Portable Lifting Equipment

Inspection
 Lloyds British International Training

Lloyds British International Training Services hold an International reputation for quality and technical
expertise.

With over 80 general safety, lifting, and work equipment training programmes available at an international level,
Lloyds British International are also able to tailor bespoke courses for customer requirements.

Other courses that may interest you…

Lifting, Slinging and Crane General Safety

Operation
LOLER Regulations CCNSG Passport to Safety
Slinger Signaller / Slinger Banksman IOSH Managing Safely
Pendant/Remote Crane Operation IOSH Working Safely
Mobile Crane Operation (BS 7121) Manual Handling
The Appointed Person Workplace Risk Assessment
The Crane Supervisor
Cab Controlled Crane Operation
Lorry Mounted Crane Operation Working at Height

Truck Driving Ladder Safety and Inspection

Mobile Access Towers
Counterbalance Fork Lift Truck Mobile Elevated Work Platforms
Fork Lift Truck Examination Safety Harness Inspection
Lorry Mounted Fork Lift Truck Working at Height Regulations
Lorry Shunting
Narrow Aisle Fork Lift Truck
Order Picker Fork Lift Truck
Pedestrian Trucks …and many more courses
Rough Terrain Fork Lift Truck
Sideloader Fork Lift Truck available
Telescopic Materials Handler
Vehicle Banksman

To see our full course portfolio please visit

lloydsbritishinternational.com
Email [email protected] for more
information
Lifting Equipment Accessories Inspection

Page 2 of 59
Revision:
Revision Date:

Disclaimer
These course notes are intended to give general information only and must not be regarded in any
way as giving an interpretation of the law or any guidance issued by the Health and Safety Executive
or others.

Regulations for this purpose must be obtained from the Stationery Office, and official guidance from
the Health and Safety Executive.

© Lloyds British International Ltd

COMMITMENT
Lloyds British Training Services are committed to equal opportunities in its delivery of training
courses.

Page 3 of 59
 This commitment applies to all, regardless of gender, age, racial origin, nationality, creed, sexual
orientation, marital status, employment status or disability.

The aim of our policy is to promote procedures and practices that ensure equality of opportunity and
aims to eliminate any which unfairly discriminate, directly or indirectly.

Lloyds British Training Services seek to ensure the following:

 The content and assessments of its training courses, allowing for the whole diversity of
persons attending, are non-discriminatory and appropriate to the knowledge and skills
required;

 Training documentation and course hand-outs are understandable and do not reflect biased
attitudes;

 The process of examinations and assessments are carried out in a just and fair manner.

IMPLEMENTATION
To achieve successful outcomes, Lloyds British Training Services will:

 Provide development activities appropriate to the needs of its training staff and appointed
consultants on a regular basis;

 Issue policy statements on request to interested parties.

 Ensure that equal opportunities are addressed as part of any training course carried out in-
house or at any chosen venue.

Contents

Definitions.............................................................................................................................................6
Man Made Fibre Slings.........................................................................................................................7
Chain Slings........................................................................................................................................10
Wire Rope Slings.................................................................................................................................14
Open Wedge Sockets ...…………………………………………………………………………19
Sheave Blocks / Snatch Blocks………………………………………………………………….20
Shackles...............................................................................................................................................21
Eyebolts...............................................................................................................................................22

Page 4 of 59
Rigging Screws and Turnbuckles........................................................................................................24
Hooks and Rings…………………………………………………………………………………...25
Jacks....................................................................................................................................................27
Hand Operated Chain Blocks..............................................................................................................29
Hand Operated Chain Lever Hoist.......................................................................................................31
Manual/Hydraulic Operated Lifting and Pulling Machines.................................................................33
Cargo Carrying Units……………………………………………………………………………...36
Fall Protection………………………………………………………………………………………41
Pallet Trucks........................................................................................................................................44
Runway Beams....................................................................................................................................46
Plate Clamps……………………………………………………………………………………….48
Beam Clamps......................................................................................................................................49
Lifting and Spreader Beams................................................................................................................50
Travelling Girder Trolleys...................................................................................................................51
Lifting Equipment Storage and Handling............................................................................................53
Proof Load Testing..............................................................................................................................55
Non-Destructive Testing…………………………………………………………………………..56
Thorough Examination Report............................................................................................................57

Page 5 of 59
 Definitions
Lifting Operation
Any operation concerned with the lifting and lowering of a load. (The term load could also be people)

Lifting Equipment
Comprises lifting appliances and lifting accessories, they are defined as follows:

Lifting Appliances
Any mechanical device capable of raising or lowering a load and includes its attachments for anchoring,
fixing and supporting it, e.g. Cranes, Fork Lift Trucks, Powered Hoists, Manual Hoists, Lever Hoists, Rope
Hoists, Beam Clamps, Sheave Blocks, Winches, Runway Beams.

Lifting Accessories
Any device whatsoever which is used or designed to be used directly or indirectly to connect a load to a
lifting appliance and which does not form part of the load, e.g. Wire Rope Slings, Chain Slings, Man-Made
Fibre Slings, Hooks and Fittings, Swivels, Shackles, Eyebolts, Rigging Screws, Plate Clamps.

Working Load Limit (WLL)

The maximum load which an item of lifting equipment is designed to raise, lower or suspend. The WLL
does not account for particular service conditions which may affect the final rating of the equipment (See
SWL). Note: The Working Load Limit as determined by the manufacturer must NEVER be exceeded.

Safe Working Load (SWL)

The maximum load (as certified by a Competent Person) which an item of lifting equipment may raise,
lower or suspend under particular service conditions, e.g. the SWL can be lower than the WLL.
Note: The Safe Working Load as determined by the competent person must NEVER be exceeded.

Factor of Safety / Safety Factor

The ratio of the load that would cause failure of an item of lifting equipment to the load that is imposed
upon it in service, i.e. SWL (this is to allow for detrimental criteria such as wear and tear, dynamic loads,
etc.)

General Lifting Equipment 5:1

Shackles 6:1
Chains 4:1
Man-Made Fibre Slings 7:1
The lifting of people requires a safety factor of 10:1

Colour Code
A method of marking equipment (Normally with paint or a tag) to give a visual indication of its
certification status only, this does not prove that the equipment is safe. This colour / tag should be changed
at each periodic examination.

Thorough Examination
A thorough examination by a competent person (Third Party Service Provider) as determined by the
Company at set intervals as specified within the Lifting Operations Lifting Equipment Regulations 1998.

Man Made Fibre Slings

Page 6 of 59
Introduction
The most common materials used in man-made fibre slings are nylon, polyester or polypropylene,
however the most common material used is polyester-(Blue Tag) and manufactured to BS EN 1492
the colour of the sling gives a visible indication of its WLL or SWL
They are less robust than wire rope and chain slings, and are more easily damaged. They also degrade
with age and exposure to sunlight and other sources of UV light. They can be stored and used in
temperatures ranging from (Polyester) Minus 40°C to 100°C

Marking
Man-made fibre slings are marked using different colour labels and relate to the properties of the
sling.

