Schedule 4 Test and thorough examination procedures
for material handling equipment
(subsections 11.2, 29.2, 38.1 and 38.2)
1 Items other than wire and fibre ropes, nets and slings
1.1 Material handling equipment for use in loading or unloading a ship must be tested and thoroughly examined by a competent person in accordance with this Order:
(a) before being put into use for the first time; and
(b) following renewal or repair of any stress bearing part, except when the renewal is pursuant to a routine maintenance schedule.
1.2 In addition to the requirements of subclause 1.1, and subject to subclauses 1.3, 1.5, and 1.6, material handling equipment for use in loading or unloading a ship must subsequently:
(a) be tested and thoroughly examined in accordance with this Schedule by a competent person at intervals not exceeding 5 years; and
(b) be thoroughly examined at intervals not exceeding 12 months by:
(i) in the case of equipment under survey with a classification society — a competent person; and
(ii) in any other case — a responsible person.
1.3 Paragraph 1.2(a) does not apply to loose gear except where specific provision is made in subclause 1.7, 1.8 or 1.9.
1.4 Items of equipment permanently attached to a lifting appliance, including lower cargo blocks, ponder balls and cargo hooks dedicated to use with a specific lifting appliance and forming part of the assembly, need not be separately tested at the 5 yearly testing of the lifting appliance to which they are attached.
1.5 In relation to ship equipment, a thorough examination required by subparagraph 1.2(b)(i) may be postponed, for a period of not more than 3 months, if the postponement will enable the examination to be carried out with a scheduled annual Class survey of the ship, provided that a responsible person carries out a thorough examination at the due date, and if the equipment is found satisfactory, has endorsed the register of material handling equipment.
1.6 If the design of specialised material handling equipment or heavy lift equipment is such that, in the opinion of a competent person, the equipment cannot reasonably be tested or retested in the manner specified in this Schedule, or the equipment would require unnecessary dismantling, the periodic test and thorough examinations required by subclause 1.2 may be dispensed with, provided that:
(a) the manufacturer’s equipment specification, schedule of examination and maintenance manual are available to the competent person; and
(b) examination and maintenance procedures have been carried out in compliance with the manual and recorded in the appropriate register by a competent or responsible person; and
Schedule Sch 4 - Marine Order 32, issue 3 - Test and thorough examination procedures | Zoe
(c) the equipment is fit for use.
1.7 Subclauses 1.1 and 1.2 do not apply to an intermediate bulk container having permanently attached fittings for handling, provided that its design and construction conforms to a container that has been type tested in accordance with clause 9 of this Schedule.
1.8 Subclauses 1.1 and 1.2 do not apply to a mechanical stowing appliance:
(a) being shore equipment; or
(b) being ship equipment for use solely in or on the ship, provided the appliance complies with subclause 4.3 of Schedule 1.
1.9 Subclauses 1.1 and 1.2 do not apply to a specialised cargo handling system being:
(a) shore equipment; or
(b) ship equipment for use solely in or on the ship and there is on board details of the manner by which the safe working load has been established, a description of the method by which cargo should be handled and details of any limitations on the use of the equipment or any of its component parts.
2 Cranes and derricks
2.1 Proof load
2.1.1 Where a crane or derrick is tested, the proof load must not be less than the applicable load specified in Table 1, except that where a hydraulic crane is tested in accordance with paragraph 1.1(b) or 1.2(a) of this Schedule, and it is not practical for the crane to raise the full test load, a reduced test load may be accepted but in no case is this to be less than the SWL x 1.1.
Table 1
SWL of derrick gear or crane (tonnes)
Proof load
Not more than 20
SWL x 1.25
More than 20 but not more than 50
SWL + 5 tonnes
More than 50
SWL x 1.1
2.1.2 Where derricks in union purchase are tested, the proof load specified in Table 1 must be based on the SWL of the derricks when rigged in union purchase, as stated on the drawing or drawings specified by subsection 25.1 of this Order.
2.1.3 For a test of a crane or derrick, the load imposed on any accessory block, topping lift, shackle, preventer, guy or other accessory part must not exceed the SWL of that part by more than the proportion by which the proof load exceeds the SWL of the crane or derrick.
