| S.No. | Checkpoint | IS Requirement | Status |
|---|---|---|---|
| A. TEST SETUP | |||
| A1 | Test apparatus set up; load cell calibrated; deflection gauges zeroed Acceptance: Equipment working; Load cell cert valid; Baseline recorded | Cl.1 - Equipment | OK NC NA HOLD |
| A2 | Load applied in increments: 25%, 50%, 75%, 100% design load Acceptance: Gradual increment; Hold time 2-3 min each; Data logged | Cl.2 - Loading | OK NC NA HOLD |
| A3 | Deflection measured at mid-span and supports Acceptance: Readings recorded at each load level; Linearity checked | Cl.3 - Measurement | OK NC NA HOLD |
| B. TEST RESULTS | |||
| B1 | Final deflection ≤ L/360 at design load; no permanent set > 5% Acceptance: Deflection ratio acceptable; Recovery elastic; No cracking | Cl.4 - Acceptance | OK NC NA HOLD |
| B2 | No visible damage, cracks, or member failure observed Acceptance: Member condition post-test satisfactory; Structure intact | Cl.5 - Integrity | OK NC NA HOLD |
For engineered scaffolds (over 6 m height, supporting heavy loads, used for façade work / cladding / heavy materials) — IS 3696 Part 2 mandates load capacity verification before use. A scaffold rated for 250 kg/m² that has been overloaded or improperly assembled can fail catastrophically.
The Load Capacity Test verifies that the as-built scaffold can support the design load + safety factor without excessive deflection or any structural failure. Without this test, the scaffold's actual capacity is unverified; using it = gambling with worker safety.
The test is mandatory for: tall scaffolds, heavy-duty scaffolds (façade with stone cladding, etc.), specialty scaffolds (cantilever, suspended), scaffolds in high-risk weather conditions.
Pre-test preparation: 1. Verify scaffold built per design + checklist (toe boards, guardrails, ties, bracing) 2. Identify test points (typically working platform mid-span) 3. Clear workers from area 4. Position test load weights (sandbags, concrete blocks, water tanks)
Test procedure: 1. Initial measurement — record platform level at test points 2. Load application — apply 25%, 50%, 75%, 100% of design load progressively 3. Wait period — 30 minutes at full design load 4. Final measurement — record platform level + observation of any visible deformation, cracking, slippage 5. Overload test (optional, for engineered scaffolds) — additional 25% (total 125% of design) 6. Release — remove loads in reverse order; observe scaffold recovery
Acceptance criteria: - Deflection ≤ L/300 (where L = span length) - No visible structural damage - No connector slippage - Recovery > 90% of pre-test position - Operators / inspectors signature confirms safe state
Documentation: load applied, deflection at each load increment, final loaded state, photos, inspector + supervisor signatures.
1. Test skipped — scaffold used without verification; failure under actual load. 2. Inadequate test load — partial load only; unverified ultimate capacity. 3. No structural inspection — bolt / coupler loosening missed; subsequent vibration causes failure. 4. Inappropriate scaffold type for load — light scaffold rated 150 kg/m² used for heavy façade work (300+ kg/m²); failure inevitable. 5. No deflection measurement — visual inspection only; minor cracking / micro-deflection invisible. 6. Workers on scaffold during test — safety risk; clear area first. 7. Wrong load placement — concentrated point load when actual usage is distributed; misleading test results. 8. No re-test after modification — scaffold modified post-test; original certification void.
Companion QA/QC: - Scaffold Inspection Register (QC-SCF-REG-001) — periodic inspection log - Work at Height Checklist (QC-SCF-CHK-004) — per-task safety verification - Scaffold Method Statement (QC-SCF-FRM-001) — design + erection methodology
Standards + regulations: - IS 3696 Parts 1-2 — Safety code for scaffolds and ladders (load testing in Part 2) - IS 4014 Parts 1-2 — Code of practice for steel tubular scaffolding - BOCW Act 1996 — building workers' welfare + safety - NBC 2016 Part 7 — Construction Practices and Safety