Blue Polyester
Acid Resistant

Green Polyamide (Nylon)

Alkali Resistant

Inspection Criteria
Red/Brown Polypropylene
Resists Acid & Alkalis. Damaged by solvents
They should be checked by examiners for the following defects:

• Illegible markings or missing label

• Damaged, chaffed or cut webbing or cuts in protective sleeve on round slings
• Damaged or loose stitching or exposed core on round slings
• Heat damage,
• Chemical damage
• Damaged or deformed end fittings
• Solar degradation
• Sling abrasion
• CE marking
• Safety Factor 7:1

Types of Man-Made Fibre Slings

Flat Woven Webbing Sling

They are a form of textile sling that is soft

and easy to handle whilst being rigid across
the width.
These qualities make them ideal for
handling loads which require some support

Page 7 of 59
 when being lifted as the load is spread across the full width of the webbing, the strength lies in the
width.
Thus avoiding point contact as in chain and steel wire rope slings

Examples of Damage

Heat Damage Cuts Abrasions

Notes

Round Sling

The most favoured man-made synthetic fibre

rope sling is the round sling manufactured to
BS EN 1492 part 2 and are used in a variety of
applications.
A roundsling for practical purposes is taken as
a hank of yarn joined to form an endless sling
protected by a tubular sleeve.
The protective sleeve plays NO part in the
LOAD bearing qualities of the sling

Examples of Damage

Page 8 of 59
 Abrasion Cut Burn

Notes

Chain Slings

Introduction
Chain slings come in many types and sizes to suit a wide variety of applications. The majority of
chain in use today use mechanical joining devices.
Relevant standards Grade 80: ISO 3076 and BS EN 818-1
These can comprise of a Master Ring, it goes on the crane or hoist hook, a coupling device, a length
of chain, then another coupling device and finally the end fitting.
The end fitting can be a hook or a special shackle.
Chain slings can be fitted with shortening clutches for shortening a leg with no reduction in SWL.

Master link and

Coupling

Page 9 of 59
 Chain length

Hook length

Grades of Chain
Standard grade designations are 30, 40, 70, 60, 80 and 100. The grade number equates to the strength
level of the chain. Higher grade numbers indicates higher strengths.
Grade identification is necessary to assure that the correct grade is selected for the application. You
may also see Grade markings designated by letters for example M,S,T or V the higher the letter the
stronger the grade of steel
Some numbers and letters correspond with each other
M = 40, S = 60, T = 80, V = 100
If chain is unmarked you must assume it is made from mild steel.

Marking
Each sling must be fitted with a marking plate as shown blow, displaying the WLL for different load
situations. There must be:

 Safe working load / Working load  Date of inspection or colour code

limit  CE marking
 Unique identity number/reference  The grade or manufacturers mark

Markings every 20th link or 1 metre of chain

 
 4 - Grade 40 Normalised Condition
 04 - Grade 40 Hardened and Tempered
 06 - Grade 60 Hardened and Tempered
 08 - Grade 80 Hardened and Tempered
 M - Grade M Hardened and Tempered

Page 10 of 59
  S - Grade S Hardened and Tempered
 T - Grade T Hardened and Tempered

Inspection Criteria
Examination is to take place in good light. Where possible hang the chain sling from a Crane or Hoist
alternatively use a clean level bench. Before inspecting, clean the chain with a non-acid/non-caustic
solvent so that any defects are easily visible and identifiable.

Equipment required wire brush, tape measure and magnifying glass.

Chain slings should be checked by examiners for the following defects:

• Illegible markings
• Stretched legs
• Bent or twisted links
• Twist in the sling leg
• Cracks or faults in the weld area
• Pitting or corrosion in the weld area
• Excessive wear
• Bent or damaged hooks or top rings,
• Missing safety catches, if appropriate.

Measurement Methods

Masterlink I.D Tag

 Identify size  Present
 Identify manufacturer  Correctly labelled & legible

Chain Hook
 Size  Identify manufacturer
 Grade  Grade
 Manufacturer  Working Load Limit
 Correct latch & functioning

Rejection Criteria
 Maximum permissible stretch 5%
 Turned or twisted legs a maximum ½ a turn over 4 metres
 Single/Double legs have an even number of links
 Three/Four legs have an odd number of links

Page 11 of 59
  No more than 8/10% wear allowable on the links

Notes

Examples of Damage

Bent / twisted links Stretched links Inner link wear Heat damage / nicks
and gouges

Rust / Corrosion
Deformation

Page 12 of 59
Wire Rope Slings

Introduction
Wire rope slings provide a low cost, versatile means of connecting a load to a lifting appliance.

They should be manufactured to BS EN 13414 /1-3 and components should comply with BS EN
13411.

Multi leg wire rope slings should have a maximum of 2 legs on one ring unless a third leg is used as a
top leg.

Make up of a typical wire rope

Below is the typical make up of a wire rope. Steel wires are spun together to make a strand, which is
then twisted around a central core.

Wire Strand Core

Typical construction

6x19 (9/9/1) = 6 strands with 19 wires in each strand in a pattern of 9 wires on the outside, 9 wires in
the next layer and 1 core wire. The four most common constructions are:

• 6 x 19 Fibre Core (FC)

Page 13 of 59
 • 6 X 36 Fibre Core (FC)n
• 6 X 19 Internal Wire Rope Core (IWRC)
• 6 X 36 Internal Wire Rope Core (IWRC)

Notes

Rope Lay
Ordinary lay ropes have wires laid in one direction whilst the strands are laid in the opposite direction.
These ropes have good resistance to kinking and are easy to handle.

Langs lay ropes have the wires in the strands and the strands in the rope in the same direction. These
ropes have wires running diagonally across the rope, making them more liable for kinking

Notes

Page 14 of 59
Measurement Methods
Always measure the diameter of a wire rope sling across the outermost strands this assures
consistency of measurement

Correct Incorrect

Inspection Criteria
Wire rope slings should be checked for the following defects:
• Broken or cut wires, damage to terminal fittings
• Signs of movement at splices or ferrules
• Illegible markings
• Ineffective or missing safety catches
• Protrusion of core or disturbance of the positon of wires
• Kinks (small kinks acceptable but look for other signs of damage)
• Wear no more than 10% of nominal diameter, distortion, cracking, corrosion, discolouration
due to heat.
• Opening out of hooks if fitted

Wear Criteria
Wear is to be no more than 10% of nominal diameter, distortion, cracking, corrosion, and
discolouration due to heat.

Page 15 of 59
 Rejection Criteria
Discard rope when these numbers of broken wires occur:

Construction: 6 x 19 = 5 wires
6 x 24 = 7 wires
6 x 36 = 11 wires

The maximum allowable number of adjacent broken wires in one strand is 4-6 (depending on
construction)

Safety of a FSWR can be calculated by a competent person using this rule of thumb formula.
Note: wire is unsafe when more than 5% of total number of wires within a length of 10 times the
diameter is broken

For example

• Construction of wire is 6 x 24 = 144 wires

• 5% of total wires is 5% of 144 = 7.2
• Diameter of wire is 25 mm x 10 = 250 mm

So, rope is unsafe if 7 or more wires are broken in a length of 250mm

Broken Wires
Discard rope when these numbers of broken wires occur:

Construction: 6 x 19 = 5 wires
6 x 24 = 7 wires
6 x 36 = 11 wires

The maximum allowable number of adjacent broken wires in one strand is 4-6 (depending on
construction)

Safety of a FSWR can be calculated by a competent person using this rule of thumb formula.
Note: wire is unsafe when more than 5% of total number of wires within a length of 10 times the
diameter is broken

Safety of a FSWR can be calculated by a competent person using this rule of thumb formula.
Note: wire is unsafe when more than 5% of total number of wires within a length of 10 times the
diameter is broken.

For example

• Construction of wire is 6 x 24 = 144 wires

• 5% of total wires is 5% of 144 = 7.2
• Diameter of wire is 25 mm x 10 = 250 mm
• So, rope is unsafe if 7 or more wires are broken in
a length of 250mm

Page 16 of 59
Examples of Damage

Broken wires Corrosion

Memory
External Kink
wear

Kinks Strand protrusion

Waviness

Localised increase in rope diameter due to core deterioration

Memory Kink

Open Wedge Sockets Core protrusion

Page 17 of 59
 Introduction
Open Wedge Sockets are detachable end terminations, in which the rope is clamped between housing
and the wedge.

They should be manufactured to BS 463-1:1958 Specification for sockets for wire ropes and
components should comply with BS EN 13411-6:2004+A1:2008 Terminations for steel wire ropes.
Safety. Asymmetric wedge socket.

How to install a wedge socket?

