29 C.F.R. Subpart H—Certification of Shore-Based Material Handling Devices
Title 29 - Labor
(a) Certification of shore-based material handling devices shall conform to the requirements contained in this subpart, except in cases for which exemptions or variations have been granted by the Assistant Secretary as provided in §§1919.50(d) and 1919.60(a). (b) Any replacements or repairs deemed necessary by the accredited person shall be carried out before application of a proof test. (c) Ton in this subpart means a ton of 2,000 pounds. (d) When applied to shore-based material handling devices, ratings may be stated in pounds rather than tons. When stated in tons of 2,000 pounds, this fact shall be indicated. (a) Unit proof tests of cranes shall be carried out at the following times: (1) In the cases of new cranes, before initial use and every 4 years thereafter. (2) In the cases of uncertificated cranes which have been in use, at the time of initial certification and every 4 years thereafter. (3) After important alterations and renewals and after repairs due to failure of, or damage to major components. (b) Unit proof load tests of cranes shall be carried out where applicable with the boom in the least stable direction relative to the mounting, based on the manufacturer's specifications. (c) Unit proof load tests shall be based on the manufacturer's load ratings for the conditions of use and shall, except in the case of bridge type cranes utilizing a trolley, consist of application of a proof load of 10 percent in excess of the load ratings at maximum and minimum radii, and at such intermediate radii as the certificating authority may deem necessary in the circumstances.1 1 The manufacturer's load ratings are usually based upon percentage of tipping loads under some conditions and upon limitations of structural competence at others, as well as on other criteria such as type of crane mounting, whether or not outriggers are used, etc. Some cranes utilizing a trolley may have only one load rating assigned and applicable at any outreach. It is important that the manufacturer's ratings be used. (d) An examination shall be carried out in conjunction with each unit proof load test. The accredited person, or his authorized representative, shall make a determination as to correction of deficiencies found. The examination shall cover the following points as applicable: (1) All functional operating mechanisms shall be examined for improper function, maladjustment, and excessive component wear, with particular attention to sheaves, pins, and drums. The examination shall include operation with partial load, in which all functions and movements, including, where applicable, maximum possible rotation in both directions, are performed. (2) All safety devices shall be examined for malfunction. (3) Lines, tanks, valves, drains, pumps, and other parts of air or hydraulic systems shall be examined for deterioration or leakage. (4) Loose gear components, such as hooks, including wire rope and wire rope terminals and connections, shall be checked with particular attention to sections of wire rope exposed to abnormal wear and to sections not normally exposed for examination. The provisions of §1919.24 shall apply in wire rope examinations. Cracked or deformed hooks shall be discarded and not reused on any equipment subject to the provisions of part 1918 of this chapter and this part 1919. (5) Rope reeving shall comply with manufacturer's recommendations. (6) Deformed, cracked, or excessively corroded members in crane structure and boom shall be repaired or replaced as necessary. (7) Loose bolts, rivets, or other connections shall be corrected. (8) Worn, cracked, or distorted parts affecting safe operation shall be corrected. (9) Brake and clutch system parts, linings, pawls, and ratchets shall be examined for excessive wear and free operation. (10) Load, boom angle, or other indicators shall be checked over their full range for any significant inaccuracy. A boom angle or radius indicator shall be fitted. (11) It shall be ascertained that there is a durable rating chart visible to the operator, covering the complete range of the manufacturer's capacity ratings at all operating radii, for all permissible boom lengths and jib lengths, with alternate ratings for optional equipment affecting such ratings. Necessary precautions or warnings shall be included. Operating controls shall be marked or an explanation of controls shall be posted at the operator's position to indicate function. (12) Where used, clamshell buckets or other similar equipment such as magnets, etc., shall be carefully examined in all respects, with particular attention to closing line wires and sheaves. The accredited person may supplement such examination by requesting any operational tests as may be appropriate. (13) Careful examination of the junction areas of removable boom sections, particularly for proper seating, cracks, deformities, or other defects in securing bolts and in the vicinity of such bolts. (14) It shall be ascertained that no counterweights in excess