Free crane 10-year major inspection checklist
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Free crane 10-year major inspection checklist per AS 2550.1. NDT, structural assessment, mechanical components and load testing. Download free.
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See the first part of the crane 10-year major inspection checklist below. Download the full version above.
What is a crane 10-year major inspection checklist?
A crane 10-year major inspection is the most thorough examination a crane undergoes during its operational life. Required under AS 2550.1 and the relevant crane-type-specific standards (AS 2550.3 for overhead cranes, AS 2550.4 for tower cranes, AS 2550.5 for mobile cranes, AS 2550.11 for vehicle-loading cranes), it involves a comprehensive assessment of all structural, mechanical, hydraulic, electrical and safety systems. The inspection must be supervised by a professional engineer experienced with the specific crane type, and all NDT must be performed by AINDT-certified technicians.
The mechanical component inspection is triggered at 10 years from the date of manufacture. Structural assessments have a longer cycle, with the first major structural inspection required at 25 years. Between these cycles, the crane must continue to receive annual inspections, periodic services and pre-operational checks. The 10-year inspection covers wire ropes, sheaves, hook blocks, brakes, gearboxes, bearings, hoist drums, hydraulic systems, electrical controls, all safety devices including the RCI/LMI, and concludes with a load test at rated capacity across multiple radii.
In Australia, cranes are registered plant items in most jurisdictions. A crane cannot legally be operated once mechanical components reach the 10-year mark without a completed major inspection. Operating non-compliant registered plant is a breach of WHS Regulations 2011, Chapter 5. Penalties for a body corporate can reach $11.84 million. For crane hire companies, an expired major inspection removes the crane from the available fleet entirely.
Learn more about compliance and inspections in MapTrack.
Benefits of using this crane 10-year major inspection checklist
- Legal compliance: the 10-year major inspection is mandatory under AS 2550.1. Without it, the crane cannot legally be operated, hired out or sold as compliant registered plant.
- Structural integrity assurance: NDT of all critical welds, pins and structural connections detects fatigue cracking, corrosion and weld defects that visual inspections cannot identify.
- Mechanical component validation: detailed inspection of wire ropes, sheaves, hook blocks, brakes, gearboxes and bearings confirms these high-wear components remain within manufacturer tolerances.
- Safety device verification: load testing at rated capacity across multiple radii, combined with RCI/LMI calibration and limit switch testing, confirms all safety systems function correctly under real load.
- Insurance and liability protection: a current major inspection certificate from a professional engineer demonstrates due diligence and supports insurance claims. Operating without one may void coverage.
- Extended asset life: a completed major inspection effectively recertifies the crane for continued service, extending the useful life of a capital asset worth hundreds of thousands to millions of dollars.
Benefits of digitising forms in MapTrack
When you digitise crane checklists in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Automatically get alerts when faults are identified.
- Link every form digitally as a PDF to the relevant asset, location or person.
- Receive a digital PDF copy with every submission to your email.
- Ability to share forms digitally.
- 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.
- Restrict permissions (who can view, complete or approve).
- Build forms with AI (describe what you need and MapTrack suggests the form).
- Set recurring audit schedules with automatic reminders and escalation.
- Produce regulator-ready PDF compliance packs in one click.
- Track corrective actions from finding to close-out with full audit trail.
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What to include in a crane 10-year major inspection checklist
This crane 10-year major inspection checklist covers 9 key areas:
- Pre-inspection documentation: serial number verification, maintenance history, WHS regulator registration, manufacturer manual and critical component list.
- Structural assessment: main boom, jib, chassis/carrier frame, turntable and slewing ring, outrigger beams and cylinders, counterweight mounting, NDT of all critical structural welds and pins.
- Mechanical components: wire ropes (broken wires, corrosion, diameter reduction), sheaves and pulleys, hook block (throat opening, twist, NDT), brakes (hoist, slew, travel), gearboxes, slewing ring gear teeth, bearings, hoist drum.
- Hydraulic system: cylinder condition, system pressures, hoses and fittings, oil condition, control valves, filter condition.
