Engineering a piece of lifting equipment

  • Engineering LAM

Five steps to a safe piece of lifting equipment suitable for your application.

Engineering a piece of lifting equipment

Arrow 1Design

Intelligent lifting equipment

The best advice always depends on the individual circumstances. Together with the manufacturer, AXZION-GKS, Evers is always able to find the perfect solution for you. This holds true whether seen from a price or solution point of view. The fact that almost 85% of what we supply is a modified or customised solution speaks volumes: only every one in six pieces of lifting equipment that we provide is a standard solution.

We carry the responsibility for you

The manufacturer is whichever party „is responsible for the design and manufacture of a product“ marketed under their name. In so far as operators design and produce their own lifting equipment, then they themselves become the manufacturer. Time and again insufficient attention is paid to the dangers and potential liabilities when lifting and moving heavy loads - with occasionally dramatic consequences for both those responsible and those affected. Even choosing an unsuitable manufacturer can lead to personal liability against the individuals responsible.

We carry the responsibility for you. You are purchasing from a company that observes all applicable standards. These include the Major Proof of Suitability for Welding according to DIN 18800 and DIN 15018 for static and dynamic load-bearing structures, the EN 10 204/3.1 material inspection certificate and also the test report, operating instructions and CE declaration according to the new Machinery Directive 2006/42/EC.

Engineering lifting equipment - design

Standard or individual solution – we give the best advice

As AXZION-GKS carries out its own construction and assembly, it possesses a variety of individual construction elements, which form a construction kit that can be assembled as needed to create an all-embracing solution. Our strengths lie in being able to provide bespoke pieces of equipment in a short turnaround time. We find the right solution for you, whether this is a low-cost standard solution or an individual design.

The number of load changes is key

a) Maximum 20,000 load changes

EN 13155 applies in its entirety to lifting equipment that will have to undergo a maximum of 20,000 load cycles. This means that the mechanical load-bearing components have to meet the following mechanical stability requirements:

  • The lifting equipment must be dimensioned in such a way that it is able to bear a static load that is three times its load-bearing capacity and hold the load, even if permanent distortions may develop.
  • The lifting equipment must be dimensioned in such a way that it is able to bear a static load that is twice its load-bearing capacity without the development of any permanent distortions.
  • Section 6 of EN 13155 includes an additional, but not insignificant, requirement. Individually constructed and assembled products must undergo both a type inspection and an individual inspection. For series products, the type inspection must be carried out on one or several representative products from the series and the individual inspection must be carried out on each of the individually manufactured products.
  • The manufacturer of the lifting equipment must provide evidence that the welding was carried out by EN 287-1 qualified personnel. Furthermore, the quality of the weld seams must be verified according to EN 25817.
  • The company tasked with carrying out welding work on lifting equipment of this nature must hold the „Major Proof of Suitability for Welding“ according to DIN 18800 Part 7.

b) More than 20,000 load changes, special cases (e.g. offshore applications), use at high/low temperatures

Evers supplies certified lifting equipment for all the application areas listed. DIN EN 13155 does not cover the hazards relating to the mechanical stability of lifting equipment that is intended for more than 20,000 load changes. In its place, DIN 15018 „Cranes – Steel structures“ applies to the design and dimensioning of components. The lifting equipment is designed to comply with the standards covering the application in which it will be used.

Precise planning guarantees perfect operation

Even during the planning phase, close contact with the user will result in an optimum design. By using the most advanced 3D CAD systems and computer-assisted calculation programs (FEM) for design work, subsequent editing or changes can be made at any time.

Expert on-site advice

A skilled team of experienced advisors draw on the expertise gained from countless previous problems and solutions when providing advice. The applications engineer is also happy to come and assess on-site the specific operating requirements and conditions. Intra-company specifics may mean that a further risk assessment is necessary; we can take care of this - just ask.

Arrow 2Material

A good solution depends entirely on good ingredients

We have worked with the best manufacturers for many years; for example, the tested blasted steels are generally sourced from Thyssen and Arcelor.

Chain components come from the RUD chain factory in Aalen, and forged crane hooks and suspension lugs are delivered by Stahlhammer Bommern and the Peter Schöttler drop forge in Hagen. Textile lifting tackle, such as web slings and round slings, are naturally provided by SpanSet in Übach-Palenberg.

Engineering lifting equipment - materials 

Only with certificates

All materials used are provided with 3.1 material inspection certificates according to DIN EN 10204. For offshore applications, 3.2 certification according to DIN EN 10204 can also be provided. A qualified incoming goods inspection is carried out, and steel only proceeds to the manufacturing process when it is provided with the 3.1 certificate according to DIN EN 10204. Trusses are measured and sent back if they are not sufficiently parallel or demonstrate unacceptable torsional twisting.

The materials certification and evidence of use are administered with the aid of computers and remain available indefinitely.

Flame cutting

We consider a perfect burning performance and the complete traceability of the materials used to be very important. Therefore we flame-cut all parts ourselves on a modern CNC-guided flame-cutting machine.

Arrow 3Assembly

 Engineering lifting equipment - assembly  Major proof of suitability for welding

The manufacturing qualification according to DIN 18800-7:2008-11 is confirmed annually by TÜV Rheinland. Class E rating: this means that AXZION-GKS may assemble primarily statically-loaded and primarily dynamically-loaded structures.

