As more forklift options and attachments become available, it is increasingly important for forklift operators to have a clear understanding of their forklifts load capacity and the risks that are involved in exceeding it. This week’s blog will highlight what forklift operators should know regarding a forklifts load capacity and practices that should be in place in order to maintain safety around the workplace.
What is a forklift load capacity?
A forklifts load capacity is determined as the maximum weight that a forklift is able to safely carry at a specified load centre. If the load is not centred at the precise position then the forklifts capacity will therefore be reduced.
 
What is a load capacity data plate?
The load capacity data plate specifies the load each forklift can safely lift at different mast angles or when it is fitted with an attachment. The plate should display; the load capacity, lift height, load centre distance, brand and model number. The plate should also display:
 
•             Down rating of lifting capacity if a mast is fitted
•             Down rating for specific attachments that are identified on the capacity plate
 
Attachments and Load Capacity
If an attachment is fitted to the forklift then there is the potential that the dynamic and operating characteristics of the forklift will change. It is important for attachments to have rated capacities as well as de-rated capacities. Ensure you have access to information regarding the de-rated capacity of the forklift when an attachment is fitted.
 
Lift Heights
A forklifts load carrying capacity is significantly affected by lift height or maximum fork height. Forklifts with high masts have a greater carrying capacity at lower lift heights than at maximum lift heights, therefore, forklifts with high masts may have a dual capacity rating at the maximum lift height, allowing the forklift operator to work with heavier loads at low heights.
 
Risks
Workers with an inadequate knowledge of a forklifts load capacity are placing themselves and those around them at serious risk. Forklift operators should be aware of the following:
 
•             The effects of a loads weight, shape and size on a forklift
•             The correct way that a load should be fitted
•             The difference between the model number on the forklift and the forklifts load capacity plate

Load testing is a common source of confusion for many of our customers simply because many Businesses are often unclear or unfamiliar with the Occupational Health and Safety regulations specifying requirements and standards for load testing. FB Cranes offers comprehensive Load Testing Services for all makes and types of cranes giving clients peace of mind that their cranes meet legal compliance standards. This includes Mine Health and Safety Act (MHSA) , Occupational Health and Safety Act (OHS) and South African National Standards (SANS).
Your crane needs to be tested...
On an annual basis to comply with SANS standards. However, SANS also specifies that if a Lifting Machinery Inspector deems the Crane as old or in a poor condition, more regular tests need to be performed.
New Overhead crane systems SHALL be load tested prior to being placed into service.
Existing crane system SHALL be load tested after modification or re-rating
After a major component has been replaced or repaired on the load path of the crane

It is critically important that lifting equipment is in proper working order before placing it in service, for the safety both employees and a facility. When it comes to safety, any part of equipment inspection cannot afford to be overlooked. The equipment inspection and maintenance process includes the testing of equipment before it is used in operations.
 
It is critically important that lifting equipment is in proper working order before placing it in service, for the safety both employees and a facility. When it comes to safety, any part of equipment inspection cannot afford to be overlooked. The equipment inspection and maintenance process include the testing of equipment before it is used in operations.
 
Load testing is an essential tool that helps to ensure overhead hoist and crane safety; load testing is “the process of putting a demand on a software system or computing device and measuring its response. It is often performed in order to determine a system’s behaviour under both normal and anticipated peak load conditions.
 
So what are some of the Reasons why People Have Load Testing Completed?
 
Load Testing is not an optional choice, it is mandatory. The Provincial Labour laws and the resulting Health and Safety acts, make it a requirement to have a regular inspection of rigging and lifting equipment.
Load testing reveals functional errors that only occur under stressing and lowers the frequency and serious nature of incidents involving overhead cranes and hoists.
It is also important for learning what the performance bottlenecks and breaking points are on a piece of lifting equipment.
The Occupational Safety and Health Administration (OSHA) has also set forth certain standards for load testing to ensure that it is a part of regular maintenance.
 
Some of the standards that OSHA has set for include:
 
Management should appoint a designated person to perform duties as an operator as well as a qualified person who has processional knowledge, training and experience when it comes to overhead cranes and hoists.
Prior to use, all new and altered cranes need to be tested to ensure the following functions are working correctly: hoisting, lowering, trolley travel, bridge travel, limit switches and locking and safety devices.
The trip setting of hoist-limit devices shall be determined by tests with an empty hook travelling at increasing speeds to the maximum speed.
The actuating mechanism of the upper-limit device shall be located so that it will trip the device under all conditions and in sufficient time to prevent contact of the hook or load block with any part of the trolley or crane.
In a Rated Load Test, the test loads cannot be less than 100 percent or more than 125 percent of the rated load capacity unless otherwise recommended by the manufacturer. These reports should be placed on a file so that they are easily accessible to appointed personnel. The timing of inspections and load testing depends on the equipment, frequency of use and conditions of the environment. Severe service load testing means normal or heavy use in some irregular or nonstandard environment.
 
The avoidance of costly accidents and fines is essential for your company’s bottom line. All performance and safety choices translate into profits and the justification for load testing is no different.
 
To recap, 4 important facts about load testing to keep in mind include:
 
Load testing is not an optional choice, it is mandatory
Management should appoint a designated person to perform duties as an operator
Load testing helps to determine what the performance bottlenecks and breaking points are on a piece of lifting equipment
Tests should not be less than 100 percent or more than 125 percent of the rate load capacity
Does your company regularly load test overhead cranes and hosts?