2.2 Application of proof load
2.2.1 The proof load for a test of a crane (including a derrick crane), derricks in union purchase and the initial test of a derrick must be applied by hoisting movable weights.
2.2.2 The proof load for a test of a derrick or derrick crane, following renewal of a part or repair, must be applied by hoisting movable weights, or by means of a spring or hydraulic balance or similar appliance.
2.2.3 The proof load must be applied:
(a) with the derrick boom or crane jib at its minimum working angle (or load radius in the case of a crane or derrick crane), measured from the horizontal plane and stated in the certificate of test; or
(b) in the case of a variable length jib crane, with the jib at its maximum and minimum operating lengths, stated in the certificate of test, and at a length approximately midway between maximum and minimum.
2.3 Structural test with movable weights
Where a crane or derrick is tested with movable weights, after the movable weights are hoisted:
(a) the crane or derrick must be swung at slow speed to the extremities of its slewing arc; and
(b) in the case of a jib crane with a travelling capability, the crane must be moved the entire length of its travelling track at slow speed with the jib extended to the maximum working outreach perpendicular to its direction of travel on one side of its travelling track, and again, with the jib similarly extended to the other side; and
(c) in the case of a bridge or gantry crane with a travelling capability, the crane must be moved the entire length of its travelling track with the hoist at one extremity of the traversing span, and again, with the hoist at the other extremity; and
(d) in the case of a bridge or gantry crane without a travelling capability, the crane must be made to move the weights from one extremity of its traversing span to the other; and
(e) in the case of a derrick crane, in addition to paragraph (a), the derrick crane is to be luffed at slow speed to its maximum operating angle measured from the horizontal plane, then returned at slow speed to its minimum operating angle.
2.4 Structural test with spring or hydraulic balance
Where a derrick or crane is tested with a spring or hydraulic balance, or similar appliance, the proof load must be applied, for a period of not less than 5 minutes, at the minimum working angle at each extremity of its working arc and in its midship position.
2.5 Operational test of crane
A crane must undergo an operational test, including testing of its limit switches, by hoisting a load at least equal to the SWL while carrying out all motions occurring in normal operations, such as hoisting, luffing, slewing and travelling, using its full range of speeds. All brakes must be tested in accordance with subclause 3.3 of this Schedule.
2.6 Structural test of derrick gear in union purchase
For the purpose of testing derrick gear in union purchase, the proof load must be manoeuvred throughout the working range of the gear, rigged over one side of the ship and hoisted to a level that:
(a) makes the angle between the runners close to, but not in excess of, 120°, or
(b) such lesser angle as is specified in the drawing or drawings specified in Schedule 7,
and again, with the gear rigged over the opposite side of the ship.
2.7 Thorough examination
Following testing of a crane or derrick, the crane or derrick and all accessory gear must be thoroughly examined by a competent person for damage or permanent deformity, and overload limit switches reset.
3 Winches
3.1 Span gear winches
If a derrick is fitted with a span gear winch, the winch must be tested while the derrick is supporting the proof load at its lowest working angle by in turn subjecting each sprocket to the resultant load.
3.2 Topping and main winches
On completion of the tests with the proof load, each winch must be tested with a load equal to the SWL suspended from the derrick head, and the derrick placed in various positions such that each winch serving the derrick is subjected to loading while having the maximum working length of rope layers upon its drum.
3.3 Brake test of winches
After completion of the proof load tests of a derrick, a load equal to the SWL for that derrick is to be hoisted then, with the derrick slewed outboard to each side of the ship and with the derrick amidships, lowered at the normal lowering speed of the winch for a distance of approximately 3 m. The winch is then to be braked sharply and the load brought to a halt. It is then to be demonstrated that a load equal to the SWL of the derrick can be held stationary by the winch brake when the winch drive is switched off.
4 Cargo lifts and mechanical ramps
4.1 Proof load
Where a cargo lift or mechanical ramp is tested, the proof load must be not less than the applicable load specified in Table 2.
