applications
- New crane commissioning
- Post-major-repair inspection
- Periodic statutory inspection
- Pre-offshore mobilisation
- Vessel crane recertification
Applies stress to structure — should be performed by Competent Person following written procedure; not appropriate for cranes with known defects.
Non-Destructive Testing (NDT)
Range of methods to detect flaws in crane structures and components without damage. MPI for surface cracks in ferritic steel; UT for volumetric flaws and thickness; PT for non-magnetic materials; visual inspection as baseline for all.
Key Features
- MPI (Magnetic Particle Inspection): surface/near-surface cracks in welds
- UT (Ultrasonic Testing): internal flaws, wall thickness
- PT (Penetrant Testing): surface cracks in stainless or aluminium
- RT (Radiographic Testing): volumetric assessment of welds
- Visual Inspection (VT): baseline requirement before any NDT
- Wire Rope NDT (ROPE): electromagnetic flux leakage for wire rope
Typical Applications
- Main structural weld inspection
- Hook and shackle fatigue assessment
- Wire rope internal corrosion detection
- Gearbox housing and frame inspection
- Fitness-for-purpose assessment after overload
Requires certified Level 2/3 NDT inspector (PCN / CSWIP / ASNT); interpretation of indications requires experience.
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