Cranes play a crucial role in Australia’s construction, mining, and heavy industries, lifting and moving heavy loads with precision. However, given their high-risk nature, stringent safety measures are essential to prevent catastrophic failures. One of the most critical safety protocols is the major inspection, a thorough assessment of a crane’s structural and mechanical integrity to ensure compliance with Australian safety standards.
In this article, we’ll explore what major crane inspections involve, why they’re required, and how they help keep Australian workplaces safe.
What Is a Major Inspection on a Crane?
A major inspection is a comprehensive examination of a crane’s structural, mechanical, and electrical components to assess its continued safety and operational fitness. It is far more detailed than routine servicing and is typically required when a crane reaches 10 years of service or has undergone 10,000 hours of operation, whichever comes first.
The inspection aligns with Australian Standard AS 2550.1-2011, which outlines safe use, maintenance, and inspection requirements for cranes.
Why Are Major Inspections Required?
1. Compliance with Australian Standards
WorkSafe Australia and state-based workplace health and safety (WHS) regulators require major inspections under AS 2550.1-2011. Failure to comply can lead to penalties, operational shutdowns, and liability issues.
2. Ensuring Structural Integrity
Over time, crane components such as booms, hoists, and wire ropes experience fatigue, corrosion, and wear. A major inspection identifies potential failures before they become hazards.
3. Enhancing Workplace Safety
Cranes operate under extreme conditions, and a failure can result in serious injuries, fatalities, and extensive property damage. Thorough inspections reduce risks and improve workplace safety.
4. Extending Equipment Life
A well-maintained crane can continue operating safely beyond its original service life. Inspections allow for timely repairs and upgrades, potentially delaying the need for costly replacements.
What Does a Major Crane Inspection Involve?
A major inspection follows a structured approach, including:
1. Visual & Structural Examination
• Inspecting welds, booms, counterweights, and chassis for cracks, fatigue, or corrosion
• Assessing pins, bolts, and connections for wear or deformation
• Checking for fluid leaks, hydraulic hose degradation, and corrosion
2. Non-Destructive Testing (NDT)
• Using ultrasonic, magnetic particle, and dye penetrant testing to detect internal cracks or weaknesses
• Testing critical load-bearing components for material fatigue
3. Mechanical System Assessment
• Inspecting brakes, clutches, and gears for wear
• Assessing the wire ropes, sheaves, and pulleys for fraying or breakage
• Checking the slew ring bearing and gearbox operation
4. Electrical & Control System Testing
• Ensuring limit switches, safety interlocks, and emergency stop systems function correctly
• Checking wiring, control panels, and sensors for faults
5. Load Testing & Operational Assessment
• Conducting a full-load test to verify lifting capacity and performance
• Ensuring the crane meets manufacturer’s specifications and regulatory requirements
6. Certification & Documentation
• A qualified engineer or inspector provides a detailed report of findings
• If the crane passes, a certificate of compliance is issued
• If defects are found, repairs or part replacements are required before clearance
Who Can Perform a Major Inspection?
Only competent persons, such as licensed crane inspectors, mechanical engineers, or WHS-certified professionals, can conduct major inspections. These individuals must have extensive knowledge of crane design, engineering, and safety regulations.
What Happens if a Crane Fails the Inspection?
If a crane does not meet safety standards, the owner must:
• Perform necessary repairs or part replacements
• Conduct a re-inspection after maintenance is complete
• In severe cases, decommission the crane if it is beyond repair
Operating a non-compliant crane is a serious offense that can lead to heavy fines, legal action, or workplace shutdowns.
Keeping Cranes Safe and Compliant
Major crane inspections are not just a regulatory obligation—they are a critical investment in safety, longevity, and efficiency. Regular inspections reduce risks, prevent accidents, and help businesses comply with Australian safety laws.
For crane owners and operators, staying proactive with routine maintenance and timely major inspections ensures continued compliance and peace of mind.