Table 2
SWL of lift or ramp (tonnes)
Proof load
Not more than 20
SWL x 1.25
More than 20 but not more than 50
SWL + 5 tonnes
More than 50
SWL x 1.1
4.2 Application of proof load
For the purpose of testing, a cargo lift or mechanical ramp must be hoisted and lowered through its full range of travel with the proof load consisting of movable weights distributed in accordance with the designed operating requirements.
4.3 Thorough examination
Following testing, a cargo lift or mechanical ramp and its accessory gear must be thoroughly examined by a competent person for damage or permanent defects.
The proof load for a single sheave block is 4 times the block’s SWL.
5.2 Method of application of proof load for single sheave block
The block is to be suspended head down by a wire (or chain in the case of a chain block) passing around its sheave. A mass equal to 4 times the SWL is to be secured to the block’s head fitting, and lifted from the ground. The test may be carried out in any other manner provided that the same stress is applied to the block. Where a single sheave block is provided with a becket, the test must be done with a part of the supporting wire secured to the becket, to avoid overstressing the sheave or pin.
5.3 Proof load for multiple sheave block
5.3.1 Where a multiple sheave block is tested, the proof load must be not less than the applicable load specified in Table 3.
Table 3
SWL of block (tonnes)
Proof load
Not more than 25
SWL x 2.0
More than 25 but not more than 160
(SWL x 0.933) + 27 tonnes
More than 160
SWL x 1.1
5.3.2 The multiple sheave block is to be rove in its normal operating condition and the proof load is to be applied to the head fitting of the block to be tested. Testing of a multiple sheave block normally requires the use of a second block or an equivalent arrangement for the rope.
5.4 Proof load for chain, etc
Where a chain, ring, hook, shackle, swivel, connecting plate or overhauling weight is tested, the proof load must be not less than the applicable load specified in Table 4.
Table 4
SWL of article (tonnes)
Proof load
Not more than 25
SWL x 2
More than 25
(SWL x 1.22) + 20 tonnes
5.5 Other articles
Hand operated blocks used with pitched chains, their associated chains, and any permanently attached rings, hooks, swivels and associated shackles must be subjected to a proof load not less than SWL x 1.5, unless tested in conjunction with the articles referred to in subclause 5.1, 5.3 or 5.4.
5.6 Thorough examination
Following testing of an article referred to in subclause 5.1, 5.3, 5.4 or 5.5, the article must be thoroughly examined by a competent person for permanent deformation, cracks, flaws or other defects including, in the case of a block, the head fitting, sheave or sheaves, axle, crosshead, becket and other parts.
6 Trays, crates, tubs, grabs, scrap bins, other receptacles for loading or unloading cargo, and personnel cradles
6.1 Proof load
Where a personnel cradle, tray, crate, tub, grab or other receptacle for use in loading or unloading cargo other than a container or returnable cargo unit referred to in clause 9 or 10 of this Schedule is tested, the proof load must be not less than the applicable load specified in Table 5 and must be wholly supported by the bottom surface of the receptacle.
Table 5
SWL of article (tonnes)
Proof load
Not more than 3
SWL x 2
More than 3 but not more than 12
SWL + 3 tonnes
More than 12 but not more than 20
SWL x 1.25
More than 20
SWL + 5 tonnes
6.2 Thorough examination
Following testing of an article referred to in subclause 6.1, the article must be thoroughly examined by a competent person for permanent deformation or other damage or defects.
7 Lifting beams, spreaders, lifting frames, magnetic lifting devices and vacuum lifting devices
7.1 Proof load
Where a lifting beam, spreader, lifting frame, magnetic lifting device or vacuum lifting device is tested, the proof load must be not less than the applicable load specified in Table 6, and must be attached in the manner for which the article is designed.
Table 6
SWL of article (tonnes)
Proof load
Not more than 10
SWL x 2
More than 10 but not more than 160
(SWL x 1.04) + 9.6 tonnes
More than 160
SWL x 1.1
7.2 Thorough examination
Following testing of an article referred to in subclause 7.1, it must be thoroughly examined by a competent person for permanent deformation or other damage or defects.