Align live end of rope with centre line of pin. Use a hammer to seat Wedge and rope as deep into the
socket as possible. Apply first load to fully seat the wedge and wire rope in the socket. Ensure that the
rope end is welded and/or properly seized before inserting the rope into the socket.

* SWL will vary according to actual diameter and type of rope fitted. Efficiency of termination =
80%.

Inspection Criteria
 Remove main load pin and wedge.
 Examine load pin and check for wear/distortion.
 Examine wedge and check for wear/distortion/cracking. (Ensure it is the correct wedge for the
rope dia. marked on the socket).
 Remove any coating on the socket to expose bare metal.
 Examine socket and check for wear/elongation of pin holes and cracking.
 If all satisfactory, re-assemble and subject the unit to a S.W.L. + 100% proof load*

Sheave Blocks

Introduction

Page 18 of 59
Sheave Blocks come in two basic types. Single sheave block and Multi sheave block, with a variety of
different head fitting types covered by BS MA 47 / BS ISO 16625

Single sheave types are used to change the direction of the hoisting or pulling rope and Multi sheave
type are used for reducing the line pull of the rope.

Inspection Criteria
Ensure SWL and identification number is legible and is cross-referenced on the current proof load
report or current examination report.

 Cracks at bends or changes in section.

 Mechanical damage, nicks, gouges and corrosion.
 Sheave for smooth finish and that it rotates freely by hand. Axle pin is positively locked and
does not move when the sheave is rotated.
 Sheave groove for profile and any chips or cracks are cause for rejection.
 Slackness in the bush or bearing.
 Head fitting for mechanical damage, wear, nicks, gouges and corrosion. It should swivel
freely and the shank should not be stretched. If the shank is bent or stretched it is to be
removed from service.
 Becket (if fitted) for elongation of the hole and deformation.
 Side plates for distortion and rope markings caused by incorrect lead angles.
 Loose or insecure locking nuts, bolts and split pins
 Lubrication point is to be clear and working.
 Retainer pins or “R” clips are to be fitted to the head fitting pin and side plate pin.

Shackles

Introduction

Page 19 of 59
 Shackles come in two basic types. DEE shackles and BOW shackles, with a variety of different pin
types covered by BS 3032, BS 6994, ISO 2415, ISO 2791 & ISO 2731.

Bow Shackle Dee Shackle

Inspection Criteria
British Standard and ISO standard shackles are rated to take the full safe working load as a point in
the centre of the pin (i.e. the worst case loading).
Shackles should be checked for the following defects:

• Free working of pin

• Damaged threads
• Illegible markings
• Distortion holes must align
• Excessive wear maximum permissible wear on pin or body is 8%
• Nicks, cracks, corrosion or other defects
• Incorrect or bent pins

Notes

Eyebolts

Introduction

Page 20 of 59
Eyebolts are one of the most widely used lifting accessories due to their low cost and simplicity of
use. They are formed from a single piece of forged steel to produce a single eye with a threaded shaft.

There are 3 main types of eyebolts:

Collar Eyebolts: BS4278 Table 1 Metric/BS529 Part 1/Imperial

This eyebolt may be used for both axial and angular loading. However, it should be noted
that there is a considerable reduction in the safe working load when used for angular
loading and in pairs.
 
 

Dynamo Eyebolts: BS4278 Table 3/DIN 580

This eyebolt has a severe restriction in its use as it must only be used for vertical lifting
i.e. with the load applied axially. Because of this restriction its use is banned in many
companies. This eyebolt must not be used in pair.
 
 

Eyebolt with link: BS4278 Table 2

This eyebolt is designed for both axial and angular loading.
 
 

Inspection Criteria
Eyebolts should be checked for the following defects before each use:
• Illegible markings i.e. SWL thread type or identification numbers
• Distortion 8% of nominal diameter
• Worn or bent shanks and threads maximum 8%
• Incomplete or incorrectly formed threads
• Damaged eyes
• Nicks, cracks, corrosion or other defects
• Maximum permissible wear on the eye is 8% of the nominal diameter.

Swivel Hoist Rings

Introduction

Page 21 of 59
 Swivel Hoist Rings are a relatively new introduction to the lifting equipment market and although
expensive compared with standard eyebolts they have one crucial advantage in that they can be used
at any angle with no reduction in SWL or WLL.

RUD Star Points. Looks Swivel, Pivots 180°and RUD, VLBG, 360°
like a standard eyebolt, but rotates 360°. This is the rotation, top pivots as well.
rotates 360° light duty version.

Inspection Criteria
Swivel hoist rings should be checked for the following defects before each use:

• Illegible markings i.e. SWL/WLL thread type or identification numbers

• Distortion 8% of nominal diameter
• Worn or bent shanks and threads maximum 8%
• Incomplete or incorrectly formed threads
• Damaged eyes
• Nicks, cracks, corrosion or other defects
• Maximum permissible wear on the eye is 8% of the nominal diameter.
• Ring swivels freely

Notes

Rigging Screws and Turnbuckles

Introduction
Rigging Screws and Turnbuckles as the names suggest are generally used to facilitate tensioning and
fine adjustment of length.

Page 22 of 59
They can be used in lifting assemblies where chain or wire rope form the main component of the
assembly in this case they should comply with BS 4429

They can also be used for cargo restraint, suspension or tensioning guy ropes etc. When using
turnbuckles in an area which is susceptible to vibration a wire lock or some means of positive locking
device is required.

Types of rigging screws and turnbuckles:

Turnbuckle Eye-Eye Turnbuckle Hook-Eye

Turnbuckle Hook-Hook Turnbuckle Jaw-Eye

Turnbuckle Jaw-Jaw

Inspection Criteria
Rigging Screws and Turnbuckles should be checked for the following defects before each use:

• Illegible markings i.e. SWL thread type or identification numbers

• Distortion 8% of nominal diameter
• Worn or bent shanks and threads maximum 8%
• Incomplete or incorrectly formed threads
• Damaged eyes
• Nicks, cracks, corrosion or other defects
• Maximum permissible wear on the eye is 8% of the nominal diameter

Hooks and Rings

Inspection Criteria

Check for signs that Maximum 8% of nominal

hook is opening up diameter wear on the eye

Safety catch must

work properly

Page 23 of 59
 No more than 1.5% Maximum stretch is 10%
wear (inside hook)

No more than 8% Markings illegible

wear (outside hook)

Check for overall cracks, twisting, wear and deformation

Wear Criteria
• Maximum allowance for wear is 8%.
• Maximum stretch is 10% for Alloy components.
• Maximum 8% of nominal diameter wear on eye.
• Maximum 8% on body section depth.
• Distortion – Reject if any deviation from plane of eye.
• Give more serious consideration to marks on the inside of the hooks.
• Cracks, nicks, score marks maximum 1.5% on inside of hook – 8% on outside of hook
• Do not allow a re-set hook to be put back into service.
• Do not weld worn or damaged hooks.

Rejection Criteria
• Mechanical damage such as any deviation across the mouth, no more than 1.5% cracks, nicks
or score marks on the inside faces of the hook and 8/10% on the outer faces.
• Stretching across the throat of 5% or more.
• 8/10 % wear in the eye and across the body.
• Chains used in construction must have a “C” hook or a safety hook unless the main
Contractor allows the use of Sling Hooks with safety catches fitted. Safety Hooks are popular
as the load closes the hook and the hook locks in the closed position and does not snag.

Page 24 of 59
Rejection Criteria- Self Locking Hooks Rejection criteria

Hook Tolerance

Clevis Type Hook Swivel Type Hook Eye Type Hook

Page 25 of 59
 Jacks

Introduction
Jacks shown below are manually operated, utilizing hydraulic or mechanical means to facilitate the
lifting motion and in some cases the lowering motion, but most hydraulic jacks rely on gravity for
lowering.
 
