A crane load chart is the manufacturer's table that shows how much a crane can safely lift at each radius, boom length and setup. Crane load testing proves the crane can really handle those rated loads: the crane lifts a test load, typically up to 125% of its rated load, to confirm that hoisting, travel, limit switches, locks and safety parts all work before the crane goes into service.
Every load chart lists the crane's rated capacity for each combination of radius, boom length and crane configuration. Before a lift, the operator works out gross capacity, net capacity and capacity deductions, and checks range, work area and parts-of-line. Using the right chart for the way the crane is actually set up is just as important as the math.
Load charts are a big part of crane operator certification. On the CCO mobile crane written exams, load charts make up 26% of the Core Exam and 35% of the Specialty Exam. Our online CCO prep courses include a full load chart module with practice problems ($399, $499 or $599 depending on specialties, with 90-day access), and our 2-day live webinar prep course ($995 per person) covers load charts in its classroom sessions.
During load testing, cranes are intentionally subjected to excessive loads in order to assess their operational capabilities. It is imperative that the cranes are able to safely lift and move the loads under normal operating conditions. Typically, the crane lifting equipment is subjected to overload tests of up to 125% to ensure compliance with OSHA standards. Daily inspections are conducted to scrutinize hoist chains, wire ropes, and locks, while comprehensive or rigorous load tests should be conducted semi-annually or periodically.
A crane load test checks that the crane can safely lift and move the test load through its normal motions. The test weight is based on the rated load from the crane's load chart and should not exceed 125% of it unless the manufacturer recommends otherwise.
To ensure the safety and productivity of your operators and workplace, it is crucial to stay updated on the latest practices regarding crane load management and ensure that your crane equipment is in optimal working condition. This section provides valuable insights into the essential pre-service operational inspection and load testing procedures that are required.
These protocols are standard parts of crane maintenance and training programs:
All newly installed or modified overhead cranes must undergo a thorough inspection and testing to verify the proper functioning of the following essential features:
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Rated load testing
Load testing should not exceed 125 percent of the rated load unless specifically recommended by the manufacturer. When it comes to workplace safety, it is crucial not to overlook any aspect of the equipment inspection and support process, including thorough testing of equipment prior to its operational use.
Prior to initial use, all newly installed or modified cranes must undergo comprehensive testing to ensure compliance to the requirements outlined in this section including the evaluation of the following key functions:
The trip function of the hoist limit control needs to be thoroughly tested by gradually increasing the speed of an empty hook up to the maximum speed limit. The control device responsible for activating the limiter should be positioned in a manner that ensures the switch is triggered under all circumstances, allowing enough time to prevent any contact between the hook or hook block and the trolley components.
On construction sites, cranes fall under OSHA's cranes and derricks in construction rule (29 CFR 1926.1400). The same basics apply to construction crane load testing: test new, repaired or modified cranes before use, stay within 125 percent of the rated load unless the manufacturer says otherwise, and make sure the load chart in use matches how the crane is set up on site. Operators must also be certified for the crane type and capacity they run. See our crane operator training for the construction industry and our current dates and locations.
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