Guidance on Load Testing Suspended Access Equipment

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1 Guidance on Load Testing Suspended Access Equipment SPECIALIST ACCESS ENGINEERING AND MAINTENANCE ASSOCIATION (This document must be read in conjunction with the SAEMA document: Guidance on Using Suspended Access Equipment.) CONTENTS: 1. Introduction 2. Scope 3. Background 4. SAEMA position 5. Aim 6. Health and Safety 7. Recommended Testing Procedure 8. SAEMA Load Test Certificate 1. Introduction Permanently installed suspended access equipment is designed and installed to provide a suspended platform that gives safe access to areas of a building or other permanent structure and to serve only that structure. Such installations are customarily used for window cleaning and light building maintenance. The Construction (Design and Management) Regulations 1995 (CDM Regulations) [1] require that all facades including windows and skylights are designed and positioned so that they can be accessed safely. The requirements for permanently installed access equipment should be considered at an early stage in the building design process. Disclaimer: Whilst every effort has been made to provide reliable and accurate information, we would welcome any corrections or information provided by the writer which may not be entirely accurate, therefore for this reason, SAEMA or indeed the writer, cannot accept responsibility for any misinformation posted. 1

2 2. Scope This guidance gives recommendations for the ongoing testing of permanently installed suspended access equipment and not the initial handover/commissioning tests covered in BS EN Background This document complies with the provisions of: The Workplace (Health, Safety and Welfare) Regulations The Management of Health and Safety at Work Regulations - particularly regulation 3(1) Provision and Use of Work Equipment Regulations 1998 (PUWER98) Lifting Operations and Lifting Equipment Regulations 1998 (LOLER 98) BS : 2003 Code of practice for the planning, design, installation and use of permanently installed access equipment - Part 1: Suspended access equipment; in particular, sections 14 and 19.1 to 19.4 inclusive. LG3 Guidelines for the Thorough Examination of Suspended Access Equipment and Building Maintenance Units (Permanently installed) 4. SAEMA Position 4.1 SAEMA recommends that all in-service activities concerning suspended access equipment use BS as a baseline since, as a code of practice, it is considered to be good practice. Failure to comply with BS may result in successful prosecution in a legal action. 4.2 Duty holders should note that they have legally required duties and responsibilities towards the suspended access equipment and all those that use it. Those duties and responsibilities are laid down in PUWER98, LOLER98 and highlighted in BS6037-1; ignoring these documents leaves the duty holder in peril of prosecution under health and safety legislation. 4.2 Note that a duty holder is defined in BS as a designated person with management responsibility for the safe use, maintenance and thorough examination of suspended access equipment. 4.1 Load testing is a crucial aspect of the management of suspended access equipment. Even though normally only an annual event, it is a procedure that cannot be rushed or shortcut - essentially, it is comparable to the MOT test for road vehicles in that it is primarily concerned with safety. If the equipment is unsafe, then so are those that use it. Suspended access equipment must be load tested following modification or repair to safety critical components. In such circumstances, the test is additional to the annual load test. 5. Aim 5.1 The principal purpose of this document is to provide guidance to organisations engaged in load testing suspended access equipment on how they can do so in a safe, structured and orderly manner. 5.2 It should also help duty holders to understand better what is required of the testing organisation. Normally, the testing organisation will be the company employed to maintain the suspended access equipment. All SAEMA members are bound to comply with this document.. 2

