TUV SOUTHWEST

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PROCEDURE FOR INSPECTION AND

CERTIFICATION OF

CHAIN BLOCK & LEVER HOIST

Prepared By: Mohammed Nisar

Reviewed By: Naresh Kumar

Authorized By: Waqas Arshad

Procedure Ref #.: SW/TIP-CLH/001 Rev.03 Issue Date:12/02/2019

This is an official document of TUV South West. Printed copies without the original seal of the company is “Uncontrolled Copy”.
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I NDEX

1.0 Intent
2.0 Cleaning
3.0 Examination
4.0 Load chain – Examination
5.0 Body and Internal Mechanism – Examination
6.0 Acceptance and rejection Criteria
7.0 Reporting

This is an official document of TUV South West. Printed copies without the original seal of the company is “Uncontrolled Copy”.
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Objective:

To define and outline the responsibilities, sequence and procedural requirements for
Chain Block and Lever Block Inspection in accordance with International Standards
mentioned below.

Scope:

This procedure covers all Inspection bodies in all areas.

Duties / Responsibilities:
 The Inspector assigned for the job has to be a competent person with
sufficient experience and knowledge in the inspection/ test of lifting
equipment.

 Lifting head is responsible for the review of this Procedure.

 Lifting head is responsible for the preparation and revision of this procedure.

 The dept manager is responsible for the review of the procedure and General
Manager is responsible for the Approval.

Relevant Standards and Code of Practice

SN Applicable Standards Title Identifier

1 BS EN 13157:2004+A1:2009 Cranes Safety, Hand Powered Cranes

2 Short link chain for lifting purposes, safety, fine tolerance

BS EN 818-7:2002+A1:2008
hoist chain, Grade T(Types T, DAT, DT)
UAE. Federal Ministry of Law Federal Ministry of Law and Social Affairs, 10.1.83 - M.O. No:
3
10.1.83 32 – Article 20
Note:
1. Also, considerations and reference to the standard /code to which the equipment has been built has to be
given due attention.
2. Related reference standard may also be referred during inspection / test.
3. In addition to requirements stipulated in this document, Project site/ Client specific requirements are applied
and shall be followed all the time.

The Documents to be reviewed prior to examination are:

 Record of Pre use & in-services check lists
 Previous Reports of thorough examination
 Lifting attachments marked with their safe working load
 Individual Certifications of personnel involved
 Maintenance records
 Check identification and SWL is clearly marked on the chain block/lever hoist. Then
compare these marking against the current test certificate
 Prior to performing any tests loads, the manufacturer’s instructions should be
obtained or alternatively, a referenced authority on the design and construction of
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the crane. The said Information should be consulted, understood and implementation
prior to test load

Procedure Instructions:

Site Conditions
 Before proceeding for inspection, the site of lifting appliances/gears should be assess
properly.
 The site should be free from any hazards or danger during testing.
 Site location should have enough lighting.
 The testing facility should be available for load test if necessary.
 There should be enough space for the worker to move around.
 In case of emergency, there should be evacuation point available.
 Fire extinguisher & first aid box should be nearby.

Weather Conditions
 The weather should be in good condition for testing. Excessive heat, fog or sand
storm should be avoided for safety purposes.
 Gusting wind conditions will make safe handling of the load unsafe and dangerous.
 During testing, in case of sudden change of weather, always be alert and stop the
test once hazards occur immediately.

Toolbox Meeting
 Before proceeding in any kind of job, test or inspection, a Toolbox Meeting should be
conducted that focuses on safety topics related to the specific job, such as workplace
hazards and safe work practices.

Test weights
Test weights used should be:
 Weights of proven accuracy to within ± 2%
 Weights proven on weighbridge, valid 12 months calibration certificate required.
 Weights suspended from calibrated weighing device, 12 month calibration certificate
required.

Preparation of PPE & Tools:

The inspector should ensure that:
 Personal safety equipment that is appropriate for the conditions of the location is
available, such as helmets, safety spectacles, fall protection equipment, safety boots,
ear defenders and life jackets or other buoyancy aids;
 Equipment is inspected before and after use and maintained in good working order
 Ensure all the equipment used during inspection/test i.e caliper, Spirit Level,
measuring tape, Load cell etc shall be in good condition and shall be certified where
ever applicable.

Examination:-
 The manufacturer design must be stand on SF: 4:1, 1500 cycles & 110% of rated
capacity.
 Examine test certificate for correct detailing.
 Markings should be clear and legible.
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 The item should be dimensionally verified as per manufacturer’s specifications.

Visual Examination

Top and Bottom Hook:

 Examine top and bottom hook for excessive wear, distortion, stretch, cracks and
corrosion. Check suspension pin for cracks, distortion and wear, localized wear or
reduction in diameter will render the pins as scrap.
 Ensure hooks swivel freely.
 Check that a safety catch is fitted to both hooks and that they close properly.

Note: Wear on hooks shall not exceed 8% of the original bearing section, and hook admittance shall
not exceed the manufacturer’s tolerance.