• Hydraulic jack with claw attachment
• Mechanical jacks with claw attachment
• Screw jacks

Screw Jacks Mechanical Ratchet Hydraulic jack with

lowering jack claw attachment

Inspection Criteria
Wherever practical, all equipment must be operated through a full cycle of its operation, before and
after inspection. 

An examination must be carried out with the Jacks in a reasonably clean condition and in adequate
lighting. If any of the following faults are present, the Jacks should be withdrawn from service and
referred to the Client’s Responsible Person.

Notes

Hydraulic Jacks

Page 26 of 59
Hydraulic rams usually retract by gravity, so once the load is fully lowered, the movement of the ram
will slow considerably or even stop. This is normal and if pressure is applied to the ram, it will
continue to lower.

 Jack fails to sustain the load. When lifting operation ceases, the load begins to lower on its
own.
 Oil leaks, particularly during jacking operations of the jack.
 The ram is scored, nicked or otherwise damaged.
 Jack fails to lift. The jack will not raise the load or after a short period of movement the load
rises and falls (pumps) with each stroke of the lever.
 Ram fails to lower; lowering is jerky or fails to fully retract. The ram may appear to lower in
stages or move at varying speeds during lowering and in some cases stops moving altogether.
 Release valve is difficult to operate or fails to release the load.
 Cracks, dents or other mechanical damage to the jack body.
 Base of the jack is twisted or bent preventing the jack from sitting solidly on the floor.
 Claw attachment will not sit correctly on head of jack or the claw is cracked, distorted or
otherwise damaged.

Ratchet Jacks

It is a feature of ratchet jacks that the load will raise a short distance prior to lowering; the load will
then be lowered the distance of the pitch of one tooth on the rack. This process is repeated with each
stroke of the operating lever.

• The teeth of the rack could be chipped, worn, corroded or otherwise damaged.
• The screw could be chipped, worn, corroded or otherwise damaged.
• The body or main frame of the jack could be bent, cracked or otherwise damaged.
• Swivel heads could be seized or do not turn freely.
• The rack, including the toe, could be bent, cracked or otherwise damaged.
• The base of the jack could be twisted or bent preventing the jack from sitting solidly on the
floor, or the base is cracked
Notes

Hand Operated Chain Blocks

Introduction
A typical set up of a hand operated chain block is as follows:

Page 27 of 59
 Head fitting
The head fitting is to suspend the hoist from a beam clamp or trolley

Load chain
Load bearing chain which is highly calibrated to ensure smooth
passage over load sprocket / pocket wheel

Safety hook
The safety hook is the is the load bearing hook

Operating chain
Pulling on the operating chain raises and
lowers the load

Marking
The following information should be permanently and legibly marked on a suitable part of the block
or plate attached to the block:

• Identification mark.
• Safe working load.
• Class of use.
• Grade of the load chain.
• Range of lift.
• Name of maker or supplier.

Brake Mechanism
The block should be fitted with an automatic brake capable of arresting and sustaining the load. If it is
intended to lift a load which is very light in relation to the chain block’s working load limit, the
manufacturers or supplier’s advice should be sought with regard to the performance of the brake.

This is because the brake relies upon the hoisting effort for its operation and with a very light load the
effort available may be inadequate to operate the brake ful

Inspection Criteria
Wherever practical, all equipment must be operated through a full cycle of its operation, before and
after inspection.

This examination must be carried out with the Hand Operated Chain Block in a reasonably clean
condition and in adequate lighting. It should be taken out of service if:

Page 28 of 59
 • The load chain is worn or damaged. In particular, attention should be given to the wear
which occurs on the bearing surfaces inside of the links and to damage in the form of bent,
notched, stretched or corroded links. The chain should articulate freely.

• Obvious signs of ‘opening out’ of hooks, that is, any noticeable increase in the throat
opening, or any other form of distortion in the hooks or suspension fittings.

• Obvious signs of damage to the slack end anchor which connects the load chain to the
block casing or to the load chain stop where one is fitted.

• The hand chain is worn or damaged, particularly on the bearing surfaces on the inside of
the links, or is corroded, bearing in mind possible damage to the operative’s hands.

• When operated under load there is any jumping or excessive noise of either the hand chain
or load chain, any undue effort is required or any visible slipping of the brake.

• General damage to the block body, including any gear covers or chain guides.

Notes

Hand Operated Chain Lever Hoist

A typical set up of a hand operated chain block is as follows:

Page 29 of 59
 Head fitting

Hand Wheel

Operating lever

Load chain

Safety hook

Marking
The following information should be permanently and legibly marked on a suitable part of the hoist:

• Identification mark
• Safe Working Load
• Grade of load chain (in the case of link chain)
• Range of lift
• Name of maker or supplier

Inspection Criteria
Wherever practical, all equipment must be operated through a full cycle of its operation, before and
after inspection.

This examination must be carried out with the Hand Operated Chain Lever Hoist in a reasonably
clean condition and in adequate lighting. It should be taken out of service if:

• The load chain is worn or damaged. In particular, attention should be given to the wear which
occurs on the bearing surfaces inside of the links and to the damage in the form of bent,
notched stretched or corroded links. The chain should articulate freely.
• Obvious signs of ‘opening out’ of hooks, which is any noticeable increase in the throat
opening, or any other form of distortion in the hooks or suspension fittings.
• Obvious signs of damage to the load chain stop or the chain anchor which connects the load
chain to the lever hoist casing, whichever is applicable.
• When operated under load, there is jumping or any undue effort is required or there is visible
slipping of the brake.
• General damage to lever hoist body, including any gear covers, breaking of overload
protection devices, controls or chain guides, and in particular to the operating lever which
could indicate a previous overloading.

Page 30 of 59
In the case of link chain, the load chain wheel should be checked for debris in the pockets and in the
case of roller chain, the space between the rollers and the mating sprocket should be checked for a
build-up of debris. Any build-up of debris will prevent the load chain from seating correctly and
should be removed.

In certain circumstances, very rapid wear of link type load chain can develop which is characterised
by a rough appearance on mating surfaces inside of the links. If such circumstances are suspected,
then the equipment should be withdrawn from service immediately.

No person other than the Competent Person or someone under the supervision of a Competent
Person should dismantle the hoist or replace the load chain.

Notes

Manual/Hydraulic Operated Lifting and Pulling Machines

Introduction
Lifting and pulling machines are, by their nature, versatile pieces of equipment and are widely used
throughout industry for both permanent applications and temporary or rigging applications.

It should be noted however that manufacturers of this type of machine may permit a lower factor of
safety (and therefore a higher safe working load) when the machine is used for pulling applications as
compared to lifting applications

Page 31 of 59
 Manually Operated Machines

Manually operated machines have a hand operated lever activates a mechanism to provide a direct
pull on an integral rope which is attached to the load. The pull is applied by means of two pairs of
self-energising jaws, which exert a grip on the rope, the distance of travel being limited only by the
length of rope. The initial pressure which causes the jaw to grip the rope and give the self-energising
action is provided by powerful springs.

Hydraulic Operated Machines

Hydraulic machines are based on the same mechanical principle of operation as the manual type but
with the addition of an integral hydraulic mechanism to provide power operation.  
The hydraulic system is of piston and cylinder design, the piston rods being directly connected to the
forward and reverse operating handles. These machines may be used singly or gange

Rope Construction
The wire rope supplied for use with a lifting and pulling machine should be considered as much an
integral part of the mechanism as is the chain of a chain block or lever hoist. Some ropes, even those
which appear to be of the correct size and which initially the machine may seem to accept, may not be
suitable because the efficiency and safety of the friction grip of the machine’s jaws around the rope
depends entirely upon the rope being of the right diameter and of a construction designed to withstand
the immense gripping power of the jaws. It is essential therefore to use only ropes approved by the
rope or machine manufacturer and certified by them as suitable for this use.

