When it comes to rigging equipment, safety and reliability aren’t optional—they’re essential. Whether lifting heavy machinery on a construction site or securing loads in a warehouse, equipment failure can have catastrophic consequences. That’s where load testing comes in.
Load testing ensures that your rigging gear—wire rope, slings, hoists, shackles, cranes, and more—can safely handle its intended working load. It’s not just about compliance; it’s about protecting people, property, and operations.
Types of Load Testing
There are several types of load testing, each designed to verify different aspects of equipment performance:
- Proof Load Test
This test simulates operational load paths and “worst-case scenario” conditions. A static load—typically above the equipment’s designated Working Load Limit (WLL)—is applied and held for a designated interval before being released. It confirms structural integrity, often after manufacturing or repair, and is followed by post-test inspections. Traceable load test documentation is provided before the equipment is placed into service. - Functional Load Test
Similar to a Proof Load Test, but with a key difference: it involves simulating mechanical functions. Dynamic loads are applied to equipment such as hoists, winches, load positioners, or vertical center of gravity (VCG) lifting devices to ensure performance under real operating conditions. - Ultimate Load Test
This test pushes equipment to failure to determine its maximum load-bearing capacity. It simulates operational conditions with loads applied until the point of ultimate failure. This method is typically used for residual strength analysis, research and development, or testing of retired equipment. - Cyclical Fatigue Load Test
Designed to evaluate how equipment holds up under repeated stress, this test involves dynamic application of tensile, compressive, or bending fatigue forces over time. It simulates the long-term effects of service life and often includes environmental considerations.
How Often Should Load Testing Be Performed?
Frequency can vary depending on the type of equipment, how often it is used, and environmental conditions. However, general guidelines include:
- Initial Testing: New or repaired equipment should undergo a proof load test before first use.
- Periodic Testing: Some equipment must be tested annually or at intervals specified by the manufacturer or governing body.
- Post-Incident Testing: If equipment has been dropped, overloaded, or involved in an incident, testing is essential before it returns to service.
Standards That Govern Load Testing
Regulatory and industry bodies have established clear standards to guide load testing procedures and frequency. The most commonly referenced include:
- ASME (American Society of Mechanical Engineers): Standards such as ASME B30.9 for slings, ASME B30.20 for lifting devices, and ASME B30.26 for rigging hardware outline requirements for inspection, testing, and maintenance.
- OSHA (Occupational Safety and Health Administration): OSHA regulations—like 29 CFR 1910.184—mandate safe practices for lifting and rigging equipment in the workplace.
- ANSI and ISO: Additional standards may apply depending on your location or industry.
Failing to follow these standards can result in costly fines, equipment downtime, or worse—injury or loss of life.
Protect Your Team and Equipment
Whether you’re responsible for a single crane or an entire fleet of lifting gear, proper load testing should be part of your ongoing safety and maintenance program. Not only does it help meet regulatory requirements, but it also builds confidence in your equipment’s performance and longevity.
Need load testing services?
CERTEX provides certified load testing solutions that comply with all major industry standards. Click here to learn more about our load testing services.
