Cranes are among the highest-risk plant on any worksite. A thorough inspection before use, and at regular intervals, is essential to prevent catastrophic failure, dropped loads and fatal incidents.
This guide covers the inspection process for mobile cranes, tower cranes and overhead cranes, from documentation checks through to operational testing and record-keeping. It applies to daily pre-start checks and periodic inspections.
Before you start
Gather your crane inspection checklist, the crane's current load chart, previous inspection records and the logbook. You will also need PPE (hard hat, high-vis vest, safety glasses), a torch for dark areas under the superstructure and a camera for photographing defects.
Only a competent person should conduct crane inspections. In Australia this means holding the relevant High Risk Work (HRW) licence class. In the US, operators must hold NCCCO certification or equivalent. Review the crane's maintenance history and outstanding defect notices before beginning, and confirm registration compliance.
Step-by-step inspection
1. Check documentation and certification
Confirm registration is current and the plate is displayed. Check the load chart is legible, correct for the crane configuration and accessible to the operator. Verify the operator's licence (HRW in Australia, NCCCO in the US). Review the logbook for outstanding defects and the last thorough examination certificate date.
2. Inspect the base, slew ring and outriggers
Inspect ground conditions under each outrigger pad. The ground must be firm, level and able to support the imposed loads. Check outrigger pads for cracks and correct positioning. Inspect slew ring bolts for tightness and signs of cracking. Examine the turntable and slew bearing for wear, play or grease leaks. Confirm the crane is level.
3. Check wire ropes and sheaves
Inspect all wire ropes for broken wires, kinking, bird-caging, corrosion and flat spots. Count visible broken wires against the discard criteria in AS 2759 (Australia) or ASME B30.5 (US). Check sheave grooves for wear and correct rope seating. Ensure rope end terminations are secure.
4. Inspect hooks and load-handling attachments
Check the safety latch operates freely. Measure the hook throat opening, which must not exceed 5% of the original dimension. Look for deformation, twisting and wear on the hook saddle. Confirm the swivel rotates freely without binding.
5. Check safety devices and limiters
Verify the load moment indicator (LMI) is functioning and calibrated. Test the anti-two-block device, boom angle indicator, slew limit switches and hoist limit switches. For tower cranes, also check trolley travel limits and the wind speed indicator.
6. Test operational controls
With the crane unloaded, test each function: hoist up/down, boom up/down (luffing for tower cranes), slew left/right, and trolley travel for overhead cranes. Listen for unusual noises or hesitation. Check hydraulic hoses and cylinders for leaks. Confirm the emergency stop works and controls return to neutral when released.
7. Record and tag the crane
Complete the inspection register with the date, inspector name, crane ID and findings. Attach a green tag (fit for use) or red tag (do not operate). Note all defects and corrective actions required. Use a crane pre-start checklist to standardise the process across your fleet.
Common defects and required actions
| Defect | Action required |
|---|---|
| Broken wires in rope exceeding discard criteria | Remove rope from service, replace before next lift |
| Hook throat opening exceeds 5% | Remove hook from service, replace |
| Cracked or corroded structural members | Stand down crane, engage structural engineer |
| LMI not functioning | Do not operate, repair and recalibrate before use |
| Hydraulic leak on boom cylinder | Stand down crane, repair and test before use |
| Worn sheave grooves | Replace sheaves to prevent rope damage |
| Missing or illegible load chart | Do not operate until correct chart is displayed |
| Outrigger pad cracked or damaged | Replace pad before setting up the crane |
Daily vs periodic inspections
| Aspect | Daily pre-start | Periodic inspection | Thorough examination |
|---|---|---|---|
| Frequency | Every shift | Monthly or quarterly | 12 months (or 6 months for some plant) |
| Who | Trained operator | Competent person | Certified inspector (AU: crane inspector, UK: per LOLER) |
| Depth | Visual and operational checks | Visual, operational and measurements | Dismantling as required, NDT, load testing |
| Record | Daily checklist | Inspection register | Formal report with recommendations |
Standards and regulations
In Australia, AS 1418 covers crane design and inspection while AS 2550 sets the standard for safe use. WHS Regulations Part 4.5 requires registration of cranes with a capacity of 10 tonnes or more. States and territories may impose additional crane inspector requirements.
In the US, OSHA 29 CFR 1926.1400 to 1926.1442 governs cranes and derricks in construction. The ASME B30 series provides inspection and maintenance standards. Operators must hold ANSI/NCCCO certification.
In the UK, LOLER 1998 requires thorough examination of lifting equipment at prescribed intervals. PUWER 1998 covers general equipment safety and BS 7121 provides the code of practice for safe crane use. Load testing requirements vary by jurisdiction, so confirm local rules.
Going digital with MapTrack
Paper crane logbooks get left in cabs, damaged by weather or lost entirely. MapTrack replaces paper records with digital crane pre-start forms that operators complete on their phone before each shift. Every inspection captures timestamped defect photos, GPS location and a digital signature, creating a complete compliance trail.
Build custom crane inspection checklists for each crane type in your fleet. When an inspection is overdue or a critical defect is logged, MapTrack triggers automated alerts to the responsible supervisor. For a related guide, see how to inspect scaffolding.