Marking
The following information should be permanently and legibly marked on a suitable part of the
machine.
• Identification mark.
• Application(s) for which the machine is intended i.e. lifting, pulling, man-carrying.

Page 32 of 59
 • Safe working load (or loads if machine is intended for more than one application).
• The diameter of rope required.
• Name of manufacturer or supplier. 

Wire ropes used with lifting and pulling machines are detachable and, providing the correct
specification, i.e. diameter and construction, are interchangeable. The following information should
therefore be permanently and legibly marked on the ferrule terminal fitting of the rope. 

• 1 Identification mark.
• 2 Safe working load.
• 3 The length of the rope.

Notes

Inspection Criteria
Wherever practical, all equipment must be operated through a full cycle of its operation, before and
after inspection.

This examination must be carried out with the manual/hydraulic operated lifting and pulling machines
in a reasonably clean condition and in adequate lighting. It should be taken out of service if:

• The safe working load and identification markings are illegible.

• The shear pins are distorted, indicating overload.
• The operating handle is distorted, indicating excessive applied operating effort.
• An incorrect wire rope is fitted.
• The rope is kinked.
• The rope is suffering from obvious wear or corrosion.
• The rope has broken wires. (Even one broken wire can cause the rope to jam in the
mechanism of the machine). The danger of the operative’s hands must also be
considered.
• The rope terminations are intact. (The rope should be fused and tapered at one end
with an eye or alternative terminal at the other).
• Wear, nicks, cracks and gouges in terminal fittings and hooks. Hooks should also be
checked for opening and correct operation of safety catches. In the case of cargo or C
hooks safety catches are not required to be fitted.
• Randomly distributed wire breaks are not to exceed 5% in any length of 10 diameters.
Localised breaks are not to exceed 3 in a close group or in any one strand within the
length of 6 diameters.
• Rope loss of diameter must not exceed 10% from nominal.

Page 33 of 59
 Notes

Cargo Carrying Units (CCU’s)

Introduction Design
Offshore Containers
Portable unit for repeated use in the transport of goods or equipment handled in open seas to, from
and between fixed and/or floating installations and ships.

Offshore Freight Containers

Offshore container built for the transport of goods.

Offshore service container

Offshore container built and equipped for a special service task, usually as a temporary installation.

Offshore waste skip

Open or closed offshore container used for the storage and removal of waste.

Whichever standard they are designed to, CCUs still come in various
shapes, sizes and capacities, e.g. containers, cargo baskets / boxes, tool
baskets, tote tanks, etc:

Page 34 of 59
Their final design will influence your method of testing. D.N.V 2.7-1, BS EN 12079, EN ISO 10855

Marking
Plating of container

Container should be fitted with 2 (two) plates made of corrosion resistant material
securely attached externally in a manner designed to avoid unauthorised or accidental removal and
should be fitted to the door, or on containers with no doors, in a prominent position. Characters used
in the marking of the plate should be not less than 4mm in height.

Information plate

This plate should be headed “OFFSHORE CONTAINERS”.

The plate should contain the following information: -

□ Name of manufacturer.
□ Month/year of manufacture.
□ Manufacturer’s serial number.
□ Maximum gross mass (kg) at design sling angle.
□ Tare mass (kg).
□ Payload (kg) and intermediate deck payload (if applicable).
□ Certificate number.
□ Design temperature.
□ Inspection plate

This plate should be headed “INSPECTION DATA - OFFSHORE”

The plate should contain the following information: -

Page 35 of 59
 □ Owner’s container number.
□ Maximum gross mass (kg) at design sling angle.
□ Tare mass (kg).
□ Payload (kg) and intermediate deck payload (if applicable).
□ Owner’s name and international telephone number(s).
□ Date of last inspection.

Cargo Carrying Unit Markings

□ The tops of closed containers and the top rails of open and framed containers shall be
marked to clearly delineate their perimeter.

□ Where a container is fitted with fork pockets designed for handling the container when
empty only, then the words “Empty Lift Only” should be clearly displayed near each set of
fork pockets in characters not less than 50mm high.

Identification Markings

□ Where reasonably practicable the container identification should be displayed on the roof,
in characters not less than 300mm high. The marking should be carried out in such a way as
to avoid incorrect interpretation (e.g. by underlining). Where applicable the lower edge of the
marking should be positioned near the side of the container in which the door is located.

□ Container identification should be prominently displayed on all sides of the

container in characters of a contrasting colour, not less than 75mm high.

□ For open side containers it may be necessary to attach panels specifically to carry the
container number

Information marking

□ A black matt square not less than 400mm x 400mm should be provided for
information markings such as cargo, destinations, hazards etc. It should be located on the door
or on one side of a container without doors.

Page 36 of 59
 □ Immediately below the black matt square the tare mass, the payload and the maximum
gross mass (in kilograms) should be displayed in characters of a
contrasting colour not less than 50mm high.

□ Any additional marking for electrical hazard classification (e.g. zone marking etc.) should
be displayed in this location.

□ If the container is used to transport dangerous goods, then the requirements of the IMDG
code regarding hazard warning labels should be observed.

Inspection Criteria
The examination is to be conducted in adequate lighting, in a systematic manner and take in to
account the operational conditions and environment in which the equipment is being used. The
container must be in a safe condition to use and this must be taken into account when deciding
whether to accept or reject the equipment.

Ensure tare mass, payload, gross mass and identification number is legible and is cross-referenced on
the current proof load report or examination report.

Examine:
 All load bearing parts including the base structure and interior.
 All accessible load bearing welds to ensure freedom from defects.
 The structure for corrosion, mechanical damage or injurious deformation.
 The lifting points for distortion, mechanical damage or any other sign of distress or overload.
 Doors, frames, seals, hinges and locks etc. to ensure that they operate in a satisfactory manner
without undue force being required.
 The floor on the inside of the container to be substantially flat with no sign of distress or over
load. Drainage facilities, where fitted are to be clear of debris etc.
 Information and inspection data plates and paint markings to meet the requirements of DNV
2.7-1/BS EN 12079 or EN ISO 10855.
 After a thorough examination the “DATA PLATE” is to be stamped with the letter V.
 After a thorough examination which includes a non destructive examination of the lifting
point welds the “DATA PLATE” is to be stamped with the letters VN.

Load Testing Procedure

 Before the container is load tested it should be visually inspected and have a 100% MPI on
lifting points and primary welds.

Page 37 of 59
  A suitable sling assembly with the current colour code shall be used for testing. It must be
checked for adequate strength and it must be capable of taking the proof load of the container,
preferably without exceeding its own proof load

 4 Point Load Test Section 3.7.1.2 DNV2.7-1 4 Point Load Test Section 7.3.2 BS EN 12079
BS EN ISO 10855-3-2018 The actual load shall be 2.5 times the gross weight less the tare.
The test hook load should equate to 2.5 times the MGW. The container shall be raised by the
mobile crane to the required test load and held for 5 minutes.

 2 Point Load Test Section 3.7.1.3 DNV2.7-1 2 Point Load Test Section 7.3.3 BSEN12079
The actual load shall be 1.5 times the gross weight less the tare. The test hook load should
equate to 1.5 times the MGW. The container shall be raised by the mobile crane to the
required test load and held for 5 minutes.
 The test masses/test load shall normally be evenly distributed inside the container. If it is not
possible to place the entire test mass inside the container, some of it may be placed outside or
under the container, provided that this gives a loading on the structure similar to the
distribution of the container loading in operating condition.

 The container with its test load shall be lifted to a sufficient height to enable the entire floor
area to be visually inspected from below, and the reading on the measuring device shall be
recorded.

 No deflections during testing shall be greater than 1/300 of the span of the member. The
offshore container shall show no permanent deformation or other damage after testing.

 Deflection not to exceed 1/500 of the distance between the lifting points (on skid mounted
units)

 After the container is load tested it should be visually inspected and have a 100% MPI on
lifting points and primary welds.

