Why Cargo Gear Load Testing Is Mandatory Under SOLAS and ILO Regulations

Cargo handling operations are among the most critical activities carried out on board ships. Cranes, derricks, lifting appliances, hooks, shackles, wire ropes, chains, spreaders and other loose gear are routinely exposed to heavy loads and demanding operating conditions.

A failure of cargo gear can result in serious injury, loss of life, cargo damage, structural damage and vessel downtime. For this reason, international maritime regulations require lifting appliances and associated gear to be properly tested, examined, inspected and maintained.

In 2026, cargo gear compliance has become even more important with the entry into force of SOLAS Chapter II-1 Regulation 3-13, which establishes requirements for onboard lifting appliances and anchor-handling winches. IMO's supporting MSC.1/Circ.1663 – Guidelines for Lifting Appliances provides guidance on design, testing, examination, operation and maintenance.

At the same time, ILO Convention No. 152 contains established requirements covering testing, examination, inspection and certification of lifting appliances and loose gear used in ship and dock work.

What Is Cargo Gear Load Testing?

Cargo gear load testing is a controlled test performed to verify that a lifting appliance or lifting gear can safely withstand its specified Safe Working Load (SWL) and the applicable test load.

The objective is not simply to place weight on a crane or lifting appliance. A proper cargo gear load test is part of a wider safety assessment involving:

• Verification of Safe Working Load (SWL)
• Examination of the lifting appliance
• Inspection of structural components
• Checking wire ropes and terminations
• Examination of hooks, shackles and blocks
• Testing of brakes and operational functions
• Verification of load-bearing components
• Application of the prescribed test load
• Thorough examination after testing
• Documentation and certification

The test should be performed under the supervision or acceptance of an appropriately recognized competent person, Administration or Recognized Organization (RO), as applicable.

Why Is Cargo Gear Load Testing Mandatory?

Cargo gear is designed to lift heavy loads, but its condition can deteriorate due to:

• Corrosion
• Metal fatigue
• Excessive loading
• Wire-rope deterioration
• Cracks in structural components
• Deformation
• Wear and tear
• Brake failure
• Poor maintenance
• Incorrect repairs
• Environmental exposure
• Unauthorized modifications

A lifting appliance may appear satisfactory during a visual inspection but still have structural or mechanical weaknesses.

Load testing provides an additional level of confidence that the equipment remains capable of safely performing its intended lifting function.

This is particularly important for shipboard cranes and lifting appliances because failures can occur over personnel, cargo holds, decks, quaysides or other working areas.

SOLAS Requirements for CargoGear Load Testing

A major regulatory development took effect on 1 January 2026.

The IMO introduced SOLAS Chapter II-1 Regulation 3-13, addressing the application, design, construction, operation, inspection, testing and maintenance of onboard lifting appliances and anchor-handling winches. The associated IMO Guidelines for Lifting Appliances are contained in MSC.1/Circ.1663.

Key requirements include:

1. Load testing before first use

For applicable new lifting appliances, load testing is required after installation and before the appliance is placed into service for the first time.

This verifies that the installed lifting appliance and its supporting arrangements can safely perform their intended function.

2. Testing after major repairs or modifications

Load testing is also required following repairs, modifications or alterations of a major character that could affect:

• Safe Working Load
• Strength
• Stability
• Service life
• Primary load-bearing structure
• Functionality or structural integrity

The IMO guidelines specifically identify these types of changes as major alterations requiring attention.

3. Periodic retesting

Under MSC.1/Circ.1663, applicable lifting appliances should be retested at least once every five years.

4. Thorough examination

A thorough examination is required following load testing and periodically thereafter. ABS summarizes the SOLAS/IMO regime as requiring thorough examinations after load tests and annually.

What About Existing Cargo Gear?

The 2026 SOLAS requirements are particularly important for vessels with existing lifting appliances.

For lifting appliances installed before 1 January 2026, the applicable equipment is required to be tested, thoroughly examined, permanently marked and supported by documentary evidence no later than the vessel's first renewal survey on or after 1 January 2026, subject to the applicable SOLAS provisions and Administration/RO requirements.

This means shipowners and managers should review their existing cargo gear records rather than assuming that previously issued certificates automatically satisfy the new SOLAS requirements.

Where existing equipment does not have acceptable certification or supporting documentation, additional testing and examination may be required.

ILO Convention No. 152 and Cargo Gear Testing

The ILO Occupational Safety and Health (Dock Work) Convention, 1979 (No. 152) specifically addresses the safe use of lifting appliances and loose gear.

