Non-Standard Crane Site Load Test & TSG Acceptance Process
Site Acceptance Standard for Non-Standard Cranes: Static test with rated load of 125% for 10 min with no residual deformation, dynamic load test at 110% over full travel with no abnormalities, braking distance S ≤ v/100 mm, and all safety devices fully functional. TSG Q7016-2016 requires that newly installed cranes pass supervisory inspection before being put into service. Kelude provides full-process support and documentation from on-site installation through TSG acceptance.
Site installation and acceptance of non-standard cranes is the final gate before project delivery—and technically the most demanding stage. Unlike standard cranes with well-established installation procedures, non-standard units require individual rail foundation alignment, electrical system commissioning from scratch, and on-site preparation of test blocks for load testing. After installation, the crane must pass TSG Q7016-2016 supervisory inspection before it can be put into operation. This article walks through the technical essentials of non-standard crane site installation and acceptance in construction sequence: rail foundation inspection, lifting plan, power-on commissioning, load testing, and TSG documentation.
Rail Foundation Inspection and Main Girder Hoisting
Rail foundation work is the first step in non-standard crane installation. The runway beam concrete must reach 100% of design strength. Before laying the rail, check the top surface flatness with a 2 m straightedge (deviation no greater than 5 mm per 2 m). Anchor bolt specifications and spacing must match the rail clamps, with deviation within ±5 mm. Per GB/T 10183: rail straightness within 1.5 mm/m, full-length rail surface height difference within ±5 mm, and rail gauge deviation of ±3 mm (for spans up to 30 m). Joint misalignment must not exceed 1 mm, gaps of 2–4 mm are adjusted according to temperature, and rail clamp spacing is ≤600 mm.
Main girders are typically shipped in sections (when exceeding 22 m) and joined on site with high-strength bolts using flange connections. Before hoisting, confirm the lifting lug UT flaw detection report and that the lifting points match the lifting plan. When two cranes are used for tandem lifting, each crane's load must not exceed 80% of its rated lifting capacity, and both cranes must operate in synchronization. After the main girder is set in place, measure the end height difference (allowable ±5 mm), install the end carriage connection bolts with an initial tightening torque of 50%, and after alignment verification, final-tighten to the design torque value.
Power-On Commissioning Sequence and Parameter Settings
Power-on commissioning follows this sequence: trolley before crane bridge, no-load before loaded operation, and manual before automatic. The hoisting mechanism is commissioned last. VFD parameter setup: first set the motor basic parameters (rated current, rotational speed, power factor), then configure acceleration/deceleration times (hoisting 3–6 s, travel 2–4 s), and finally set the brake control logic. The hoist inverter must be equipped with a braking resistor.
PLC control logic verification is completed before no-load operation: test each DI channel point-by-point to confirm limit switches and emergency stop signals are correctly wired, test DO channels to verify contactor and brake actuation, and confirm via the communication bus that data exchange between each VFD and the PLC is normal. On first start-up, jog each mechanism to verify the direction of rotation before allowing continuous operation. The hoist brake gap is set to 0.5–1.5 mm, with the difference between the two brake shoes on the same brake kept within 0.2 mm. For more on control cabinet integration, see the article on control cabinet and MES interfaces.
Load Test Procedure and Acceptance Criteria
For the static load test, use 125% of rated load: lift the test blocks 100 mm off the ground, check the brake, then raise to 200 mm and hold for 10 min. After unloading, measure the residual deformation at mid-span of the main girder—L/2000 or less is acceptable. Deflection measurement points are located on the bottom flange at mid-span, measured with a level instrument or the wire-stretch method. The travel mechanisms must not be operated during the 125% load test.
For the dynamic load test, use 110% of rated load: perform at least 3 full hoisting and lowering cycles, and run the trolley along the full length of the main girder for 2 round trips. Check that braking distance S ≤ v/100 mm (where v is the rated lifting speed), travel is smooth with no wheel rail gnawing or abnormal noise, limit switches actuate at all extreme positions, and the overload limiter alarms at 110% and cuts off the hoisting circuit at 125% of rated load. All data is recorded in the load test report, which is a mandatory document for TSG inspection.