Certified welders

The quality of the weld seams we produce is very important to us. All welders possess valid welder certificates according to DIN EN 287 and receive continuous in-house training. Only the most modern welding equipment is used, which is regularly examined and continually updated.

Assembly support from professional welding engineers

The professional welding engineer designs the construction to be suitable for welding and dimensions the requisite weld seams. The welding processes and welding sequences are established in a WPS (Welding Procedure Specifications) according to EN ISO 15609-1. WPS welding means that the welding is carried out according to certified welding instructions. It serves as instructions on how the weld seam is to be carried out and which settings the welder must use on the welding equipment. Furthermore it includes details on preparing the weld location and finishing the weld seam.

Independent weld seam and materials testing

Materials and procedure testing means additional safety. We therefore arrange for an independent testing institute to carry out the required inspections. As a result, our work is verified by completely independent testers using the very latest testing equipment. All certificates are readily available.

a) Magnetic particle testing

Magnetic particle inspection is the most commonly used method for detecting surface errors and near-surface errors such as hairline cracks in magnetisable iron and steel materials. The leakage flux, which results at surface cracks due to magnetisation of the component, means that the magnetisable particles in the test medium adhere at that location. The effect is visible and results from the contrast between the background and the test medium.

b) Dye penetration testing

Dye penetration testing is one of the oldest non-destructive testing methods for detecting surface errors. The test can be performed on almost all metallic and non-metallic materials. During this procedure the testing liquid penetrates into any type of surface error in a material as a result of the capillary effect. After the solution is carefully washed off, a developer is applied which creates a counter-capillarity. This draws out the liquid which had penetrated into cavities and cracks and makes the errors visible.

c) Ultrasonic testing

Ultrasonic testing is particularly useful in detecting external and internal errors in sound-conducting materials, thereby detecting errors throughout the entire cross-section of the component. The acoustic procedure for non-destructive materials testing is used for quality assurance in pipes, weld seams and cast components as well as to test wall thickness.

d) Notched bar impact testing

How tough can a material be? Notched bar impact tests are carried out in order to determine the toughness of a metallic material even at extremely low temperatures.

Quality management system

The quality management system according to DIN EN ISO 9001 assists in optimising processes and is therefore at the very core of our company. Recurring work processes are described, responsibilities are established and the execution of testing is regulated.

Modern assembly machines for optimal results

Our production department is equipped with new and modern machinery. This is the only way to achieve perfect quality at an affordable price. However, a modern CNC-guided machine is only as good as the operator - our specialists receive continuous in-house training and we of course train our own technicians of tomorrow. We work to the conventional mechanical engineering standard, replacement parts can be produced and sent at very short notice, adaptations to the lifting equipment are not usually necessary.

Arrow 4Documentation

 Correct manufacturing, comprehensively documented

Sometimes documentation is just as important as the manufactured product. In international plant engineering the materials used must be precisely documented; an undocumented component may lead to the rejection of the entire piece of lifting equipment. Manufacture must be comprehensively described; the Major Proof of Suitability for Welding proves the basic suitability of the company.

Perfect documentation for further use

Verifiable statistics are often requested for the lifting equipment; failure of the lifting solution must be definitively ruled out. Customers and operators receive the technical diagrams in pdf format for long-term filing, although other workable formats such as Step or Iges are also available.

 Engineering lifting equipment - documentation

Mandatory documentation

Compliance with the new Machinery Directive 2006/42/EU is demonstrated by the CE declaration, the official 2.2 test report guarantees the agreed properties.

Instructions for safe operation

The general operating instructions for using our lifting equipment are provided alongside the product and in the requisite languages according to Machinery Directive 2006/42/EC. Safety-related replacement parts are described in the attached technical diagrams along with details of the manufacturer.

Arrow 5Testing

The loads to be lifted are often very important and extremely valuable. Failure of the lifting equipment must always be definitively ruled out. Damage to a gas condenser or a generator, for example, would have dramatic consequences. The insurers of the delivery as well as the customers of the large-scale plant therefore insist on additional supervision by an independent testing agency (e.g. TÜV, Dekra, GOST). For offshore use, testing by Germanischer Lloyd, Lloyds Register or Norske Veritas is required.

Load test

The practical test of the lifting equipment is the most important part of an independent inspection. The load test can reliably demonstrate the durability of the manufactured lifting solution.

Supervision during operation and repairs

Our test engineers are able to reliably test and repair complicated pieces of lifting equipment with hydraulic and electrical components. Renowned customers send their lifting beams directly to us following on-site use; our in-house testing and inspection guarantees perfect operation when it is next used again. Please contact us directly if you have any questions regarding testing or the product.

Insurance and product liability

Our promises are worth something. We possess a major and extensive insurance cover for the lifting solutions that we deliver. „Known indirect exports to the USA and Canada“ are also covered.

Some examples of special solutions (please click on the corresponding image):

  280 t lifting beam for MAN Turbo AG
   90 t spreader beam
 58.5 t beam grab, motor-powered 
   Motor-powered beam grab with two-crane suspension
 Hydraulic lifting beam for load tilting 
   160 t lifting beam for transporting machines in one and two-crane operation
380 t lifting beam with pin attachment, adjustable under load   380 t lifting beam preview
 Combination lifting beam with lateral spreaders preview  Combination lifting beam with lateral spreaders
 Combination lifting beam with side arms 
  70t lifting and transportation equipment for rotors
VarioBeam modular lifting beam   

Notes on attachment below the load's centre of gravity with lifting beams

Please note and comply!


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