Lifting Point Padeye Design

Padeyes should be designed to suit specific shackles:

 Minimum hole size should be equal to the diameter of the shackle pin plus 10%

 Maximum plate thickness should be equal to the jaw gap of the shackle less 10%

Page 38 of 59
  Maximum hole size should not be greater than 125% times the shackle pin diameter

 Minimum plate thickness should not be less than 75% of the shackle jaw gap

Fall Protection-Safety Harness & Lanyards

Introduction Design

A safety harness is a system of restraints that prevent the wearer from falling from a height. ... The
harness allows the user to attach themselves to a stationary object, therefore ensuring they will not hit
the ground in the event of a fall.

Body support primarily for fall arrest purposes, i.e. a component of a fall arrest system.

The full body harness may comprise straps, fittings, buckles or other elements, suitably arranged and
assembled to support the whole body of a person and to restrain the wearer during a fall and after the
arrest of a fall.

BS EN 361:2002 Personal protective equipment against falls from a height. Full body harnesses.

Identification Marking

Page 39 of 59
 1.) Shoulder Straps
2.) Chest Strap
3.) Torso Adjustment
4.) Tongue Buckle/ Quick-Connect Fastener
5.) Thigh Strap
6.) Dorsal D-Ring
7.) Back Plate
8.) Sub-Pelvic Strap
9.) Inspection/ ID Label
10.) Warning/ Instruction Label
11.) Standards Label
12.) Lanyard Parking Attachment
13.) Lanyard Parking Label
14.) Strap Retainer
15.) Load Indicator

Inspection Criteria

The whole Harness and Lanyard should be checked. Pass the webbing through your hands slowly
look for the following defects:-

 Small cuts of 1 mm or more in the edges.

 Softening or hardening of fibres and ingress of contaminants.
 Surface abrasion across the face of the webbing.
 Abrasion at the edges
 Damage to stitching (eg cuts or abrasion).
 Knots and twists.
 Heat or friction damage indicated by fibres with a glazed appearance which may feel harder
than surrounding fibres.
 UV-degradation which is difficult to identify, particularly visually, but there may be some
loss of colour (if dyed) and a powdery surface.

Warning

A harness should not be used after 5 years of use. How do we ensure that a harness is not used
after 5 years. Each harness should have a specific serial number and a date of manufacture. At
LBI the start of use date is taken as the manufacture date so that we can ensure that a harness is
not used after 5 years

Page 40 of 59
Lanyard Connectors and Karabiners
Single Lanyard

These are used only if connection is maintained between the harness and safety line. For example
access and egress to overhead gantry cranes.

Always ensure that the length of the fully extended (including the fall arrest) lanyard + the length of
your body is not longer than the distance that you could fall.

Twin Tail Lanyard

These are used only if connection cannot be maintained between the harness and safety line by a
single lanyard. For example during maintenance of cranes, where you may need to gain access to
different areas or levels.

They are fitted with fall arrest systems that slow down the impact of the fall.

Always ensure that the both tails of the lanyard are connected at all times. Do not put the second tail
onto the harness when it could be a hazard.

Fall Arrest

A Fall arrest lanyard is fitted with fall arrest systems that slow down the impact of the fall. This
reduces the jolt factor, the sudden stop at the end of a fall that can cause damage to your internal
organs.

There are different types: -

 Shock absorbing - In a fall a user will travel the length of the lanyard before the fall is
arrested.
 Energy dissipating - Usually a nylon or braided safety rope incorporating a guided type fall
arrester with an energy dissipation element.

A Fall restraint lanyard is not always fitted with fall arrest systems that could slow down the impact of
the fall.

Instead it is designed to be shorter and prevent the person from reaching the edge (hazard). This way
instead of catching someone from falling it prevents them from falling in the first place.

These lanyards should not be used if there is a chance that someone could fall. Note Fall arrest
lanyards can be used as fall restraint however you MUST consider the length or distance.

Page 41 of 59
 There are self-retracting lanyards that are fitted with a deflection brake shock absorber operation
system. (Inertia Reels)

These allow the user to operate in different distances from the anchor point and because of the
retraction of the lanyard it does not spool around the user.

If the user falls then the brake activates and prevents the user falling further.

These are used during maintenance activities.

The Karabiner is used to connect a harness to a lanyard or to connect the lanyard to the attachment
point.

The Karabiner is used on certain harnesses to join together two straps to make an attachment point

Each Karabiner has its capability noted on it in KN. This denotes Kilo Newton's. There is 10 KN to 1
Tonne. 25 KN= 2.5 tonne. The strength of the Karabiner differs when used in different positions e.g.
side load.

Pallet Trucks

Introduction Design
A pallet truck (also known as a pump truck or pallet jack) is a wheeled trolley designed to lift and
transport pallets. The truck's tapered forks slot underneath the pallet and the pump handle can then be
used to raise and lower the load.

BS EN 1757 Part 2: 2001 “Safety of industrial trucks-pedestrian propelled truck. Pallet trucks”.

Marking
The function and controls shall be legibly and indelibly marked in graphic symbols indicating the
function. Each symbol shall be affixed on or close to the control to which it applies. The following
minimum information shall also be marked legibly and indelibly on the truck: -

• Name and address of the manufacturer or the authorised representative

• Designation of series or type.
• Serial number and year of manufacture.
• Unladen mass of the truck with integral attachments.
• Rated capacity

Inspection Criteria

The examination is to be conducted in adequate lighting, in a systematic manner and take in to

account the operational conditions and environment in which the equipment is being used. The truck

Page 42 of 59
must be in a safe condition to use and this must be taken into account when deciding whether to
accept or reject the equipment.

Examine:

• Damage or deformation to the operating controls,

• horizontal lifting arms and main body such as cracks, bends, twists or seized parts.
• Retaining pins are to be fitted and all bolts and nuts are to be secure.
• Corrosion of any of the main body members or parts.
• Loose, missing or distorted bolts.
• All washers, including locking washers where appropriate must be in place.
• Cracks or undercut in any welds.
• Moving parts for slackness, wear and any other damage.
• Wheels for freedom of movement and that they are not deformed.
• Hydraulic fluid levels are sufficient.
• Operated over its entire range and examine for any hydraulic leaks.

Load Testing Procedure

Rated capacity only (WLL)

• After the pre test examination has been carried out, a load equal to the rated capacity only is
to be evenly distributed on the lifting arms of the pallet truck.
• The load is then to be operated thorough its full range of operation.
• The release mechanism is then to be operated to permit controlled lowering until the load is
just clear of the ground. The pallet truck is then to be pulled along a flat even surface so that
one complete revolution of the wheels is achieved.
• During the test keep the truck under observation in order to detect any obvious defects.
• If all is satisfactory mark the truck with its rated capacity and unique identification number
and issue the test report.

Page 43 of 59
 Runway Beams

Introduction Design
The crane runway beam section of overhead cranes can consist of a rolled I-section, either with or
without side reinforcements for supporting horizontal loads, an I-section that has been welded
together or a box girder. The same type of sections can be used for suspended cranes, however
without a rail.

BS EN 1993-6:2007, BS 2853:2011 “Design of steel structures. Crane supporting structures’’

Marking
The safe working load, identification number and any limiting conditions shall be plainly and
permanently marked on the runway beam so that it is clearly visible to the operator. If the beam has
been tested for powered appliances the word “POWER” is to be marked against the SWL. If the beam
has been tested for manual appliances only, then the word “MANUAL” is to be marked against the
SWL.