3 6. Health and Safety 6.1 Duty holders are legally required to conduct a risk assessment of the suspended access equipment, the access routes to it and its surroundings. However, the suspended access equipment maintenance organisation might be better placed to conduct such a risk assessment in consultation with other interested parties, such as window cleaners. 6.2 Only suitably trained and experienced persons shall conduct or supervise load testing. 6.3 All personnel involved in the testing shall wear the appropriate personal protective equipment (PPE). 7. Recommended Testing Procedure 7.1 Note that it may be necessary to include a statutory thorough examination (LOLER 1998) of specific items (eg: dismantling swivel pins and subjecting them to visual inspection followed by nondestructive tests) as part of the testing regime; BS recommends that a load test should be carried out on the suspended access equipment at intervals of twelve months. After every two years service, the load testing should be arranged by the duty holder to coincide with a thorough examination in order to allow the competent person carrying out the thorough examinations to witness the load testing in accordance with SAFed guidance note LG3 Guidelines for the Thorough Examination of Suspended Access Equipment and Building Maintenance Units (Permanently installed) 7.2 Immediately prior to commencing the test procedure, review the risk assessment to ensure that no changes in hazards exist. Additional hazards and their associated controls should be noted on the risk assessment and thus incorporated into it; this then becomes the working risk assessment. 7.3 Implement all the controls specified in the working risk assessment. Where it is not possible to implement the controls, consideration must be given to abandoning the test until such time as the controls can be implemented. If the test cannot be completed until more than twelve months after the previous load test certificate, the suspended access equipment must be placed out of service until the load test has been successfully completed. 7.4 The duty holder should make available the equipment operating manuals, and any other relevant documents, and ensure that these have been read and understood by those involved in the testing 7.5 Closely inspect visually and check the complete installation undergoing testing. This includes but is not limited to the following: The equipment undergoing testing should be complete and in serviceable condition The information plates (ID plates), etc must match the suspended access equipment inventory (also known as the equipment schedule or the equipment log) Look for signs of corrosion, damage, distress, dislodged items and overstrain, etc; where practicable, report any defects prior to the load test. Defects may be left uncorrected only when they do not affect the outcome of the load test, or are not made worse by the effects of the load test. If the equipment is electrically powered, the mains supply should be fitted with RCD s at the correct rating. Check that the RCD s operate correctly Any power cables and their connections, etc should be serviceable and electrically safe Electrical controls, hoists, motors and gearboxes, etc operate as designed Moving parts do not show signs of undue wear All moving parts operate freely 3

4 All connections are sound7.5 No bolts are loose or missing Suspension ropes, hooks and terminations, etc are serviceable Traverse and luff ropes, etc are serviceable Limit switches, stops and safety features etc are fitted, adjusted correctly and operate All required signs are in place, current and legible 7.6 Rig the platform (generally known as a cradle ) to its designated suspension rig. as stated in the Operation and Maintenance (O&M) Manual. 7.7 Load the equipment with its Rated Load Normally this will be either the safe working load (SWL) or the working load limit (WLL), found on the information plate. The load can be the designated number of operators, test weights, self weight of platform or a combination of them. 7.8 Where a platform is not available an assessment and application of the appropriate test load must be determined by the person responsible for carrying out the test. 7.9 Test Weights (where a platform is used) 7.9 Test weights normally weigh 25 kg each. They should be loaded into the platform using accepted manual handling methods and the following recommendations: Two persons are frequently required for this operation, one inside the platform and the other outside Each person must wear suitable gloves and safety boots Only one weight should be handled at a time Personnel should check that each test weight is secure before releasing their grip. The Load should be placed in the platform in such a way that the overall weight is evenly distributed within the platform Raise the platform so that it is just clear of the ground or roof Traverse the platform slowly around the building whilst checking the anchorages to the building for movement, distress, deformation and cracking, etc To replicate the use of the platform when in service operate the platform over its full range of movements as necessary whilst checking all the mechanical functions, limits, safety devices, and restraint systems, etc for correct operation Some equipment may have materials lifting equipment as part of the system Testing Procedure for Systems Fitted with Materials Lifting Equipment. Some Building Maintenance Units (BMU s) and Travelling Gantry s and Ladder systems (TGLS) are designed and supplied with a Glass Replacement Unit (GRU). The GRU which can either be a complete materials lifting system for such tasks as replacement of window glass/cladding panels, or an anchor point to allow a proprietary Material Lifting Hoist to be attached. Where such a lifting system or anchor point is provided as part of the BMU equipment it should be incorporated into the LOLER inspection and testing regime Equipment with complete materials lifting systems: Determine the load involved: - The WLL of the GRU system should be clearly marked. If this is not the case the Duty Holder should be asked to provide the loading details, which he should be able to do via the equipment manufacturers handbook. 4

