Pedestal Crane Load Testing Procedure
Pedestal crane load testing is a critical process conducted to verify the operational integrity and safe working condition of cranes used in offshore platforms, ports, and anchorages. Due to logistical challenges in these locations, water bags are typically used in place of traditional solid test weights. Testing is performed in accordance with international safety standards using calibrated digital dynamometers and load monitoring systems.
Testing Methodology: Water Weights & Dynamometers
Instead of conventional steel test weights, lifting load bags (water bags) are employed for proof load testing due to their ease of transport and setup in remote or offshore areas. These bags are filled with water during testing and weighed using digital dynamometers for accurate load measurement.
Step-by-Step Procedure for Pedestal Crane Load Testing
- Identify SWL (Safe Working Load):
Determine the crane’s rated capacity to establish test parameters. - Develop Lifting & Rigging Plans:
Prepare detailed lifting and rigging plans, considering crane type, hook configuration (single or double), and site layout. - Conduct Risk Assessment & Job Scope Analysis:
Include hazard identification, mitigation strategies, and clear job responsibilities. - Site Preparation & Safety Protocols:
- Barricade the test area.
- Ensure all personnel wear minimum required PPE (helmets, gloves, safety jackets, etc.).
- Deploy emergency response procedures.
- Selection of Water Bags:
Choose water bags based on crane capacity, test load requirements, and the bag’s diameter and fill height. - Assembly for Single Hook Crane:
- Connect lifting accessories including shackles, digital dynamometer load cell, and water bags.
- Set up filling and discharge hoses at the water bag valves.
- Avoid sharp edges when handling water weights and slings.
- Assembly for Double Hook Crane:
- Ensure symmetrical load distribution.
- Carefully rig slings to avoid rope twist or imbalance.
- Load Bag Setup:
- Install master links, shackles, and wire rope slings on water bags.
- Check all connections and fittings.
- Functional Testing of Valves:
- Test the discharge valves of the water bags by pulling ropes or opening/closing valves to ensure proper function.
- Filling & Monitoring:
- Turn on the digital load cell.
- Begin filling the water bags.
- Monitor the load reading continuously and match it with the crane’s load chart and boom radius.
- Load Verification:
- Close all discharge hose valves and maintain safe distance from discharge points.
- Confirm that the required proof load is achieved.
- Water Discharge & Completion:
- Open the ball valve of the water bag for controlled discharge.
- Lower the boom and carefully remove the water bag assembly.
Approvals Required from Marine Classification Societies
To legally perform load testing and certification of pedestal cranes at major UAE ports, the service provider must hold approvals from relevant local port authorities and international classification societies, in compliance with:
- LOLER (Lifting Operations and Lifting Equipment Regulations)
- PUWER (Provision and Use of Work Equipment Regulations)
- IACS (International Association of Classification Societies)
Port Approvals in UAE:
- TRAKHEES
- Jebel Ali Port
- Port Khalid
- Fujairah Port
- AD Ports
IACS Member Approvals:
- Lloyd’s Register (LR)
- American Bureau of Shipping (ABS)
- Indian Register of Shipping (IRS)
- Bureau Veritas (BV)
Non-Destructive Testing (NDT) Requirements – Pre & Post Load Test
Pre-load and post-load NDT inspection is mandatory to assess the structural integrity of the pedestal crane. If direct access is not possible, inspections are conducted using IRATA-certified Rope Access technicians.
Common NDT Methods via Rope Access:
- Magnetic Particle Inspection (MPI)
- Eddy Current Testing (ECT)
- ACFM (Alternating Current Field Measurement)
- Ultrasonic Testing (UT)
- Dye Penetrant Testing (DPT)
All NDT personnel must hold valid certifications such as ASNT Level II/III or PCN Level II/III.
Conclusion
Pedestal crane load testing is a vital procedure for maintaining operational safety in marine and offshore environments. By utilizing advanced tools like digital dynamometers, LiDAR-based lifting bag calibration, and ensuring compliance with international and regional standards, operators can ensure reliable crane performance and regulatory compliance.