Page 44 of 59
Inspection Criteria
• Ensure SWL and identification number is legible and is cross-referenced on the current proof
load report or current examination report. Examine for:
• All support welds should be clean and free from rust where possible to enable a proper
examination to be conducted.
• Damage or deformations to the track, such as cracks, bent or twisted flanges or wear to the
running face of the track.
• Twisted, bent or “turned down” cantilever jib sections.
• Damage or deformation to supporting steel structures, such as cracks, distorted columns, bent
or twisted flanges.
• Damaged or distorted stools, packers and fixings including bent or distorted base plates.
• Corrosion of any of the structural members or track.
• Loose, missing or distorted bolts, nuts, or clamps. All washers, including taper washers where
appropriate, and locking devices must be in place. In the event of missing bolts, nuts or
washers, they must be replaced by ones of the correct size, grade and type. If any doubt exists
withdraw from service and refer to a structural engineer.
• Loose foundation bolts of any supporting column or stanchion. It may be necessary to consult
the manufacturer’s instructions as certain types of foundation bolts require periodic re-
torquing during the initial period of use. Where the manufacturer’s instructions do not
mention this or if the problem recurs, withdraw from service immediately and refer to a
structural engineer.
• Damaged, loose or missing end stops. End stops are safety devices that prevent the trolley,
block or load colliding with the structure or running off the end of the track. Their correct
fitting is of vital importance to the safe use of the runway. They must be set so that they mate
with the wheel tread and do not contact the flanges of the trolley wheels.

Load Testing Procedure

1.25 x SWL

The proof load applied is to be the weight of the appropriate heaviest lifting appliance supported by
the runway plus 25% in excess of the safe working.

SWL test

• A test load equal to the runway beam’s SWL, together with the weight of the lifting appliance
to be used, is to be lifted at one end of the beam.
• With the SWL sitting just clear of the ground traverse the load to the opposite end of the
beam.
• The load shall be halted during its passage along the runway and kept at rest at suitable
positions, in order that stable deflection readings can be taken.
• The maximum deflection of a simply supported runway beam under SWL shall not exceed
1/500 of the span.
• The maximum deflection of a cantilever beam under SWL shall not exceed 1/250 of the span.

Proof load test

• The procedure detailed above is to be repeated except that a proof load of 1.25 x SWL is to be
lifted. A stable deflection reading is to be taken and recorded only at the position where the
maximum reading was obtained during the application of the SWL referred to above. This is
to be done to check that the runway beam returns to its original position with no permanent
set.

Page 45 of 59
 • Keep the runway beam under observation to detect any obvious defects.
• Remove the proof load and examine the runway beam for any defects.
• Conduct a non-destructive test of any welds. Refer to NDT procedures
• If all is satisfactory mark the runway beam with its SWL and unique identification number
and issue the test report.

Additional Testing Comments

• The SWL marked on the runway beam shall not exceed that of any transporting or lifting
appliances used on it, even though the runway beam and its components have been tested
satisfactorily with a proof load greater than that specified for this SWL.
• When measuring the deflections of the beam, it is to be done in such a manner that relates
precisely to the same condition as those covering the calculated deflection. The deflection
measured is to refer to the runway itself and not any additional deflections attributed by the
supporting structure.
• To obtain the actual deflection of the runway beam, it will be necessary to use a fixed datum
point. This fixed datum point is not to be affected by movement of the load.
• Suitable fixing points for measuring the deflection can be solid ground, a roof member not
affected by the load or a temporary frame built beside the runway beam.

Plate Clamps

Introduction
Plate clamps are widely used, particularly in the steel fabrication industry, for handling a variety of
work including individual plates, fabricated assemblies and bundles of plates. The name covers
several types which fall into two basic categories:

1. Clamps which grip the edge of the plate by friction. These are subdivided into those
used to lift the plate in the vertical position only and those which lift from the
horizontal to the vertical or vice-versa.

Page 46 of 59
 2. Clamps designed to lift the plate in a horizontal position only, when used in
conjunction with a two leg sling or reeved onto an endless loop, according to design.

Those in which a system of levers actuated by the loading of the lifting eye or chain or in which a
chain or wire rope is attached to the jaws in such a way as to produce a force causing the jaws to come
together and grip the plate.

Such gripping action may be provided by the lever system itself, or by a combination of the leverage
and the cam action of the jaw. Clamps which are provided with a spring loaded locking device which
secures (locks) the clamp onto the plate without a force being applied are preferred

Inspection Criteria
• Inspect internal and external surfaces for forging or weld fractures, wear and distortion.
• Check all pin holes for wear.
• Inspect the throat (clamp opening) width. At zero grip, the cam should be in full contact with
the pad.
• Measure the width of the throat. If the measurement at the base, where the pad is located is
greater than at the top, the body has been overloaded. Replace the clamp; tag the defective
clamp and remove it from service.

Beam Clamps

Introduction

Page 47 of 59
 There are different types of beam clamps and trolleys with variations being based upon their
materials, their load capacity and even their modes of operation.

Inspection Criteria
Wherever practical, all equipment must be operated through a full cycle of its operation, before and
after inspection.

This examination must be carried out with the beam clamp in a reasonably clean condition and in
adequate lighting. It should be taken out of service if:

• In the case of a clamp in-situ, distortion of beam to which clamp is attached.

• Distortion of any part of the clamp.
• Cracks especially at bends or changes of section, nicks, gouges and corrosion.
• Wear at application and suspension points, pins, pivots and other moving parts.
• Insecure locking arrangements including substitute nuts and bolts where used.
• Illegible safe working load or other markings.
• In addition for clamps in-situ if either of the following faults are found the appropriate actions
should be taken: 
• Clamp of incorrect profile and/or width for the beam. Replace clamp with one of the correct
width and profile.  
• Incorrect fitting of any hook, shackle, etc. used for attaching other lifting equipment to the
clamp. (Other equipment attached to the clamp should be securely retained within the fixing
and free to align itself under load).
Notes

Lifting and Spreader Beams

Page 48 of 59
Marking
The following shall be permanently and legibly marked on each lifting beam, spreader or frame: 

• Identification mark. This should be repeated on all detachable components.

• Safe working load.
• Safe working load of individual lifting points. 
• In addition, it is recommended that the weight of the beam should be marked in a prominent
position.

Inspection Criteria
The examination must be carried out with the Lifting/Spreader Beams in a reasonably clean condition
and in adequate lighting. If any of the following faults are present, the Lifting/Spreader Beams should
be withdrawn from service and referred to the Responsible Person.

• Bolted connections to the beam should be checked for tightness.

• The beam should be checked for distortion.
• The beam should be checked for localised physical damage. Particular attention
should be given to hollow sections which may have dents or localised buckling and to
the flanges of structural steel sections.
• Corrosion damage.
• Signs of cracks and distortion especially in weld details.
• Ensure that requisite markings are clearly visible and correspond to the loadings
stated on the documentation.
• Lifting accessories, such as shackles, eyebolts, wire rope slings, chain slings,
synthetic web slings, plate clamps, hooks, turnbuckles etc.
• should all be inspected in accordance with the respective standards

Page 49 of 59
 Travelling Girder Trolleys

Inspection Criteria
Wherever practical, all equipment must be operated through a full cycle of its operation, before and
after inspection.

This examination must be carried out with the Travelling Girder Trolleys in a reasonably clean
condition and in adequate lighting. If any of the following faults are present, the Travelling Girder
Trolleys should be withdrawn from service and referred to the Responsible Person.

• Appreciable wear of the trolley wheel treads and bearings or damage to flanges.
• Insecurity of the wheels and axle pins.
• Distortion, particularly in the side plates and load bar.
• Wear on load bearing points.
• Worn, corroded or damaged hand chain particularly on the bearing surface on the inside of
the links but also the outside of the links, bearing in mind possible damage to the operatives’
hands.
• Illegible safe working load or other markings.
• Cracked or defective welding.
• Incorrectly substituted components.
• Check trolley wheels are correct shape for the beam
• Check that bolts are secure

Additional Inspection for In-Situ Trolleys

In addition, for trolleys in-situ, if any of the following defects are found the appropriate action should
be taken:
• Incorrect size of trolley for the runway beam. Replace with correct size of trolley.
• Wrongly adjusted trolley. Re-adjust to correct side clearances between the wheel flanges and
the toes of the beam. Usually 3mm to 4mm total clearance. Also ensure that the trolley is
correctly aligned centrally with the flange of the runway.
• The trolley centre line should be aligned with the centre line of the web beam.
• Wrongly adjusted anti-tilt device. Re-adjust.
• In the case of an incorrect or wrongly fitted block, remove and replace or refit as necessary.