of the manufacturer's specifications are fitted. (15) Such other examination or supplemental functional tests shall be made as may be deemed necessary by the accredited person under the circumstances. (a) In any year in which no quadrennial unit proof test is required, an examination shall be carried out by an accredited person or his authorized representative. Such examination shall be made not later than the anniversary date of the quadrennial certification and shall conform with the requirements of §1919.71(d). (a) Unit proof tests of derricks shall be carried out at the same times as are specified in §1919.71(a) for cranes. (b) Unit proof load tests and safe working load ratings shall be based on the design load ratings at the ranges of boom angles or operating radii. Unit proof loads shall exceed the safe working load as follows: Proof loads shall be applied at the designed maximum and minimum boom angles or radii, or, if this is impracticable, as close to these as practicable. The angles or radii of test shall be stated in the certificate of test. Proof loads shall be swung as far as possible in both directions. The weight of all auxiliary handling devices shall be considered a part of the load. (c) After satisfactory completion of a unit proof load test, the derrick and all component parts thereof shall be carefully examined in accordance with the requirements of §1919.71(d), as far as applicable. (a) In any year in which no quadrennial unit proof test is required, an examination shall be carried out by an accredited person or his authorized representative. Such annual examination shall be made not later than the anniversary date of the quadrennial certification and shall conform in all applicable respect with §1919.71(d). (a) In the event neither manufacturer's data nor design data on safe working loads (including any applicable limitations) are obtainable, the safe working load ratings assigned shall be based on the owner's information and warranty that those so assigned are correct. Unit test certificates shall state the basis for any such safe working load assignment. (a) If the operation in which equipment is engaged never utilizes more than a fraction of the safe working load rating, the owner of such equipment may, at his option, have the crane or derrick certificated for and operated at a lesser maximum safe working load in keeping with the use and based on radius and other pertinent factors: Provided, however, That the equipment concerned is physically capable of operation at the original load rating and the load reduction is not for the purpose of avoiding correction of any deficiency. (a) In no case shall safe working loads be increased beyond the manufacturer's ratings or original design limitations unless such increase meets with the manufacturer's approval. Where the manufacturer's services are not available, or where the equipment is of foreign manufacture, engineering design analysis by, or acceptable to, the accredited certification agency is required. All necessary structural changes shall be carried out. (a) Wherever it is considered necessary by the accredited person or his authorized representative and wherever it is practical and advisable to avoid disassembly of equipment, removal of pins, etc., examination of structure or parts by electronic, ultrasonic, or other nondestructive methods may be carried out, provided that the procedure followed is acceptable to the Assistant Secretary and the person carrying out such examination is accredited or acceptable to the Assistant Secretary for the purpose. (a) Wire rope and replacement wire rope shall be of the same size, same or better grade, and same construction as originally furnished by the equipment manufacturer or contemplated in the design, unless otherwise recommended by the equipment or the wire rope manufacturer due to actual working condition requirements. In the absence of specific requirements as noted, wire rope shall be of a size and construction suitable for the purpose, and a safety factor of 4 shall be adhered to, and verified by wire rope test certificate. (b) Wire rope in use on equipment previously constructed and prior to initial certification of said equipment shall not be required to be tested, but shall be subject to thorough examination at the time of initial certification of the equipment. (a) Wherever heat treatment of any loose gear is recommended by the manufacturer, it shall be carried out in accordance with the specifications of the manufacturer. (a) Those portions of bulk cargo loading or discharging spouts or suckers which extend over vessels, together with any portable extensions, rigging components, outriggers, and attachment points supporting them or any of their components vertically, shall be examined annually. The examination shall be carried out with particular attention to the condition of wire rope and accessories. The equipment shall not be considered satisfactory unless, in the opinion of the accredited person or his authorized representative, it is deemed fit to serve its intended