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Free bridge crane inspection checklist

Free bridge crane inspection checklist (PDF-ready). Covers runways, end trucks, hoists, wire ropes, controls and safety devices. Safe use: AS 2550.3.

Updated 2 Oct 2026

Bridge crane inspection

Daily and monthly inspection | Safe use: AS 2550.3

Live form
0 of 30 checks

Runway & rails

1Runway rail alignment - both rails
2Rail wear and splices condition
3Runway support brackets fixity
4End stops at both ends of runway
5Runway conductor bar continuity

End carriage wheels & drives

6Wheel-flange wear within limits
7Wheel tread wear and roundness
8Drive coupling condition
9End-truck frame square and welds
10Bumper condition both ends

Bridge girder & trolley

11Bridge girder camber and cracks
12Bolted connections torqued
13Trolley wheels and trolley rails
14Festoon cable track and trolley
15Walkway and handrails (if fitted)

Hoist machinery & brakes

16Hoist motor and gearbox oil
17Holding brake holds rated load
18Brake pad or shoe thickness within OEM limits
19Drum grooves and rope anchor
20Hoist limit switch (upper)

Wire rope & hook

21Rope diameter reduction less than 10%
22Broken wires per AS 2759 / ASME B30.2
23Hook throat opening within limit
24Hook safety latch functional
25Sheaves and bearings

Controls & safety devices

26Pendant or cab controls smooth
27Emergency stop functional
28Overload protection (if testable)
29Audible warning device
30Main isolator and lockout point

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Jarrod Milford

Jarrod Milford

Co-Founder & Commercial Director

Updated 2 October 2026
Also see:Compliance and inspections →Best inspection software →MapTrack vs SafetyCulture →

Short answer

A bridge crane inspection checklist records operator pre-use checks and periodic competent-person inspections of an overhead crane: runway, end stops, girder, trolley, hoist, ropes or chain, hooks, brakes, limit switches and controls. AS 2550.3:2025 Section 14 covers maintenance and inspection. Regulation 213 of the model WHS Regulations requires competent-person inspection; US sites follow OSHA 29 CFR 1910.179.

Checked against AS 2550.3:2025 on by the MapTrack templates team. How we check templates

Key takeaways

  • The MapTrack bridge crane inspection checklist contains 30 checks across 6 sections. Sections covered: Runway & rails, End carriage wheels & drives, Bridge girder & trolley, Hoist machinery & brakes, Wire rope & hook, Controls & safety devices.
  • OSHA 1910.179 sets frequent inspections (daily to monthly) and periodic inspections (1 to 12 months) for US overhead and gantry cranes.
  • Inspect wire rope against the AS 2759 discard criteria (Section 14) and record broken wires, corrosion and diameter loss.
  • Tag the crane out of service when a brake, upper limit switch or end stop fails, and keep it out until repaired and rechecked.
  • Keep maintenance, inspection and repair records for each crane (AS 2550.1 clause 7.5).
  • AS 2550.1 Section 9 covers the major assessment of a crane for continued use or changed operation.

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Used by construction, mining and field service teams

Saunders InternationalMineral ResourcesSupagasHacer GroupMetro TunnelUltrabuilt

What is a bridge crane inspection checklist?

A bridge crane inspection checklist is a structured form used to inspect and document the condition of an overhead bridge crane, one of the crane types AS 2550.3 (Cranes, hoists and winches - Safe use - Bridge, gantry, portal (including container cranes), jib cranes and monorail beams) covers. It covers every safety-critical component of a top-running or underhung bridge crane, including runway rails and end stops, end trucks and wheel assemblies, the bridge girder, the trolley and hoist, wire ropes or load chains, hooks, brakes, controls, limit switches and electrical collection systems. The checklist gives factory and warehouse operators a single repeatable record that proves each inspection happened, who performed it and what was found.

Under the model WHS Regulations, Part 5.1 requires a bridge crane to be maintained and inspected by a competent person (regulation 213), and the design of a bridge crane with a safe working load greater than 10 tonnes, or of any bridge crane designed to handle molten metal or Schedule 11 hazardous chemicals, must be registered (Part 5.3 and Schedule 5). Unlike mobile cranes, bridge cranes are permanently installed and routinely operated by general workshop staff rather than ticketed crane operators, which makes daily and periodic inspection even more important. A documented inspection programme is the record a PCBU uses to show how it is meeting its obligations under the WHS Regulations 2011, read alongside AS 2550.3, AS 1418.3 (Bridge, gantry, portal and jib cranes) and (for US operations) OSHA 29 CFR 1910.179. Failing to detect a worn brake, a deformed end stop or a corroded wire rope before a lift can lead to load drops, runway derailment, structural collapse or fatalities, making a documented daily and periodic inspection regime non-negotiable for every bridge crane on site.