Article 21 requires lifting appliances and loose gear to be properly designed, maintained and used safely, and prohibits loading beyond the safe working load except for authorized testing under the direction of a competent person.

ILO Article 22 – Testing

ILO Convention No. 152 requires:

• Testing before an appliance or loose gear is put into use for the first time
• Testing after substantial alteration or repair affecting safety
• Retesting shipboard lifting appliances at least once every five years
• Thorough examination and certification after testing

ILO Article 23 – Thorough Examination

In addition to testing, lifting appliances and loose gear are required to undergo periodic thorough examination at least once every 12 months under the Convention.

ILO Article 25 – Records and Register

Records are also an important part of compliance.

The ILO Convention requires authenticated records showing the:

• Safe Working Load
• Dates of testing
• Test results
• Thorough examination results
• Inspection results

A register of lifting appliances and loose gear should also be maintained in the prescribed form.

SOLAS vs ILO: What Is the Difference?

SOLAS and ILO requirements should not simply be treated as two interchangeable certificates.

They address safety from related but different regulatory perspectives.

The exact applicability can depend on the vessel, equipment, flag Administration, Recognized Organization, national legislation and the specific regulatory instrument being applied.

Therefore, shipowners should verify requirements with the vessel's Flag Administration and Recognized Organization rather than relying on a generic testing interval alone.

What Cargo Gear Should Be Tested?

Cargo gear load testing may apply to various shipboard lifting appliances and associated lifting equipment, depending on the applicable regulations.

Typical equipment includes:

Ship Cranes

• Provision cranes
• Deck cranes
• Cargo cranes
• Stores cranes
• Engine-room cranes
• Hose-handling cranes
• Offshore cranes where applicable

Derricks and Lifting Appliances

• Cargo derricks
• Lifting beams
• Monorail systems
• Workshop lifting appliances
• Machinery lifting arrangements

Loose Gear

• Hooks
• Shackles
• Swivels
• Blocks
• Chains
• Slings
• Wire-rope slings
• Master links
• Spreader beams
• Lifting accessories

ILO Convention No. 152 defines a lifting appliance broadly and also specifically covers loose gear used to attach loads to lifting appliances.

Cargo Gear Load Test: Typical Test Loads

MSC.1/Circ.1663 provides minimum test-load guidance for lifting appliances intended for use in port or sheltered waters.

The test load is based on the equipment's SWL:

For lifting appliances intended for open-sea operations, applicable dynamic loads must be considered and the test load should be established to the satisfaction of the Administration or recognized classification society, as applicable.

Example

Suppose a ship crane has an SWL of 20 tonnes.

The minimum test load under the table would be:

20 × 1.25 = 25 tonnes

Therefore, the applicable minimum test load would be 25 tonnes, subject to the requirements and acceptance of the Administration/RO.

How Is Cargo Gear Load Testing Carried Out?

A professional cargo gear load test should follow a controlled procedure.

Step 1: Review Documentation

The service team verifies:

• Crane details
• SWL
• Manufacturer information
• Previous test certificates
• Previous examination reports
• Repair history
• Relevant drawings
• Class/Flag requirements

Step 2: Visual and Structural Inspection

The lifting appliance is examined for:

• Cracks
• Corrosion
• Deformation
• Loose fasteners
• Structural damage
• Abnormal wear
• Weld defects
• Damaged components

Step 3: Wire Rope Inspection

Wire ropes are checked for:

• Broken wires
• Corrosion
• Kinking
• Crushing
• Bird-caging
• Diameter reduction
• Poor termination
• Lubrication condition

Step 4: Loose Gear Inspection

Hooks, shackles, chains, blocks and slings are examined for wear, deformation, cracks and identification markings.

Step 5: Load Test

The prescribed test load is applied using an appropriate and controlled testing arrangement.

The equipment is monitored during the test for abnormal movement, deformation, brake slippage or other unsafe conditions.

Step 6: Operational Test

The lifting appliance may be checked for functions such as:

• Hoisting
• Lowering
• Slewing
• Luffing
• Brake operation
• Emergency functions
• Limit switches
• Control systems

Step 7: Post-Test Examination

After completion of the load test, the lifting appliance undergoes the required thorough examination.

Step 8: Certification

Upon satisfactory completion, the applicable test and examination documentation is issued by the competent person/RO or other authority as required.

