What Type of Testing or Training is Required After a Crane Capacity Upgrade?

Once the upgrade work has been completed, the crane will need to be started up and load-tested to make sure everything is in working order. A third-party testing company may be brought in to perform the test and ensure that the crane will operate safely and productively. Per OSHA 1910.179 Overhead & Gantry Cranes Regulations, your new crane system will need to have two operational tests, plus a rated load test performed prior to initial use:

Testing of the hoist operation up and down; trolley travel; bridge travel; limit switches; and locking and safety devices.

Testing of the trip setting of the hoist limit switches to make sure the actuating mechanism of the limit switch is functioning properly.

Load test the crane at no more than 125% of the rated load and keep test reports on file where readily accessible.

The weight for load tests must be “known,” so the load testing of the crane can be performed using a certified weight from a load-testing company, or the known weight of a variety of materials including concrete, steel, or water weight bags.

In most cases, any type of operator training that the customer wants after the upgrade is complete will be written into the specifications of the project. Training could be as simple as showing one operator how to use the new features of the crane, or it could be a 2 to 3 day class involving multiple operators and other production and maintenance personnel.

During the training, the operators will be shown how to use the new features of their crane equipment, including:

• Using new remote radio or pendant controls
• Troubleshooting fault codes
• Stopping and starting the crane with new VFD technology or anti-sway controls
• Precision tuning the drives to the preference of the operator(s)
• Demonstrating how to properly inspect and maintain the new equipment

There can be a learning curve for operators to get used to the new crane equipment once the capacity has been upgraded. It could even be weeks or months before they’re 100% used to the new operating characteristics of their crane.

Operators may be used to letting off of a lever or button on the controls and the crane starting or stopping immediately. A new drive system builds in time for controlled acceleration and deceleration, so the crane may still travel an additional 5 to 10 feet once the operator lets off of the controls. The goal for most crane upgrades and modernizations is to prevent load swing, so adding in acceleration and deceleration controls can take some time to get used to. In the long run, it will significantly decrease the wear and tear on the motors, drives, brakes, and structural components of the overhead crane equipment.

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