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Benefits of using this bridge crane inspection checklist

  • Worker safety: detect cracked welds, worn brakes and damaged wire ropes before they cause a load drop or runway derailment over a workshop floor.
  • Inspection records: daily, monthly and annual records for bridge, gantry and portal cranes, the crane types AS 2550.3 covers, ready for a competent person to review.
  • Production uptime: catch wheel-flange wear, gearbox leaks and contactor wear during scheduled inspections rather than mid-lift when a crane down event halts the whole bay.
  • Insurance and warranty: documented inspection history is routinely requested by industrial liability insurers and crane warranty providers after any incident or claim.
  • Component lifecycle tracking: track wire-rope retirement criteria, brake-shoe thickness and wheel-flange wear over time to plan replacements before they become emergencies.
  • OSHA 1910.179 readiness: organisations operating bridge cranes in the United States get an inspection format that covers the OSHA frequent (daily to monthly) and periodic (1 to 12 month) inspection classes for overhead and gantry cranes.
  • Audit defence: signed and dated inspection records demonstrate due diligence to WHS, OSHA or insurer auditors after any incident, near-miss or scheduled audit visit.

Benefits of digitising forms in MapTrack

When you digitise bridge crane checklists in MapTrack, you get:

  • Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
  • Email the right people when a form is submitted, with an automation you set up.
  • File every completed form against the asset, location or person it covers.
  • Download any completed form as a PDF, with failed answers listed at the top.
  • Fill in forms offline; they upload when the device is back online.
  • Build conditional logic (show or hide questions based on answers).
  • Take pictures or attach photos. Not possible with a paper-based form.
  • Electronic signatures.
  • Edit forms later without reprinting.
  • Set who can view, fill in or edit forms with user roles.
  • Upload a paper form (PDF, Word, Excel or a photo) and MapTrack's AI builds a digital version for you to check.
  • Email safety managers when a hazard report is submitted, with an automation you set up.
  • Keep every hazard and incident report against the site it came from, with photos.
  • Turn a hazard report into a corrective-action work order with its own review step.

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What to include in a bridge crane inspection checklist

This bridge crane inspection checklist covers 13 key areas:

  • Crane details: type (top-running or underhung), make, model, serial number, SWL/WLL in tonnes, span, runway length, site location and asset ID.
  • Inspection details: inspector name, date, inspection type (daily, monthly, quarterly, annual), run hours or lift cycles.
  • Runway and end stops: rail alignment, rail wear, splices, support brackets, runway conductor bars, end stops at both ends of the runway.
  • End trucks and wheels: wheel-flange wear, tread wear, axle play, wheel bearings, drive coupling, square truck frame.
  • Bridge girder and trolley: girder camber, bolted connections, paint and corrosion, trolley wheels, trolley rails, bridge walkway and handrails (if fitted).
  • Hoist: hoist motor, gearbox oil level, brake operation, brake shoe or pad thickness, holding brake, hoist drum, drum grooves.
  • Wire ropes or load chains: rope diameter, broken-wire count per lay, corrosion, lay length, fleet angle, drum anchorage, dead-end terminations, or chain link wear and stretch.
  • Hook block and rigging: hook throat opening, hook twist, safety latch, swivel function, sheaves, sheave bearings, lower block guards.
  • Controls and pendant: pendant condition, festoon cable, control buttons, joystick centring, smoothness of operation, radio remote and battery (if used).
  • Safety devices: upper limit switch, lower limit switch (if fitted), anti-collision (multi-crane bays), overload protection, emergency stop, audible warning.
  • Electrical: collector shoes or festoon, runway conductor bar, cab heating and lighting (if cab-operated), bridge isolator, motor brake disc.
  • Defect register: each defect numbered with severity (critical, major, minor) and corrective action.
  • Sign-off: inspector signature, supervisor or workshop manager signature, date.

