Hoist, Winch and Man Rider Winch Inspection and Load Testing
Third-party inspection and load testing of chain and lever hoists, wire rope hoists, air winches, man rider winches and beam trolleys.
Hoists and winches carry load continuously in service and degrade in ways that are not visible from outside: brake linings wear, load chains stretch and rope cores corrode inside an apparently sound outer layer. They are also the items most often left in place and used daily, which is why they are the ones most often overdue. itmad inspects and load tests hoists, winches and beam trolleys, including winches used to lift people. itmad operates across the Middle East, Asia and Europe.
Equipment inspected
Manual and powered chain hoists, lever hoists and pull lifts, wire rope hoists, air and pneumatic winches, electric and hydraulic winches, man rider winches, beam trolleys and push travel units, and Tirfor and wire rope pullers.
Man rider winches
Equipment used to lift people is held to a materially higher standard than equipment lifting loads, and is inspected accordingly. The examination covers the secondary or fail-safe brake and its independent function, rope condition against the tighter discard criteria applied to personnel lifting, controls including deadman operation, and emergency lowering under load. It also confirms the correct reduced working load limit for man riding, which is not the load rating marked on an equivalent goods hoist. Inspection intervals are shorter and are not negotiable against operational convenience.
What the inspection covers
The inspector verifies identification, safe working load marking and traceability to certification, and reviews the history, previous certificates and any repair records. Load chain is examined for stretch against the manufacturer's limit, wear at the bearing surfaces, nicks, gouges, twisted or bent links and corrosion. Wire rope is assessed against ISO 4309 discard criteria, and rope terminations, wedge sockets, dead-end anchoring and minimum dead turns on the drum are checked, along with drum and sheave condition, groove wear and correct spooling.
Brake function and holding capability under load are tested, including secondary brakes where fitted, and load limiter and overload protection are tested where fitted. Upper and lower limit switches on powered units are checked, hooks are examined for throat opening, twist, wear and cracking with magnetic particle inspection where the condition or standard requires it, and the safety latch, swivel and suspension arrangement are inspected. Gearbox and drive condition, lubrication and leakage are examined, as are the air supply, lubricator and control valves on pneumatic units, and for beam trolleys the wheel and flange wear and compatibility with the beam they run on.
Load testing
Proof load testing is carried out on new equipment, after repair or replacement of a load-bearing component, after installation in a new position, and at the intervals that the client's specification requires. The load is applied at the multiple of safe working load that the applicable standard states, with brake holding, lowering control and structural condition verified during and after the test, using calibrated weights or load cells with recorded values.
Standards applied
Inspection follows the standard that the contract or governing authority specifies. The most commonly applied are ASME B30.16 for overhead hoists, B30.21 for lever hoists, B30.7 for winches and B30.23 where equipment is used for personnel lifting, together with ISO 4309 for wire rope discard criteria and LEEA codes of practice. The manufacturer's inspection and maintenance requirements are applied alongside, since they set component-specific limits that the standard does not detail.
Inspection intervals
The governing authority, the equipment type and the operating environment set the interval. Twelve months is a common baseline for lifting appliances, reduced to six months or less for equipment used to lift persons and for units in offshore, corrosive or high-duty-cycle service. Inspection is also needed after any overload event, after repair, and where the history of the equipment is unknown. Where itmad holds the client's equipment register it tracks due dates and gives notice before certificates lapse.
Where and how
Inspection takes place at the client's site, yard or offshore facility, and can be scheduled alongside crane and lifting gear inspection in one attendance.
What the client receives
An inspection certificate in the format that the governing authority requires, and a report that identifies each unit by serial number, capacity and location. Findings are recorded component by component with photographic evidence of defects, defects are classified by severity, and load test results record the applied load and post-test condition. Equipment is tagged on site with colour coding, and the lifting equipment register is updated where itmad holds it.
Frequently asked questions
What hoists and winches does itmad inspect?
Manual and powered chain hoists, lever hoists, wire rope hoists, air, electric and hydraulic winches, man rider winches, beam trolleys, and Tirfor and wire rope pullers. Inspection can be combined with crane and lifting gear inspection in one attendance.
Why are man rider winches inspected differently?
Equipment used to lift people is held to a materially higher standard. The inspection covers the independent secondary brake, the tighter rope discard criteria, deadman controls, emergency lowering under load and the reduced working load limit for man riding.
How often must hoists and winches be inspected?
Twelve months is a common baseline for lifting appliances, reduced to six months or less for equipment used to lift persons and for offshore, corrosive or high-duty-cycle service. Inspection is also required after an overload, after repair, and where the history of the equipment is unknown.
Which standards apply?
ASME B30.16 for overhead hoists, B30.21 for lever hoists, B30.7 for winches and B30.23 for personnel lifting, with ISO 4309 for wire rope and LEEA codes of practice. The manufacturer's requirements are applied alongside the standard.
What is checked on load chain?
Stretch against the manufacturer's limit, wear at the bearing surfaces, nicks, gouges, twisted or bent links and corrosion. Hoist brakes are also tested for holding capability under load.
How is load testing carried out?
The load is applied at the multiple of safe working load that the standard states, using calibrated weights or load cells with recorded values. Brake holding, lowering control and structural condition are verified during and after the test.