Page 50 of 59
Lifting Equipment Storage and Handling
A designated store that is equipped with suitable bins, racks and shelving should be used to store
lifting equipment accessories. It should be:

• Dry and free from damp.

• Free from any form of contaminants.
• Not subject to extremes of temperature

Correct Storage Wrong Storage

Notes

Page 51 of 59
 Chain Slings Steel Wire Rope Slings
• Do not drag. • Hung on a designed rack.
• Should be kept in a properly designed • Cleaned by brushing.
rack. • Protect from corrosion.
• Hooks located in the master link. • Always wear glove when handling
• Cleaned, dried and free from corrosion. SWR.
• Not galvanised, plated or painted
without the authorisation of the
manufacturer.

Man-made Fibre Slings Shackles

• Store in a suitable rack. • Ensure that the shackle has its correct
• Avoid acids, alkalis and solvents, must type of pin.
be cleaned using recommended cleaning • Avoid damaging the screw thread.
and neutralising agents. • Store on a bespoke frame where
• Wet slings should be hung in the store possible
and allowed to dry naturally.
• Frozen slings must be allowed to thaw
naturally

Eyebolts Chain Blocks

• Protect threads and machined surfaces. • Lubricate chain blocks with suitable
• Lightly oil to prevent corrosion oil/grease and when not in use store in a
• Store on a bespoke frame where dedicated storage area.
possible • The storage area shall be dry, free from
injurious pollution and extremes of
temperature.
• Ideally chain blocks should be
suspended by their top hooks and to
prevent damage to chains the load chain
and hand chain shall be clear of the
ground.
• Wet and/or dirty equipment must be
cleaned and dried before storing -
powerful solvents must not be used.

Proof Load Testing

Proof Load Testing is designed to ensure that items of lifting equipment can perform to the required
standard in accordance with the Manufacturer’s guidance and design by giving them a full strength
test.

It is required on installation of any lifting equipment before the item is brought into service.

It may be required at other times such as:

Page 52 of 59
 • Following a weld repair of a structural item
• After a complete overhaul
• Following an accident

Proof load testing must be carried out by a competent person.

Test loads 2 x SWL Test loads 1.5 x SWL Test loads 1.25 x SWL
Chain Sling Chain Block Jacks
Wire Rope Sling Pull Lift Air Hoist
Shackle Pulling/Lifting Machine Electric Hoist
Eyebolt Ratchet Jack Runway/Gantries
Plate Clamp Swing Jibs
Spreader Beam up to 3t
Lifting Beam up to 3t

No test can be applied unless metal end fittings are attached to Flat Webbing Slings.

Notes

Non-Destructive Testing
Non-destructive testing (NDT) is the application of measurement techniques in order to identify
damage and irregularities in materials.

The three main types are:

• Magnetic Particle Inspection (MPI) a procedure to detect surface and sub-surface

discontinuities in ferromagnetic materials and is commonly used on welds castings and
forgings

Page 53 of 59
 • Dye-Penetrant Testing a procedure to detect surface breaking defects such as cracks where a
liquid penetrant is applied to a surface and is drawn into any cracks by capillary action. A
developer is then applied to draw out the penetrant from the cracks giving clear visibility.

• Ultrasonic NDT uses sound waves to identify and evaluate internal flaws typically used to
assess weld penetration and welded components where visible inspection is not possible

Notes

Thorough Examination Report

A Thorough Examination is a systematic and detailed examination of the equipment and safety-
critical parts, carried out at specified intervals by a competent person who must then complete a
written report. This report must contain the information required by the LOLER regulations,
including:

 the examination date

 the date when the next thorough examination is due
 any defects found which are (or could potentially become) a danger to people

Page 54 of 59
Where serious defects are identified, the competent person carrying out the examination must
immediately report this verbally to the duty holder. This should then be followed by the written
report, a copy of which must also be sent to the relevant enforcing authority.

The Competent Person

The term 'competent person' is not defined in law but the LOLER Approved Code of Practice and
guidance (paragraph 294 on competent persons) states that:

'You should ensure that the person carrying out a thorough examination has such appropriate practical
and theoretical knowledge and experience of the lifting equipment to be thoroughly examined as will
enable them to detect defects or weaknesses and to assess their importance in relation to the safety and
continued use of the lifting equipment.'

Although the competent person may often be employed by another organisation, this is not necessary,
provided they are sufficiently independent and impartial to ensure that in-house examinations are
made without fear or favour. However, this should not be the same person who undertakes routine
maintenance of the equipment - as they would then be responsible for assessing their own
maintenance work.

When should thorough examinations be carried out?

In order to verify that lifting equipment and accessories remain safe for use, and to detect and remedy
any deterioration in good time, thorough examinations are required throughout the lifetime of the
equipment, including examinations:

 Before use for the first time - unless the equipment has an EC Declaration of Conformity less
than one year old and the equipment was not assembled on site. If it was assembled on site, it
must be examined by a competent person to ensure that the assembly (e.g. a platform lift
installed in a building) was completed correctly and safely.

 After assembly and before use at each location - for equipment that requires assembly or
installation before use, e.g. tower cranes

 Regularly, while in service - if the equipment is exposed to conditions that cause deterioration
which is likely to result in dangerous situations. Most lifting equipment will be subject to wear
and tear and so will need regular in-service examination. Some may be exposed to significant
environmental conditions which may cause further deterioration. You have a choice:

 arrange for thorough examination to be carried out at the intervals specified by LOLER
(every 6 or 12 months, depending on the equipment - see below), or

Page 55 of 59
  conduct examinations in accordance with an examination scheme, drawn up by a
competent person

 Following exceptional circumstances - liable to jeopardise the safety of lifting equipment,

which may include:

 damage or failure
 being out of use for long periods
 major changes, which are likely to affect the equipment's integrity (e.g. modifications,
or replacement / repair of critical parts)

What are the specified intervals for regular thorough examinations?

Unless there is an 'examination scheme' specifying other intervals, thorough examinations should be
conducted every:

 6 months, for lifting equipment and any associated accessories used to lift people
 6 months, for all lifting accessories
 12 months, for all other lifting equipment
Notes

What is covered by a thorough examination?

This depends on the professional judgement of the competent person undertaking the examination, but
needs to include all matters which affect the safety of the lifting equipment, including likely
deterioration with time.

For most common lifting equipment and accessories, there are industry standard procedures and
criteria which a competent person would follow when undertaking thorough examinations and making
judgements as to the continued safety of the equipment. Methods used include:

 visual examination and functional checks

 measurements of wear
 (in some cases) traditional NDT (non-destructive testing) and load testing

Some disassembly or internal examination of parts may also be required.

Where an examination scheme has been drawn up, this should identify and specify:

 the parts to be thoroughly examined

 the methods of examination and testing
 the intervals for examination (and testing of the different parts, where appropriate)

The scheme should also include details of any other inspection regimes for the equipment.
Examination schemes may be drawn up by any person with the necessary competence. This does not

Page 56 of 59
need to be the same competent person who conducts the thorough examination in accordance with the
scheme.

Although examination schemes do not need to be preserved in the form of a document, it should be
possible to produce a written copy when required (e.g. on request by the relevant enforcing authority).
These should be secured from loss or unauthorised modification. 

Notes

Page 57 of 59
International Leader in Test, Inspection, Certification
and Supply

Inspection, Testing, Maintenance & Certification

Page 58 of 59 Crane Installation, Repair & Refurbishment
Product Supply
Page 59 of 59