How to use this bridge crane inspection checklist

  1. Record crane details and pre-inspection run hours.: Note the crane type (top-running or underhung), make, model, serial number, SWL or WLL, span, current run hours from the panel and the date of last service. This ties the inspection to a specific asset and its maintenance history under AS 2550.3.
  2. Conduct visual inspection from floor level with the crane powered off and locked out.: Walk the full runway length and inspect the runway rails, splices, end stops, runway conductor bars, support brackets and any anti-collision sensors. Inspect the bridge girder, end trucks and trolley from below for cracks, corrosion, oil leaks, deformation or missing components.
  3. Inspect wire ropes or chains, hooks and rigging at the lowest practical hoist position.: Lower the hook block to a safe accessible height and inspect the wire rope or chain along its full length. For wire ropes, measure rope diameter at three points, count broken wires per lay length and check for corrosion, kinking, birdcaging and lubrication per AS 2759. Inspect the hook throat for opening, twist and safety-latch operation.
  4. Power up, perform no-load functional tests, then test with a known test load.: Energise the crane, then test each control function from the pendant or cab: hoist up and down, cross-travel, long-travel, all at no load. Cycle each motion through the upper, lower and end-of-travel limits. Apply the test load your procedure specifies and confirm each brake holds without creep; under OSHA 1910.179(k)(2), rated load test loads must not exceed 125 percent of the rated load unless the manufacturer recommends otherwise.
  5. Test all safety devices including limit switches, overload and emergency stop.: Confirm the upper limit switch activates before the hook contacts the underside of the trolley. Test the overload protection by lifting a load close to but under the trip threshold and verify the trip if the device is testable from the pendant. Press the emergency stop and confirm all motions cease and brakes set.
  6. Record all defects with severity ratings and assign corrective actions.: For each defect found, record the component, the nature of the fault and a severity rating (critical, major or minor) against AS 2550.3 and the manufacturer manual. Critical defects (failed brake, cracked load-bearing weld, broken wire-rope criteria reached) require the crane to be immediately tagged out of service.
  7. Sign off, tag the crane and update the maintenance record.: Record the overall inspection result (pass or fail), sign and date the form, and apply a green serviceable tag or red out-of-service tag to the bridge or main isolator. Update the asset service record and raise work orders for any major or minor defects so they are closed out before the next inspection cycle.

In MapTrack, you can digitise safety inspections and compliance forms. Each submission is stored as a timestamped PDF against the asset record.

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How often should you complete this checklist?

Bridge crane inspections follow a tiered schedule. This checklist uses daily, monthly, quarterly and annual tiers, which fit the frequent and periodic inspection classes in OSHA 1910.179(j). Check the current edition of AS 2550.3 for the Australian inspection rules. The operator performs a daily pre-shift visual and functional check that confirms controls, brakes, limit switches and the emergency stop work correctly. Monthly inspections by a competent person cover wire ropes or load chains, hooks, brakes, end trucks and the runway conductor system. Quarterly and annual inspections by a competent person cover the full structural inspection, gearbox condition, wheel-flange wear measurement, electrical insulation testing and a documented load test.

The major assessment for continued use (AS 2550.3), made against the crane's design working period, typically involves non-destructive testing of the bridge girder, end-truck welds and runway rails, plus a full strip-down of the hoist. Cranes in high-duty cycles (steelworks, foundries, paper mills), high-humidity environments or any crane after an overload event, side-pull incident or structural modification must be re-inspected before returning to service. In MapTrack, you can schedule each inspection tier per crane, link inspection results to the asset and trigger automatic work orders for any defect that fails AS 2550.3 or the OEM service manual.

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Frequently asked questions

AS 2550.3 (Cranes, hoists and winches - Safe use - Bridge, gantry, portal (including container cranes), jib cranes and monorail beams) is the primary standard for the safe use and inspection of bridge cranes in Australia. It is read alongside AS 1418.3 (Bridge and gantry cranes) for design, AS 2759 (Steel wire rope - Use, operation and maintenance) for rope assessment and AS 2089 (Sheave blocks for lifting purposes). WHS Regulations 2011 Chapter 5 Part 5.1 then sits over the top of all of these, placing duties on the PCBU and the competent person.

OSHA 29 CFR 1910.179(j) divides inspections into frequent inspections at daily to monthly intervals, including a monthly hook inspection with a signed certification record, and periodic inspections, which are complete inspections of the crane at 1 to 12 month intervals depending on activity, severity of service and environment; running ropes also get a thorough monthly inspection with a certification record under 1910.179(m)(1). Cranes that have been idle for one month or more must be inspected before being returned to service.

Daily pre-operational checks can be completed by a trained and competent operator. Monthly and periodic inspections should be performed by a competent person with documented training and experience in bridge crane systems. Annual and major inspections, including load testing and any structural assessment, should be performed by a competent person or licensed assessor with relevant engineering competencies. The PCBU is responsible for confirming the inspectors qualifications under the WHS framework and AS 2550.3.

The structural and functional sections of this checklist apply broadly to bridge, gantry and portal cranes covered by AS 2550.3 (and OSHA 1910.179 in the US). However, gantry cranes have additional inspection items for legs, sill beams and end-truck wheels running on floor rails, and jib cranes have unique items for the slewing bearing, jib boom and pillar mounting. Use this template as a baseline for any overhead crane but supplement with the specific items from the manufacturer manual for your crane type.

