Section 2 Fabrication of lifting appliances

2.1.1 The fabrication and inspection of lifting appliances subject to ship Classification are to comply with the Rules for the Manufacture, Testing and Certification of Materials, July 2022 (hereinafter referred to as the Rules for Materials) and the appropriate Sections of this Code.

2.1.2 The extent of non-destructive testing is to comply with Table 12.3.1 Minimum requirements for NDE in Chapter 12.

2.2.1  Re-testing of materials:

1. Check tests may be required at the discretion of the Surveyor.

2. In general, the manufacturer’s chemical analysis will be accepted but may be subject to occasional independent checks if required by the Surveyor.

3. When mechanical check tests are required, the specified tests are to be carried out using calibrated machines which are maintained in a satisfactory and accurate condition.

2.2.2  Rectification of defects:

1. In all cases, the removal of defects, and repair by welding where appropriate, are to be carried out to the satisfaction of the Surveyor.

2. Surface imperfections may be removed by mechanical means as agreed with the Surveyor. After such treatment, the dimensions are to comply with an agreed National or International Standard and the area is to be proved free from defects. The work is to be completed to the satisfaction of the Surveyor.

3. For steel castings, flame scarfing or arc-air gouging may be used, provided that pre-heating is used where necessary, the surfaces of the resulting depression are subsequently ground smooth and complete elimination of the defective material is confirmed by adequate non-destructive examination.

4. Repair by welding is not to be carried out without the agreement of the Surveyor. Agreement of the Surveyor is to be obtained before the work is commenced.

5. The complete removal of all defects is to be proved by suitable non-destructive examinations and the area is to be suitably prepared for welding.

6. Welding is to be carried out using a qualified and approved procedure which is to include the selection of suitable welding consumables. Pre-heating and post-weld heat treatment may be necessary due to the particular chemical composition or dimensions of the weld repairs. The repairs are to be carried out by qualified welders under adequate supervision.

2.2.3  Fabrication:

1. All standards related to weld procedures, qualification of welders, non-destructive test procedures, non-destructive test personnel qualifications and non-destructive acceptance criteria are to be agreed prior to the commencement of work.

2. Welding procedures are to be in accordance with the Rules for Materials or an agreed National or International Standard. All welding procedures are to be qualified by testing and be approved by the Surveyor.

3. Welding consumables are to be of a type approved by LR. A list of currently approved welding consumables is published in the Class Direct section of LR’s website at http://www.lr.org/.

4. All welders are to be qualified to the satisfaction of the Surveyor in accordance with the Rules for Materials or other equivalent National or International Standard.

5. Post-weld heat treatment is to be applied under the following conditions:

   1. For steels with nominal yield strength below 420 N/mm² where the as-welded hardness exceeds 350 Hv.

   2. For steels with yield strength between 420 N/mm² and 690 N/mm² where the as-welded hardness exceeds 420 Hv.

   3. Welding of steel castings where the thickness of the casting at the weld exceeds 30 mm.

   4. Where weld thickness exceeds 65 mm.

   Post-weld heat treatment may be omitted where the risk of fracture is demonstrated to be low or where the consequences of fracture are demonstrated to be tolerable.

6. Following welding, visual inspection is to be carried out by qualified inspectors to ensure that welds are in accordance with the approved plan and comply with agreed acceptance criteria. Surveyors will conduct visual examination spot checks to confirm the overall quality of the welds against the approved plans and agreed acceptance criteria.

7. In addition to visual checks, welds are to be non-destructively examined to verify their soundness. All non-destructive examinations (NDE) are to be carried out to a written procedure that is representative of the item under inspection and they are to be based upon a National or International Standard. Personnel carrying out non-destructive examination or interpreting the results of non-destructive examination are to be qualified to the appropriate level of a nationally recognised scheme such as ISO 9712, EN 473, PCN, ACCP or SNT-TC-1A. Level 1 personnel are not permitted to interpret results to Codes or Standards.

8. The extent of NDE is to be in accordance with Table 12.3.1 Minimum requirements for NDE in Chapter 12.

9. The verification of dimensional compliance to approved drawings is to be verified by the Surveyor after machining and/or welding operations.