8 Wire ropes and terminal or end fittings, fibre ropes and flat synthetic-webbing slings
8.1 Wire ropes — testing
8.1.1 Samples from wire rope as manufactured are to be tested to destruction in accordance with Australian Standard AS 3569 — Steel Wire Ropes, or other applicable national standard. Wire ropes supplied to ships for loading and unloading purposes, including topping lifts, preventers and standing rigging, are to be provided with a certificate.
8.1.2 The safe working load (SWL) specified in the certificate is to be calculated according to the following:
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8.1.3 The applicable safety factor (SF) is to be not less than the figure obtained from the following formula:
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provided that the safety factor need not exceed 5 for SWLs up to 10 tonnes weight, and must be at least 3 for SWLs of 160 tonnes weight and more.
8.2 Wire ropes — inspection
8.2.1 An inspection of wire ropes must be made by a responsible person at intervals not exceeding:
(a) for a wire rope which does not pass over a sheave or a winding drum —12 months; or
(b) for a wire rope which passes over a sheave or winding drum — 6 months.
8.2.2 A wire rope may only be used if:
(a) a competent person has issued a certificate in respect of the rope; and
(b) a responsible person has inspected the rope, externally and, as far as practical, internally, in the period required by paragraph 8.2.1(a) or (b) immediately preceding the proposed use and found that the rope is not worn, corroded or otherwise defective to a degree that renders it unfit for the proposed use; and
(c) the rope is free from knots and kinks; and
(d) the rope complies with the structural requirements specified in Schedule 5; and
(e) evidence, based on prototype testing, that any terminal or end fitting on the rope complies with subclause 8.3 of this Schedule is recorded in the appropriate register of material handling equipment.
8.2.3 If a wire rope with a broken constituent wire is to be used, the following requirements apply:
(a) the rope must be inspected by a responsible person prior to its initial use, and at least monthly, to determine if the rope is fit for use; and
(b) the responsible person must record the result of the inspection in the appropriate register of material handling equipment; and
(c) the rope must not be used unless the responsible person has determined that the rope continues to be fit for use.
8.3 Terminal or end fittings
8.3.1 There must be on board evidence that a terminal connection fitted to a wire rope used for hoisting a load on a crane or derrick is of a design on which prototype tests have shown that the strength of the terminal and its attachment to the rope is not less than 95% of the minimum breaking load of the rope for a rope up to and including 50mm in diameter or 90% of the minimum breaking load of the rope for a rope exceeding 50mm in diameter.
8.3.2 Subclause 8.3.1 does not apply if the equipment is under survey and inspection pursuant to a scheme of classification and certification by a classification society.
8.3.3 A certificate specifying the type and size of terminal or end fitting, the type and size of wire rope to which it was fitted, and the result of the above test, is to be supplied with each such terminal or end fitting, or set of identical terminal or end fittings.
8.4 Fibre ropes
8.4.1 Samples from fibre rope as manufactured are to be tested to destruction in accordance with Australian Standard AS 4143.1 — Methods of Test for Fibre Ropes, or other applicable national standard. Fibre ropes supplied to ships for loading and unloading purposes, including topping lifts, preventers and standing rigging, are to be provided with a certificate.
8.4.2 The SWL specified in the certificate is to be calculated according to the following:
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8.4.3 The applicable safety factor (SF) is to be not less than that given in table A1 of Australian Standard AS 4142.1 — Fibre Ropes Part 1: Care and Safe Usage.
8.4.4 Paragraphs 26(a) and (b) of this Order do not apply to fibre rope.
8.5 Flat synthetic-webbing slings
Material, design, manufacture, marking, testing and certification of flat synthetic-webbing slings must comply with the relevant Australian or equivalent international standards.
9 Intermediate bulk containers
The construction, marking, testing, inspection and certification of IBCs must be in accordance with the requirements of the IMDG Code.
10 Other returnable cargo units
10.1 Where a returnable cargo unit is type-tested, the proof load must be not less than SWL x 5.
10.2 A unit referred to in subclause 10.1 will pass the type-test if there is:
(a) no loss of contents from the unit; and
(b) no breakage or serious deformation of the unit.
11 Nets and slings
Paragraphs 26(a) and (b) of this Order do not apply to nets and slings manufactured in accordance with Schedule 5.