Why Thorough Examination Is Just as Important as Load Testing

Load testing alone does not prove that every component of cargo gear is in good condition.

For example, a crane may successfully lift a test load while still having:

• Corroded structural members
• Excessively worn sheaves
• Damaged wire ropes
• Cracked hooks
• Deteriorated bearings
• Brake problems
• Loose structural connections

This is why load testing and thorough examination should be considered complementary safety controls.

The ILO describes thorough examination as a detailed visual examination by a competent person, supplemented where necessary by other suitable methods to reach a reliable conclusion regarding safety.

What Happens If Cargo GearTesting Is Overdue?

Using cargo gear without valid testing and examination records can create serious operational and compliance risks.

Potential consequences include:

• Unsafe lifting operations
• Injury or fatality
• Cargo damage
• Crane failure
• Vessel delays
• Port restrictions
• Class/Flag observations
• Inspection deficiencies
• Detention risk where applicable
• Insurance complications
• Increased liability for owners and operators

ILO Convention No. 152 states that lifting appliances or loose gear should not be used where the competent authority is not satisfied that the required testing, examination or inspection has been carried out or where the equipment is considered unsafe.

Importance of Competent Cargo Gear Testing

Cargo gear testing should not be treated as simply attaching a test weight to a crane.

A competent person should have the necessary knowledge and experience to assess the equipment and perform the required duties.

ILO Convention No. 152 requires competent persons to be recognized or accepted by the competent authority, while the SOLAS/IMO regime places testing and examination under the applicable Administration/RO framework.

For shipowners and managers, choosing a service provider with appropriate technical capability, equipment, trained personnel and acceptance by the relevant authority is therefore critical.

Cargo Gear Testing Documentation

After testing, the vessel should maintain appropriate documentation.

Depending on the applicable regulatory framework, records can include:

• Cargo Gear Test Certificate
• Thorough Examination Certificate
• Register of Lifting Appliances and Loose Gear
• SWL information
• Test load
• Test date
• Next due date
• Equipment identification
• Defects identified
• Repairs completed
• Competent person's details
• Class/RO or Flag endorsement where applicable

ILO guidance emphasizes maintaining records and certificates as evidence of the safe condition of lifting appliances and loose gear.

Cargo Gear Load Testing and Planned Maintenance

Cargo gear testing should form part of the vessel's Planned Maintenance System (PMS).

Ship managers should maintain a tracking system for:

Equipment ? SWL ? Last Test ? Last Examination ? Certificate ? Next Due Date

This helps prevent:

• Expired certificates
• Missed five-year tests
• Missed annual examinations
• Unrecorded repairs
• Missing loose-gear certificates

The IMO's lifting-appliance guidelines are intended to support a systematic approach to operation, inspection, testing and maintenance.

Cargo gear testing should be planned well before a class, Flag or port inspection.

Waiting until the last moment can create problems such as:

• Limited availability of testing equipment
• Difficulty arranging competent personnel
• Port operation restrictions
• Vessel schedule delays
• Missing historical documentation
• Additional repair requirements discovered during inspection

A proactive cargo gear inspection and testing program allows defects to be identified and corrected before they become an operational or compliance problem.

Cargo Gear Load Testing Servicesin India

For shipowners, ship managers, technical superintendents and vessel operators, cargo gear load testing is an important part of maintaining safe lifting operations.

Marinetech Safety Pvt. Ltd. provides marine safety and cargo gear-related inspection and testing services for shipboard lifting equipment.

Cargo gear services can include inspection and testing of:

• Ship cranes
• Cargo cranes
• Deck cranes
• Derricks
• Hooks
• Shackles
• Wire ropes
• Slings
• Lifting accessories
• Loose gear

Testing requirements are assessed according to the applicable SOLAS requirements, IMO MSC.1/Circ.1663, ILO requirements, Flag Administration requirements and Class/RO requirements.

For vessels operating from Indian ports such as Mundra, Hazira, Surat, Mumbai, Sikka, Jamnagar, Kandla, Vizag, Chennai and Paradip, advance planning of cargo gear testing can help reduce operational delays and maintain appropriate certification records.