- Electrical and control systems: wiring and connectors, control circuits, slip rings and collector brushes, lighting and warning devices, power supply cables.
- Safety devices: RCI/LMI accuracy, limit switches, anti-two-block device, emergency stops, anemometer (tower cranes), overload protection, boom backstop.
- Load testing: proof load test at rated capacity, load chart accuracy at multiple radii, structural deflection under load, all motions under load.
- NDT documentation: methods used, AINDT-certified technician details, certification standard reference.
- Final assessment: engineering report, risk assessment, certification of continued serviceability, updated logbook and registration records.
How to use this crane 10-year major inspection checklist
- Complete pre-inspection documentation review and verification.: Verify the crane serial number against registration records. Review the full maintenance history, service records and defect log. Confirm WHS regulator registration is current. Obtain the manufacturer manual and critical component list. Review any previous major inspection reports and confirm operating hours or duty cycle classification.
- Perform a comprehensive structural assessment with NDT on all critical components.: Inspect the main boom sections, jib, chassis/carrier frame, turntable and slewing ring, outrigger beams and cylinders, and counterweight mounting. Perform NDT (MPI, UT, DP or RT as appropriate) on all critical structural welds, boom foot pins and major structural pins. Check torque on structural bolted connections. NDT must be performed by AINDT-certified technicians.
- Inspect all mechanical components including wire ropes, sheaves, hook block, brakes, gearboxes and bearings.: Count broken wires per lay length on all wire ropes and measure diameter reduction. Inspect sheaves for groove wear, cracking and bearing play. NDT the hook block and check throat opening, twist, swivel bearing and safety latch. Test all brakes for lining condition, adjustment and holding capacity. Inspect gearboxes via oil analysis. Check slewing ring gear teeth and all bearings.
- Inspect hydraulic, electrical and control systems, and verify all safety devices.: Check hydraulic cylinders, system pressures, hoses, oil condition, control valves and filters. Inspect all wiring, connectors, junction boxes and control circuits. Test slip rings (tower/overhead cranes), lighting and warning devices. Verify RCI/LMI accuracy, all limit switches, anti-two-block device, emergency stops, anemometer (tower cranes), overload protection and boom backstop.
- Perform load testing at rated capacity across multiple radii.: Conduct a proof load test at the crane rated capacity using calibrated test weights. Verify load chart accuracy at multiple radii. Measure structural deflection under load and compare against acceptance criteria. Test all motions under load including hoist, lower, slew, derricking and travel.
- Complete the engineering report, issue certification and update all records.: Compile a comprehensive engineering report documenting all inspection findings, NDT results, measurement data and photographs. Issue a risk assessment and certification of continued serviceability signed by the supervising professional engineer. Update the crane logbook and WHS regulator registration records. Set the next major inspection due date.
In MapTrack, you can automate compliance tracking and audit trails. Each submission is stored as a timestamped PDF against the asset record.
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Back to download formHow often should you complete this checklist?
The 10-year major inspection for mechanical components is first required at 10 years from the date of manufacture. For structural components, the first major structural assessment is required at 25 years. After the initial mechanical inspection, subsequent inspections are typically required every 5 years, though the interval may be shortened based on findings, duty cycle or manufacturer recommendations.
A major inspection may be required earlier if the crane has been involved in a significant incident, sustained structural damage or been operated in corrosive or extreme environments. In MapTrack, calendar-based and hour-based maintenance triggers ensure no crane misses its 10-year major inspection deadline, with digital records providing a complete audit trail for regulators, insurers and site operators.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- AS 2550.1 Cranes, hoists and winches - Safe use: General requirements
- AS 2550.5 Cranes, hoists and winches - Safe use: Mobile cranes
- AS 2550.4 Cranes, hoists and winches - Safe use: Tower cranes
- AS 2550.3 Cranes, hoists and winches - Safe use: Bridge, gantry and portal cranes
- AS/NZS ISO 9712 Non-destructive testing - Qualification and certification of NDT personnel
- WHS Regulations 2011, Chapter 5 (plant registration and maintenance duties)
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