Are lifting lugs required to be load tested prior to using for field erection? 1

[jochav5280]

Hello All:

Are lifting lugs required to be load tested prior to using for field erection? Does ASCE or any other building code cover these requirements?

Thank you!

jochav5280

 

[Ron]

OSHA requires that any loading or lifting apparatus "below the hook" be tested to 1.5 x the rated load.

 

[JStephen]

That OSHA requirement is for lifting apparatus (lifting beams, spreader bars, etc., designed per ASME BTH, etc), not for the load itself. I am not aware of any such requirements for the load itself.

 

[Ron]

A lifting lug is a lifting apparatus. I gave 1.5X as the amount but actually OSHA has two separate requirements, depending on the industry. In general, the following would likely apply:

OSHA 1910.184(f)(4)(ii) “All welded end attachments shall not be used unless proof tested by the manufacturer or equivalent entity at twice their rated capacity prior to initial use. The employer shall retain a certificate of the proof test, and make it available for examination.”

 

[JStephen]

From that same Section 1910.184- "Scope. This section applies to slings..." The welded end attachments are welded end attachment on the sling, not the lifting lugs welded to the load.

 

[JStephen]

I was looking around on the OSHA site for additional confirmation and really don't see much more one way or the other.

First off, let me clarify that by "lifting lug", I am referring to a steel piece welded to the item to be lifted, usually left in place. IE, it is part of the load itself, not an accessory item attached to the load. See the attached picture for an example. This is common in pressure vessel construction among other applications.

Section 1910.184(a) applies to slings, requires load testing.
1910.184(e)(e) The employer shall ensure that before use, each new, repaired, or reconditioned alloy steel chain sling, including all welded components in the sling assembly, shall be proof tested by the sling manufacturer or equivalent entity, in accordance with paragraph 5.2 of the American Society of Testing and Materials Specification A391-65, which is incorporated by reference as specified in Sec. 1910.6 (ANSI G61.1-1968).
Here it is fairly evident that it refers to components in the sling assembly, not components of the load, that are proof tested.

1910.184(f)(4)
End attachments.
1910.184(f)(4)(i)
Welding of end attachments, except covers to thimbles, shall be performed prior to the assembly of the sling.
1910.184(f)(4)(ii)
All welded end attachments shall not be used unless proof tested by the manufacturer or equivalent entity at twice their rated capacity prior to initial use. The employer shall retain a certificate of the proof test, and make it available for examination.

From the first paragraph, it seems fairly plain that the "end attachments" are parts of the sling, not the load.

The item that would come closest to being applicable is:
1926.251(a)(4)
Special custom design grabs, hooks, clamps, or other lifting accessories, for such units as modular panels, prefabricated structures and similar materials, shall be marked to indicate the safe working loads and shall be proof-tested prior to use to 125 percent of their rated load.

However, the way I read this, the grabs, hooks, clamps, etc., need to be labeled and proof-tested. The "modular panels, prefabicated structure and similar materials" do not need to be labeled and proof tested.

Looking in ASME B30.20, I find the definitions given as:
"below-the-hook lifting device": A device used for attaching loads to a hoist.
"Structural Lifting Device": A lifter consisting of an assembly of rigid parts designed to hold and attach a load to a hoisting device.
"Mechanical Lifting Device": A mechanism composed of two or more rigid parts which move with respect to each other for attaching a load to a hoisting device.
In each case, the "device" is between the load and the hoist, not a part of the load.

I went over to Google Images, put in "Lifting Lugs" and "Pad Eyes" there. I find a lot of small forged hardware that has capacities imprinted on it. However, the custom-designed plate-style lifting lugs, I don't see any that have a name plate, capacities, etc., as are required for below-the-hook lifting devices.

 

[dhengr]

Jochav5280:
I would look at OSHA, just to be sure, but I don’t think you will find anything there, if I understand the question you are asking. You might look at what OSHA has to say about structural steel erection, they have a few requirements on that account. OSHA typically pertains to lifting equipment and reusable lifting components related to the rigging business; the same goes for the ASME BTH standards. Components such as slings, clevises, lifting/spreader beams with lifting lugs or pad eyes on them, etc. OSHA does not typically comment on parts of a piece of equipment which are used in lifting it during its installation and maintenance. I tend to agree with Jstephen on this. Then, if it is a structural component I would look to AISC, and the like; if it’s a piece of equipment being lifted I would look to that industry’s design standards.

 

[oldrunner]

If I remember correctly, some codes require lifting lugs and their welds to be designed for a F.S. of 5 of the Fu of the material. Besides looking at the lug and the welds, the lifted material must also be reviewed.

 

[darthsoilsguy2]

Lifting lugs are everywhere. Perhaps they are load-tested during prototype R&D for product liability sake or to meet an industry-specific ANSI Standard (or its European superior ), but they sure are not being load tested on the production-level before they go to market... or at least not for big transformers or the heavy machinery i've been involved with on production. NDT is definitely regularly done... typically PT and MT since the geometry isn't very good for UT and RT is too big a pain for in-house QC programs.

 

[TehMightyEngineer]

My understanding is similar to what JStephen said; if a device is part of the load then it does not need to be rated or load tested (but obviously must still be designed and I will typically design in for ASME Below the hook criteria). For example, if you're lifting a tank you don't load test the tank to 125% of it's own self-weight. Similarly, it doesn't seem practical or intended to load test any lifting lugs welded to that tank. But, if you have lifting lugs welded to a lifting beam then those lugs must be tested during the same 125% load test of the lifting beam.

Maine Professional and Structural Engineer.
(Just passed the 16-hour SE exam, woohoo!)

 

[oldrunner]

Earlier I discussed the F.S. of 5 factor of the ultimate stress. This criteria is from IEEE C57.10.12(?) which is for the lifting lugs or trunnions for transformers. Jacking pads has the same criteria, but pulling tabs, the F.S. is 2. We find that many of the manufacturers don't conform to and has to be modified. A lot of manufacturers rate a lifting lug for whatever they like and then weld it to 3/8" wall plates.

 

[precast78]

Is this lifting lug purchased? If it is purchased and you follow the capacity given (reduced for edge distance, concrete strength) then I dont think you need to test it. It already has 4:1 factor of safety on it.

 

[TLHS]

TehMightyEngineer,

While I agree with your general thrust, there is at least one portable tank code that does have you test to some multiple of the empty dead weight. You fill it up part way with fluid to do the test.

 

[TehMightyEngineer]

TLHS: Yep, good point. I was thinking more ASME pressure vessel code when I made that post but you're quite right that specific requirements do vary from standard to standard.

Maine Professional and Structural Engineer.
(Just passed the 16-hour SE exam, woohoo!)

 

[ColinPearson]

I am not aware of any standard that really addresses the issue, but to be clear, my work is mainly in refineries so I'm sure other types of equipment have relevant codes which may have things to say on the matter.

That being said... OSHA won't help you here as they don't even require load testing on every type of rigging (EVEN before the first use). Neither does ASME. I agree with TehMightyEngineer in that the ASME BTH-1 (2011?) does indeed address pinned connection design but it is not immediately clear (to me, at least) that BTH-1 applies to lugs which are a part of the load itself. However, there's certainly nothing that I've seen that better addresses the issue so it's what I use for lug design as well.

David Duerr has put out some excellent articles on the matter.

 

[chicopee]

OSHA may not get you under this OSHA 1910.184 requirement, but OSHA could get you under the General Duty Clause, so a lift test may not be a bad idea after all.