function. (a) Documents issued respecting a certification function by an accredited person shall be on forms approved for such use by the Assistant Secretary and shall so state. (b) Such documents shall be issued by the accredited person to the owners of affected equipment, attesting to satisfactory compliance with applicable requirements. The forms used shall contain the following information: (1) Unit proof tests where required— (i) Identification of crane or derrick including manufacturer, model number, serial number, and ownership. (ii) Basis for assignment of safe worksigned (i.e., whether based on manufacturing load ratings, with the ratings asturer's ratings, whether for any specific service, etc.). (iii) Proof test details noting radii and proof loads, how applied, and, where applicable, direction relative to mounting. (iv) A statement that the test and associated examination were conducted and all applicable requirements of this subpart are met. (v) Any necessary remarks or supplementary data, including limitations imposed and the reason thereof. (vi) Name of accredited person and identification of authorized representative actually conducting test and/or examination. (vii) Authorized signature of accredited person; date and place of test and/or examination. (2) Annual examination of cranes or derricks— (i) Information specified in paragraphs (b)(1) (i), (v), (vi), and (vii) of this section. (ii) A statement that the required examination has been carried out and that, in the opinion of the accredited person or his authorized representative, the equipment has been found in compliance in all applicable respects with the requirements of this subpart. (3) Annual examination of bulk cargo loading or discharging spouts or suckers— (i) Specific identification of equipment. (ii) A statement that examination has been completed and that, in the opinion of the accredited person or his authorized representative, the equipment meets the criteria of §1919.81(a). (iii) Information specified in paragraphs (b)(1) (v), (vi), and (vii) of this section. (c) Certificates relating to wire rope, whether tested by or under the supervision of the accredited person or by its manufacturer and whether or not issued on the basis of the manufacturer's certificates, shall follow the general format of a wire rope test form approved by the Administration. (d) Accredited persons shall advise owners of affected equipment of the necessity for maintaining required documentation or acceptable copies thereof available for inspection at or near the worksite of the equipment involved. (1) Where initial and periodic tests as well as annual examinations are required, documentation available for inspection shall include the latest unit test certificate and any subsequent annual examination certificates, together with wire rope test certificates relating to any replacements since the last unit test or annual examination. (2) Where only annual examination is required, documentation available for inspection shall include the latest annual examination certificate and wire rope test certificates relating to any wire replaced since the last annual examination. (3) In the event that the heat treatment of any loose gear is recommended by its manufacturer, the latest heat treatment certificate, attesting to compliance with the manufacturer's specifications, shall be part of the available documentation. (e) No certification shall be issued until any deficiencies considered by the accredited person to constitute a currently unsatisfactory condition have been corrected. Replacement parts shall be of equal or better quality than original equipment and suitable for the purpose. In the event deficiencies remain uncorrected and no certification therefore is issued, the accredited person shall inform the nearest district office of the Administration of the circumstances. [39 FR 22096, June 19, 1974, as amended at 61 FR 5509, Feb. 13, 1996]
Title 29: Labor
PART 1919—GEAR CERTIFICATION
Subpart H—Certification of Shore-Based Material Handling Devices
§ 1919.70 General provisions.
§ 1919.71 Unit proof test and examination of cranes.
§ 1919.72 Annual examination of cranes.
§ 1919.73 Unit proof test and examination of derricks.
------------------------------------------------------------------------ Safe working load Proof Load------------------------------------------------------------------------Up to 20 tons............................ 25 percent in excess.20-50 tons............................... 5 tons in excess.Over 50 tons............................. 10 percent in excess.------------------------------------------------------------------------
§ 1919.74 Annual examination of derricks.
§ 1919.75 Determination of crane or derrick safe working loads and limitations in absence of manufacturer's data.
§ 1919.76 Safe working load reduction.
§ 1919.77 Safe working load increase.
§ 1919.78 Nondestructive examinations.
§ 1919.79 Wire rope.
§ 1919.80 Heat treatment.
§ 1919.81 Examination of bulk cargo loading or discharging spouts or suckers.
§ 1919.90 Documentation.
