Annual thorough examination and the five-yearly load test

The test load table

MSC.1/Circ.1663 table 1, the same figures as the ILO code of practice appendix D and the reverse of ILO Form No. 2:

The calculator above applies this table. Worked examples:

• 8 t provision crane: 1.25 × 8 = 10 t.
• 30 t cargo crane: 30 + 5 = 35 t.
• 120 t heavy-lift crane: 1.10 × 120 = 132 t.

The bands join up: at 20 t both the first and second rules give 25 t; at 50 t both the second and third give 55 t. The table applies to appliances used in port or sheltered waters. For cranes used in open-sea operations, such as offshore supply transfers, the test load is set by the Administration or the RO taking account of dynamic loads, so it is often higher.

The ILO code of practice adds practical limits. The weight of the test load, including its lifting gear, should be not less than the table figure and should not exceed it by more than 2.5%. For hydraulic cranes where pressure limits make the full 25% impossible, the reverse of ILO Form No. 2 accepts the greatest load that can be lifted, but in general not less than 10% over the SWL.

Loose gear proof tests

Loose gear is tested to a higher multiple because it is small, highly stressed and easily abused. MSC.1/Circ.1663 table 2:

A note for the careful reader: the circular as printed in 2023 shows 0.993 for multi-sheave blocks. The ILO code, ILO Form No. 3 and Liberia’s corrected marine notice all use 0.933, which is the value that makes the formula meet 2 × SWL at 25 t and 1.1 × SWL at 160 t. Use 0.933.

For a single-sheave block, the SWL is taken as half the resultant load on the head fitting. For a multi-sheave block, it is the resultant load on the head fitting.

What the annual thorough examination covers

The SOLAS guidelines list items that need particular attention:

• corrosion and damage of primary structure: jib, crane housing, pedestal, foundations, welds and bolts;
• wear, corrosion and damage of winches, hydraulic cylinders, slewing bearings, sheaves and pins;
• setting and function of safety, protection and limiting devices (limit switches, overload protection, emergency stop);
• the hydraulic and pneumatic systems, hoses, piping, brakes and drums;
• the means of access, platforms and their brackets and welds;
• certification and identification of ropes.

The ILO code adds that for ship’s gear the examination includes associated fittings such as deck eyes, mast bands and cleats, and that parts are dismantled where the competent person considers it necessary. Blocks will usually be stripped so the pin can be examined. Appliances used to lift persons should be thoroughly examined at least every six months under the ILO code.

When a load test is triggered early

A load test is needed after “repairs, modifications or alterations of a major character”. The guidelines define these as work that changes the SWL; affects the strength, stability or service life; affects the primary load-bearing structure; or modifies the functionality in a way that may affect strength, safety or structural integrity. Renewing a hoist wire with an identical certified wire is normally not in that list; renewing a slewing bearing or cropping and welding a jib section is.

How it fits the survey cycle

Where the thorough examination is not itself part of the annual or renewal survey, the surveyor verifies at that survey that it has been done. Some flags let the 12-monthly and five-yearly dates follow the harmonized survey windows. That suits SOLAS, but ports that apply ILO C152 count 12 months and five years strictly, so plan to the stricter of the two.