5 7.16 Set up of testing equipment: - The system should be set up as per the manufacturers instructions and the attachment hook or fitting of the GRU equipment attached to the test load Test Load to be used for the GRU: - The load to be used will be equal to 100% of the stated capacity of the GRU Method of testing: - The cradle of the BMU will be loaded with its test weight (100% WLL) and raised from the ground or landing place. With the cradle and its test load suspended, the GRU test load will be raised. When the total load is suspended the anchorage of the BMU to its track system shall be inspected for its full range of operations and any defects noted. The GRU test load will then be lowered to the ground or landing place. The cradle will then be lowered to the ground or landing place and the cradle test weights and the GRU test weights removed Equipment with anchor points only: Determine the load involved: - Where any anchor points for lifting operations are provided they must have the WLL clearly marked. If this is not the case the Duty Holder should be asked to provide these loads, which he should be able to do via the equipment manufacturers handbook Set up of testing equipment: - The wire rope or chain of a piece of proprietary lifting equipment (e.g.: electric or manual hoist unit which ever is specified in the user manual) should be attached to the anchor point. The hook or other fitting of the electric or manual hoist unit is then attached to the test weight Test Load to be used for the GRU: - The test loads (the test weight plus the weight of the proprietary lifting equipment and its rope or chain) to be used should be equal to the WLL marked on the BMU Method of testing: - The cradle of the BMU will be loaded with its test weight (100% WLL) and raised from the ground or landing place. With the cradle and its test load suspended, using the proprietary lifting equipment the GRU test load will be raised. When the total load is suspended the anchor point on the BMU and the system of anchorage of the BMU to its track system shall be inspected for its full range of operations and any deflects noted. The GRU test load will then be lowered to the ground or landing place using the proprietary lifting equipment. The cradle will then be lowered to the ground or landing place and the cradle test weights and the GRU test weights and proprietary lifting equipment removed. Notes: - The tests described in 7.1 and 7.2 above are for the proving of the stability of the BMU system for when/if the GRU system is taken into use. The lifting equipment and accessories of the GRU should be treated as an independent system and inspected and tested as such under a separate LOLER regime. Under this regime it may well be necessary to remove the lifting appliance from the BMU and return it to the workshop for thorough examination and testing. 5

6 7.20 Re-inspect and check the complete installation 7.21 If any defects are found that do not affect the safe operation of the equipment: Make accurate notes of the problem, including a sketch of the location if necessary, and include the equipment serial number and manufacturer s details If necessary, mark the suspect equipment with a permanent marker to ease identification If appropriate, take photographs Inform the Duty Holder Issue a report 7.21 If the suspended access equipment does not successfully complete the test: Immediately mark the equipment as Out of Operation, using a suitable notice Inform the duty holder Issue a rejection note 8. Upon successful completion of the test, issue the test certificate. For a suitable certificate see Appendix A. 20 May 2004 SAEMA, CARTHUSIAN COURT, 12 CARTHUSIAN STREET, LONDON EC1M 6EZ TEL: FAX: enquiries@saema.org 6

7 SAE03.11 Our ref: Date: SPECIALIST ACCESS ENGINEERING AND MAINTENANCE A S S O C I AT I O N LOAD TEST CERTIFICATE Job No: Site: Expiry date: ItemSerial Date Load Rated load number tested applied in platform We hereby certify that the items listed above have been subject to the requisite loads indicated in accordance with BS6037 and that the results were found satisfactory. Signature: Tester: On behalf of: Note in accordance with Regulation 9 Clause 3(a) (i) of the Lifting Operations and Lifting Equipment Regulations 1998 the equipment should be thoroughly examined at 6 monthly intervals. Load Test Certificate Loler Regs.doc SAEMA 2003 Affiliated to SAEMA, CONSTRUCTION HOUSE, LEONARD STREET, LONDON EC2A 4JX TEL FAX enquiries@saema.org 7

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