What is Proof Load Testing and Overload Testing?
When conducting a LOLER test, it’s important to understand the differences between proof load testing and overload testing. A proof load test is required to comply with LOLER, whereas an overload test could cause unnecessary risk to the equipment.
Proof Load Testing
To determine if lifting equipment can safely handle loads without sustaining permanent damage or failure, proof load testing is used. During this test, the equipment is subjected to a load greater than its normal working load limit. The goal is to ensure the equipment can function reliably under normal conditions without risk of collapse or damage.
Overload Testing
On the other hand, overload testing involves applying loads beyond the designed capacity of the equipment to assess its breaking point or to simulate extreme conditions. This test is more destructive and is generally not performed unless required by specific engineering standards. Proof load testing, which is non-destructive, is far more common and is crucial for ensuring equipment safety under normal operating conditions.
When is Proof Load Testing Required?
Like LOLER test frequencies, a proof load test is usually required before lifting equipment’s first use, after installation, before use in a new location and subsequent milestones during the equipment’s lifespan. Although LOLER inspections don’t always require a proof load test, the competent person should possess the experience, training, and confidence with the equipment to determine, through a thorough examination, whether a proof load test will be necessary.
LOLER specifies that certain types of lifting equipment must undergo proof load testing at regular intervals, particularly any equipment subject to heavy usage, environmental stress, or potential wear and tear, to ensure it remains safe for operation. The frequency required will depend on the type of equipment and is detailed under several regulations and standards:
- Supply of Machinery (Safety) Regulations 2008
- BS EN ISO standards
- Health & Safety at Work Act 1974
- Or, specific equipment manufacturer’s guidelines
What Types of Lifting Equipment Require a Proof Load Test?
Various types of lifting equipment and accessories must undergo proof load testing to ensure their safety and functionality. Some common examples include:
- Cranes: Overhead cranes and mobile cranes used in construction and industrial environments.
- Hoists: Manual, electric, or hydraulic hoists used for lifting materials.
- Slings and Shackles: Equipment used for supporting and securing loads.
- Lifting Beams and Spreader Bars: Devices used to distribute loads during lifting operations.
- Forklifts: For specific applications, such as lifting personnel.
- Load-bearing Lifting Accessories: Including hooks, eyebolts, and chains.
All of these devices play key roles in a business’ lifting operations and must be tested regularly to prevent failure and avoid the implications of non-compliance compliance with safety regulations and LOLER.
How is Lifting Equipment Tested?
The first step in a proof load test procedure is securely positioning the lifting equipment so it’s stable and ready for assessment. Once secure, a calibrated load, typically heavier than the equipment’s normal operational capacity, is then applied using specialised tools like test weights or hydraulic systems. Typical lifting movements and exercises are then completed to evaluate the equipment’s abilities whilst working under pressure.
Throughout the test, inspectors monitor the equipment to identify any signs of stress, deformation, or other potential failures. Once the load is released and the exercise complete, the equipment must undergo a thorough inspection for any damages. If no defects are found, the equipment is approved for continued use. If any faults or problems are identified, the necessary repairs must be completed, followed by another round of thorough testing before the equipment can be used again.
How to Accurately Measure the Proof Load
To accurately measure proof load, calibrated test weights or hydraulic load cells that are specifically designed for precision and accuracy are required. These devices attach to the lifting equipment, and the applied load gradually increases while being closely monitored. The key to accurate and true measurement is ensuring that the test setup mimics actual working conditions as closely as possible. Strain gauges can also be used to measure the force exerted on some components of lifting equipment, allowing for detailed analysis of stress and strain levels during the test.
What Loads Are Applied in a Proof Load Test?
In a proof load test, the load applied is generally between 1.25 to 1.5 times the maximum working load limit (WLL) of the equipment. This extra load depends on the equipment’s design, its intended use, and the safety requirements of the particular application. For example:
- Lifting gear used for people may require a more conservative proof load (typically 1.25 times WLL).
- Industrial cranes may undergo a higher factor test (up to 1.5 times WLL) to ensure robust performance in heavy-duty environments.
Is Load Testing a Legal Requirement?
Yes, load testing is a legal requirement under the LOLER regulations. These regulations stipulate that all lifting equipment used in workplaces must be thoroughly examined by a competent person at regular intervals, including proof load testing when necessary. The frequency of these tests depends on the type of equipment and how it is used, but generally, a thorough examination is required every 6 to 12 months.
Not all LOLER tests require load testing but load tests are a legal requirement at specific integral depending on the equipment.
What Records Should Be Kept of Proof Load Tests?
Keeping detailed records of proof load tests is essential for both compliance and safety. LOLER regulations state record-keeping requirements for each test, including:
- Date of the test: When the proof load test was performed.
- Equipment details: The type of lifting equipment tested, including serial numbers or identification marks.
- Test results: Whether the equipment passed or failed the proof load test, and any issues observed.
- Name of the inspector: The competent person who performed the test.
- Corrective actions: If applicable, details of any repairs or modifications made following the test.
These records should be kept for the lifespan of the equipment and made readily available during inspections or audits. Proper documentation not only demonstrates regulatory compliance but also helps track equipment performance over time, ensuring long-term safety and efficiency.
At Bramley Engineering, we like to make this easy by offering an easy-access online database for you to access after our LOLER inspections. Whenever we examine and test your equipment, your LOLER certificates and records will be automatically uploaded to our online portal where you will have 24/7 access to your own secure online account.
Book your LOLER inspection or Proof Load Test today
We’d recommend relying on third-party companies like ours to handle your LOLER inspections and proof load tests so you can trust the competent person has the necessary LOLER qualifications and accreditations. Our comprehensive LOLER inspection and proof load testing services ensure your equipment is inspected by certified professionals, keeping your business and equipment safe, compliant, and operational. We also offer convenient reminders and notifications for upcoming inspections and store all your LOLER certificates securely online.
Start by requesting a free quote. If you’re happy, we’ll schedule the test at a time that suits you. We provide thorough examinations, equipment assessments, and expert safety guidance to help you meet UK Health & Safety requirements. Our goal is to offer accurate, timely inspections that prioritise your safety and compliance.
Request your free quote today, get in touch, or call us at 01525 375225 for more details.