| Crane Rail Acceptance Crane Rail Straightness≤1.5mm/m, Track Gauge / Rail Gauge±3mm, Joint Misalignment≤1mm, Clearance2~4mm, Clamp Spacing≤600mm.Foundation Strength100%. | Commissioning Sequence First Trolley Then Crane Bridge / Long Travel No-load first, then load Manual Then automatic.Frequency Inverter / VFDAdddeceleration time Hoisting / Lifting3~6Seconds of operation2~4Seconds. | Load Test 125%static load10min Residual≤L/2000.110%dynamic load Full Travel≥3Cycles.Braking Droop S≤v/100mm. |
| Test Block Preparation 125%×QCalculation Test Block Total Weight.Optional Standard Weight/Concrete Counterweight/Water Ballast Counterweight.Weighing Error≤±1%, Lifting Lug Safety factor≥6. | Safety Device Overload Limiter110%Alarm125%Cut-off.Limit Switch Operation at All Limit Positions.Hardwired E-Stop Connection.Brake Clearance0.5~1.5mm. | TSG (Special Equipment Safety Technical Regulation)Documentation Design Documents/Permit/Certificate of Conformity/Type Test Certificate/Installation Notification/Self-Inspection Report/Purchased Components Certificate of Conformity/Load Test Report. |
Non-Standard Crane Acceptance Grades & Load Test Standards
| Test Item | Load | Test Method | Acceptance Criteria |
|---|---|---|---|
| Static load test | 125% | Off Ground200mm Hover10min | Residual deformation≤L/2000 |
| Dynamic Load Test | 110% | Full Travel Hoisting/Lowering+Travelling≥3Cycles | All Mechanisms Smooth and Normal |
| Braking Test | 100% | Off Ground1mEmergency Stop Braking | Droop S≤v/100mm |
| Overload Protection | 110%/125% | Stepwise Loading Testing Alarm | 110%Alarm125%Cut-off |
| Limit Switch Test | No-load | All Mechanisms to Limit Trigger | Stop after Limit Activation |
| Noise Testing | No-load | Cabin / Operator Cab/All Directions on Ground | ≤85dB(A) |
TSG Supervision Inspection Process and Delivery
Per TSG Q7016-2016, supervision inspection follows three stages: filing an installation notice before work begins (qualification certificates + construction plan + personnel credentials), process supervision during installation, and a final supervision inspection upon completion. The required documentation includes: design documents (strength calculation report + general arrangement drawing), a copy of the manufacturing license, Product Certificate, Type Test Certificate, installation notice receipt, installation records (including Concealed Work acceptance), self-inspection report, and Certificates of Conformity for purchased components. The inspection body reviews the documentation, inspects the physical equipment (structure, mechanisms, electrical systems, and safety devices), and witnesses the load test. Once passed, a supervision inspection certificate is issued, which is then used to obtain the operation registration permit. The typical timeline from filing the installation notice to receiving the operation registration permit is 30–45 days.
Kelude Heavy Industry provides complete documentation templates for installation notices and TSG inspections on non-standard projects. We recommend submitting the supervision inspection request two weeks before installation is completed to avoid project delays caused by waiting for the inspection. For more on the Design & Manufacturing process for non-standard cranes, see The Complete Guide to Non-Standard Crane Customization and Manufacturing Tolerance Control for Non-Standard Cranes.
Non-Standard Crane FAQ: Installation, Testing & Delivery
Q: What paperwork is required before installation?
A: Under TSG Q7016-2016, you must file an installation notice with the local special equipment regulatory authority before work begins, submitting the contractor's qualification certificate and construction plan. After installation, request a final supervision inspection from the inspection body. Once passed, you receive the operation registration permit before the crane can be put into service. The entire process takes 30–45 days.
Q: How do I prepare test weights for the load test?
A: Calculate the total test weight as 125% × Q. You can use Standard Weights, concrete counterweight blocks, or water-filled tanks. The weighing error for test weights must be ≤ ±1%, and the Safety factor for lifting lugs and Wire Rope must be ≥ 6. Concrete counterweights need to be cast at least 28 days in advance and calibrated to their actual weight. For water ballast, verify the Dead Weight of the tank and ensure even filling to prevent off-center loading.
Q: What if the Crane Rail foundation deviation exceeds tolerance?
A: Deviations up to 10 mm can be compensated with pressure plate shims. For deviations of 10–20 mm, the Runway Beam surface must be repaired (chipping away and grouting). Deviations above 20 mm require an assessment of the impact on crane operation; you may need to adjust the Wheel Block on the End Carriage or add self-aligning Bearings. We recommend inspecting the foundation during the rail installation phase to avoid discovering substandard foundations after the crane arrives on site. Kelude Heavy Industry offers pre-installation foundation acceptance guidance.
Q: What deliverables come with a Non-Standard Crane?
A: The delivery documentation package includes: the crane Operation Manual, Electrical Schematic and wiring diagrams, manuals for major purchased components (Motor, Reducer, VFD), a Spare Parts List, Product Certificate and Type Test Certificate, TSG supervision inspection certificate, and a warranty document (≥ 12 months). Kelude Heavy Industry provides a complete factory documentation package, itemized and verified before shipment.