Cargo Gear Load Testing Checklist for Shipowners

Before arranging cargo gear testing, verify:

Equipment identification available
Safe Working Load clearly marked
Previous certificate available
Previous test date checked
Annual examination status checked
Wire rope condition checked
Hooks and shackles inspected
Loose gear certificates available
Structural condition inspected
Brake operation checked
Test load requirement confirmed
Flag/Class/RO requirements confirmed
Competent person arranged
Test equipment available
Certificate and register updated after completion

Frequently Asked Questions

1. Is cargo gear load testingmandatory on ships?

Yes, applicable shipboard lifting appliances are subject to testing and examination requirements under the relevant regulatory framework. Since 1 January 2026, SOLAS II-1/3-13 and IMO MSC.1/Circ.1663 provide specific requirements for applicable onboard lifting appliances.

2. How often should a ship crane be load tested?

Under MSC.1/Circ.1663, applicable lifting appliances should be retested at least once every five years, with additional testing after installation and after major repairs or modifications as applicable.

3. Is annual cargo gear inspection required?

Yes. Annual thorough examination requirements apply under the applicable SOLAS/IMO and ILO framework. ILO Convention No. 152 specifically requires thorough examination at least once every 12 months.

4. What is SWL in cargo gear?

SWL means Safe Working Load. It is the maximum load that a lifting appliance or item of loose gear is certified to lift under specified operating conditions.

5. What is the difference between load testing and thorough examination?

Load testing verifies the lifting appliance's ability to withstand the prescribed test load. Thorough examination is a detailed assessment of the equipment and its condition. Both provide different but complementary safety assurances.

6. What cargo gear requires certification?

Depending on the applicable requirements, lifting appliances and associated loose gear such as hooks, shackles, slings, chains, blocks and other lifting accessories may require testing, examination and documentary evidence.

7. Does SOLAS replace ILO cargo gear requirements?

Not necessarily. The applicable requirements depend on the vessel, Flag Administration, equipment and regulatory framework. Owners should verify the specific requirements with their Flag Administration and Recognized Organization. ABS, for example, notes that SOLAS certification does not automatically replace applicable cargo-gear certification requirements under other instruments.

8. Can cargo gear be used if the certificate has expired?

Equipment should not be used where the applicable testing, examination or certification requirements have not been satisfied. The vessel's Master, company, Flag and RO requirements should be followed before putting the equipment back into service.

Conclusion

Cargo gear load testing is not merely a paperwork requirement. It is a critical safety measure designed to verify that lifting appliances and associated gear remain capable of safely performing their intended function.

With SOLAS II-1/3-13 entering into force on 1 January 2026, shipowners and managers need to pay particular attention to lifting-appliance testing, thorough examination, periodic retesting, loose-gear certification and proper documentation.

The combination of SOLAS, IMO MSC.1/Circ.1663 and ILO Convention No. 152 provides an important framework for safer cargo-handling operations and better control of lifting-equipment risks.

Regular cargo gear load testing can help protect crew, shore personnel, cargo, vessel structures and business operations—while supporting compliance with applicable maritime safety requirements.

If your vessel's cargo gear test, five-year load test or annual examination is approaching, arrange the inspection and testing in advance and confirm the applicable Flag/Class/RO requirements before the vessel's operation or survey.

Related Blogs

1. IMO MSC.1/Circ.1318/Rev.1 Explained: Complete Guide to Fixed CO2Fire Extinguishing System Inspection (2026)

fire fighting equipment, ship fire fighting system, IMO MSC.1/Circ.1318/Rev.1, Fixed CO2 System, Fixed CO2 Fire Extinguishing System, CO2 System Inspection, CO2 System Maintenance, CO2 Fire Suppression System, Marine Fire Safety, Marine Safety, SOLAS Compliance, SOLAS Chapter II-2

2. Marine Navigation & Communication Equipment Supplier in India: Complete Guide for Ship Managers

AIS transponder supplier India, ECDIS supplier India, VHF radio ship India, Inmarsat terminal supplier India, navcom equipment India, marine radar supplier India

3.Life Saving Equipment for Ships: What SOLAS Requires & What Marinetech Supplies

life saving equipment ship India, LSE supplier India, lifejacket supplier India, immersion suit supplier India, EPIRB supplier India, SART supplier India, SOLAS life saving equipment India

4. Fire Fighting Equipment on Ships: What SOLAS Requires & What Marinetech Supplies

fire fighting equipment ship India, SOLAS fire fighting equipment requirements, marine fire fighting equipment supplier India, fireman outfit supplier India, SCBA supplier India, fire extinguisher ship India

5.Fire Fighting Appliances Service in India 2026: Complete Guide

fire fighting appliances service India 2026, LSA FFA inspection India, fire fighting equipment service ship India, marine fire safety India, SOLAS fire fighting requirements, DG Shipping approved fire fighting service India