Load Chain – Examination

 Load chains shall be in accordance with EN 818-7, for fine tolerance short link
chains (grade T).
 Clean and lubricate along the whole length of the load chain, especially at contact
points between the links.
 Check load chain for wear, faulty welds, cracks, distortion, stretch, corrosion or
damage. Allowable wear shall not exceed 8% reduction of the original link
diameter.
 Measure the length of eleven chain links to check for stretching. The allowable
stretch shall not exceed 5%.
 If the load chain is damaged, examine load wheel sprockets for wear and correct
seating. Check load chain anchorage, or load chain end stop where fitted.
 Slack end anchorage requires the free end of the chain to be fitted with a end
stop to prevent the chain passing completely through. The stop should withstand
2.5 times of rated load tension.

Body and Internal Mechanism – Examination

 Examine case body and handle arm for cracks, distortion, missing bolts/screws
and any other possible defects that may interfere with the safe operation of the
equipment.
 Ensure chain guide rollers and chain strippers are correctly positioned and
functional.
 Operate lever arm in both hoisting and lowering modes to ensure correct
operation of pawls and direction changing mechanisms.(lever hoist)
 A deformed or bent operating lever will suggest that the lever hoist has been
overloaded and should be removed from service for complete overhaul

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 Suspend chain block and spin hand chain wheel in both directions to ensure
correct function of ratchet pawl.
 A clicking sound should be heard during normal working condition. If this is not
the case it is possible that the pawls are seized or the spring is broken.
 Check for wear on the ratchet teeth, profile and pawl. The pawl must engage fully
in the ratchet teeth. Check the pawl stud is firmly secure.
 Inspect chain guards for damage, wear or deformation.
 Ensure correct alignment of load chain guide and stripper.

Functional Test:

 Lifting equipment works at rated capacity as intended and all functions confirm
to the requirement and with the technical documentation.

Load Test:

Light Load Test:

A test load of between 2% and 10 % of the rated capacity which will be raised and lowered
through a height of between 250 mm and 500 mm

Static Test:
1. Rated capacity less than 20 t
1.5 times X Rated Capacity
2. Rated capacity Greater than or equal to 20 t
1.25 times X Rated Capacity
Note: Load shall be hold atleast 10 minutes. The test shall be considered satisfactory if no cracks,
permanent deformation or damage that would adversely affect the function or safety of the lifting
equipment is visible, and the connections have not become loose or damaged and if the braking
device can hold the load without slipping and if it is possible to perform the dynamic test with the
same lifting equipment after the static test.

Dynamic Test:
Rated Capacity X 1.1 times
Note: Tests shall be carried out for each lifting equipment movement under the most unfavorable
conditions. The tests shall comprise repeated stopping and starting for each machine movement.
The test shall be considered satisfactory if the lifting equipment has carried out all its functions, and
that when examined after the test, there is no damage to the mechanisms or structural elements,
and that the connections have not become loose or damaged.

This is an official document of TUV South West. Printed copies without the original seal of the company is “Uncontrolled Copy”.
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Acceptance / Rejection Criteria

COMPONENT DEFECT TYPE REJECTION CRITERIA

a) Wear in excess of 8% of original link dimensions.

a) Wear b) Cracks, heat damage, severe nicks, gouges or
distortion of links
b) Damage
Load Chain c) Excessive corrosion, pitting or any chemical
c) Corrosion
(Round Link) attack.
d) Reeving
d) Load chain reeving incorrect.
e) Gauge Length
e) Load chain gauge length increase greater than
3%.

a) Wear in excess of 8% of original link or pin

dimensions.
a) Wear
b) Cracks, heat damage, severe nicks, gouges or
Load Chain b) Damage distortion of links

(Plate Link) c) Corrosion c) Excessive corrosion, pitting or any chemical

attack.
d)Gauge Length
d) Load chain gauge length increase greater than
3%.

a) Wear in excess of 8% of original diameter.

Chain a) Wear
Anchorage b) Any cracks or distortion.
b) Damage
c) Excessive corrosion, pitting or any chemical
c) Corrosion
attack.

a) Wear
a) Broken or distorted links.
Hooks b) Damage
b) Any cracks, excessive wear or distortion.
c) Corrosion

Block Body a) Damage a) Any mechanical damage or loose covers.

Manual Drive a) Chain a) Broken or distorted links.

(where fitted) b) Drive sprocket b) Any cracks, excessive wear or distortion.

a) Damage a) Cracked or broken operating lever

Ratchet Lever
b) Operation b) Incorrect or labored drive operation.

This is an official document of TUV South West. Printed copies without the original seal of the company is “Uncontrolled Copy”.
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REPORTING

On completion, record examination details and issue report to OIM, or designated

Supervisor. If the chain block is considered to be unsafe for continued service, a copy of
the last examination report must be sent to the company safety officer within 7 days.

S.No Control Name Retention Period Document No.

1 Inspection Report or Certificate of Inspection 3 years FL/02

2 Filled-up Inspection Checklist / Rough Reports 1 year FL/02

This is an official document of TUV South West. Printed copies without the original seal of the company is “Uncontrolled Copy”.
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