A bridge crane must be tagged out of service if any critical defect is found. Typical critical defects that take a bridge crane out of service include: a brake that fails to hold the rated load, a wire rope reaching the broken-wire retirement criteria of AS 2759 or ASME B30.2, a hook with throat opening exceeding 15% of the original or twist exceeding 10 degrees, a cracked load-bearing weld in the bridge girder or end trucks, an inoperative upper limit switch, or a deformed end stop. Tag and lock out the main isolator immediately and raise a work order before any further use.

Yes. Download and use this bridge crane inspection checklist for free. It downloads as a ready-to-print PDF. No MapTrack account is required. If you want to run digital bridge crane inspections against each asset with photo evidence, broken-wire counts saved against the rope record, automated reminders for monthly and annual inspections and a compliance dashboard across every bay, MapTrack can do that. Book a demo to see how it works.

Applicable regulatory standards

This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.

  • Cranes, hoists and winches - Safe use, Part 3: Bridge, gantry, portal (including container cranes), jib cranes and monorail beams

    Edition: AS 2550.3:2025

    Safe use standard for bridge cranes: maintenance, inspection and repair, and runway inspection.

    • Section 14: Maintenance, inspection and repair of bridge, gantry, portal and jib cranes.
    • Section 16: Inspection and maintenance of crane runways.

    Standards AustraliaSold by the publisher

  • Model Work Health and Safety Regulations

    Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)

    Competent-person maintenance and inspection following the manufacturer, and registration of listed crane designs.

    • reg 213: Plant must be maintained, inspected and, if necessary, tested by a competent person, following manufacturer or competent person recommendations; annual inspection applies only if neither is practicable.
    • Part 5.3: Registration of plant designs and items of plant with the regulator.
    • Schedule 5: Plant requiring registration: plant designs (Part 1) and items of plant (Part 2), such as boilers and tower cranes.

    Safe Work Australia (drafted by the Parliamentary Counsel's Committee)

  • Cranes, hoists and winches - Safe use, Part 1: General requirements

    Edition: AS 2550.1-2011

    Records of maintenance, inspection and repair, and major assessment of a crane for continued use.

    • 7.5: Records of maintenance, inspection and repair.
    • Section 9: Major assessment of a crane for continued use or changed operation.

    Standards AustraliaSold by the publisher

  • Steel wire rope - Use, operation and maintenance

    Edition: AS 2759-2004

    In-service wire rope inspection and discard criteria.

    • Section 13: Inspection of steel wire ropes in service.
    • Section 14: Criteria for discarding steel wire ropes.

    Standards AustraliaSold by the publisher

  • Cranes, hoists and winches, Part 3: Bridge, gantry, portal (including container cranes) and jib cranes

    Edition: AS 1418.3:2024

    Design standard for bridge, gantry, portal and jib cranes.

    Standards AustraliaSold by the publisher

  • 29 CFR Part 1910, Occupational Safety and Health Standards

    Edition: Current eCFR text, up to date as of 2026-10-22 (read 2026-10-26)

    US overhead and gantry crane rules, including frequent and periodic inspections.

    • 1910.179: Overhead and gantry cranes: design, initial, frequent and periodic inspections, testing, maintenance, ropes and operation.

    US Occupational Safety and Health Administration (text via eCFR)

Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.

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  <p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
  <p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Bridge crane inspection checklist</p>
  <ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
    <li style="margin:4px 0;">Crane details: type (top-running or underhung), make, model, serial number, SWL/WLL in tonnes, span, runway length, site location and asset ID.</li>
    <li style="margin:4px 0;">Inspection details: inspector name, date, inspection type (daily, monthly, quarterly, annual), run hours or lift cycles.</li>
    <li style="margin:4px 0;">Runway and end stops: rail alignment, rail wear, splices, support brackets, runway conductor bars, end stops at both ends of the runway.</li>
    <li style="margin:4px 0;">End trucks and wheels: wheel-flange wear, tread wear, axle play, wheel bearings, drive coupling, square truck frame.</li>
    <li style="margin:4px 0;">Bridge girder and trolley: girder camber, bolted connections, paint and corrosion, trolley wheels, trolley rails, bridge walkway and handrails (if fitted).</li>
    <li style="margin:4px 0;">Hoist: hoist motor, gearbox oil level, brake operation, brake shoe or pad thickness, holding brake, hoist drum, drum grooves.</li>
  </ul>
  <p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/bridge-crane-inspection-checklist" style="color:#071D49;font-weight:600;text-decoration:none;">Bridge crane inspection checklist</a> by MapTrack</p>
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The MapTrack bridge crane inspection checklist contains 30 checks across 6 sections.

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