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Free crane 10-year major inspection checklist
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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50 checks · 8 sections
50 checks
The fields in the printable form, in a view that fits your screen.
- Make / Model
- Serial Number
- Fleet / Asset ID
- Year of Manufacture
- Crane Type
- SWL / Rated Capacity
- Max Radius
- Boom Length
- Registration Number
- Inspection Start Date
- Inspection End Date
- Inspecting Engineer
- Engineer Reg. Number
- Dye Penetrant (DP)
- Magnetic Particle (MPI)
- Ultrasonic (UT)
- Radiographic (RT)
- NDT Technician Name
- AINDT Certification No.
- NDT Cert. Standard
- NDT Report Reference
- SWL / Rated Capacity
- Proof Load Applied
- Test Radius
- Boom Angle / Config
- Hold Duration
- Deflection Measured
- Weights Calibration Cert.
- Result
- Next Mechanical Insp.
- Next Structural Insp.
- Estimated Date
- Conditions / Limitations
1. Pre-Inspection Documentation
2. Structural Assessment
3. Mechanical Components
4. Hydraulic System
5. Electrical and Control Systems
6. Safety Devices and Instrumentation
7. Load Testing
8. Final Assessment and Certification
The MapTrack crane 10-year major inspection checklist contains 50 checks across 8 sections.
General guidance only. Check the form against your equipment manual, site procedures and local requirements before using it.
Short answer
A crane major inspection checklist records the strip-down examination of a crane's critical components, structure, mechanisms, hydraulics, electrics and safety devices, with NDT results. Regulation 235 of the model WHS Regulations requires a major inspection of registered mobile and tower cranes at the end of the manufacturer's design life, else as a competent person recommends, else every 10 years from first commissioning or first registration, whichever occurred first.
Checked against Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) on by the MapTrack templates team. How we check templates
Key takeaways
- The MapTrack crane 10-year major inspection checklist contains 50 checks across 8 sections. Sections covered: 1. Pre-Inspection Documentation, 2. Structural Assessment, 3. Mechanical Components, 4. Hydraulic System, 5. Electrical and Control Systems, 6. Safety Devices and Instrumentation, 7. Load Testing, 8. Final Assessment and Certification.
- For regulation 235, the competent person is a registered professional engineer with the knowledge and skills for the inspection, or a person the regulator determines.
- Schedule 5 lists tower cranes and mobile cranes with a rated capacity over 10 tonnes as items of plant that must be registered.
- The 10-year default applies only when following the design life or a competent person's advice is not reasonably practicable, counted from first commissioning or registration, whichever came first.
- A major inspection examines all critical components, stripping paint, grease and corrosion where needed, and checks the crane operates safely (regulation 235(6)).
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 should be performed by technicians certified to AS/NZS ISO 9712, for example through AINDT.
Under regulation 235, the major inspection of a registered mobile or tower crane is due at the end of the manufacturer's design life, or as a competent person recommends, or, if neither is reasonably practicable, every 10 years from first commissioning or first registration. Structural assessments run on a longer cycle set by the manufacturer or the crane-type part of AS 2550, and this checklist uses 25 years for the first major structural inspection. Regulation 235 sets no separate structural interval. 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.
Under Schedule 5 of the WHS Regulations 2011, tower cranes and mobile cranes with a rated capacity greater than 10 tonnes are items of plant that must be registered. For a registered mobile or tower crane, regulation 235 requires a major inspection by, or under the supervision of, a competent person at the end of the design life recommended by the manufacturer, as a competent person recommends where there is no manufacturer recommendation, or, if neither is reasonably practicable, every 10 years from first commissioning or first registration. Operating the crane past that point without the inspection breaches regulation 235, and the heaviest WHS Act penalties apply where a breach of the primary duty of care exposes someone to a risk of death or serious injury (Category 1 and 2 offences). For crane hire companies, an expired major inspection removes the crane from the available fleet entirely.
Learn more about compliance and inspections in MapTrack.
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Benefits of using this crane 10-year major inspection checklist
- Legal compliance: the major inspection is mandatory for registered mobile and tower cranes under WHS regulation 235, and operating one past its major inspection point without it breaches that regulation.
- 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.
What to include in a crane 10-year major inspection checklist
- 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 should be performed by technicians certified to AS/NZS ISO 9712, for example through AINDT.
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.
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How often should you complete this checklist?
For a registered mobile or tower crane, regulation 235 requires the major inspection at the end of the manufacturer's design life, or as a competent person recommends, or, if neither is reasonably practicable, every 10 years from first commissioning or first registration. For structural components, this checklist schedules the first major structural assessment at 25 years, unless the manufacturer or the crane-type part of AS 2550 sets another point. After the initial mechanical inspection, this checklist schedules subsequent inspections 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.
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Frequently asked questions
Practical answers about the form, record keeping and using MapTrack.
A crane 10-year major inspection is a comprehensive examination of all structural, mechanical, hydraulic, electrical and safety systems, required for registered mobile and tower cranes under WHS regulation 235 at the end of the manufacturer's design life, or as a competent person recommends, or failing both every 10 years from first commissioning or registration. It includes NDT of all critical structural welds and pins, detailed inspection of wire ropes, sheaves, hook blocks, brakes, gearboxes and bearings, and a load test at rated capacity. It must be supervised by a professional engineer.
Link to this answerNot if it is a registered mobile or tower crane that has reached its major inspection point. Regulation 235 of the WHS Regulations 2011 requires that inspection at the end of the design life recommended by the manufacturer, or as a competent person recommends, or, if neither is reasonably practicable, every 10 years from first commissioning or first registration. Tower cranes and mobile cranes with a rated capacity greater than 10 tonnes are items of plant that must be registered under Schedule 5 of the WHS Regulations 2011. For other cranes, regulation 213 requires inspection in line with the manufacturer recommendations, and AS 2550.1 sets out the major inspection. Insurance coverage may be voided.
Link to this answerThe 10-year inspection focuses on mechanical components: wire ropes, sheaves, hook blocks, brakes, gearboxes, bearings, hydraulic system and safety devices. The 25-year inspection is a major structural assessment covering the primary load-bearing structure including boom sections, chassis, turntable and slewing ring. Both require NDT and professional engineer supervision.
Link to this answerThe inspection must be supervised by a registered professional engineer with demonstrated experience in the inspection, testing and assessment of the specific crane type. NDT must be performed by AINDT-certified technicians or those holding qualifications to AS/NZS ISO 9712. In practice, major inspections are performed by crane OEM service centres, specialist crane inspection firms or consulting engineers.
Link to this answerA crane 10-year major inspection typically takes 5 to 15 working days, depending on the crane type, size and condition. Mobile cranes at the smaller end may take 5 to 7 days. Large tower cranes or cranes in poor condition may require 10 to 15 days or more. The crane is out of service for the entire duration.
Link to this answerApplicable regulatory standards
This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.
| Standard | Edition | Clauses this template relies on | Source |
|---|---|---|---|
| Model Work Health and Safety RegulationsMajor inspection of registered mobile and tower cranes, who may do it and what it covers, records for registered plant, and which cranes need registering. | Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) |
| Safe Work Australia (drafted by the Parliamentary Counsel's Committee) |
| Cranes, hoists and winches - Safe use, Part 1: General requirementsMajor assessment of a crane for continued use, maintenance and inspection records, and personnel competency. | AS 2550.1-2011 |
| Standards AustraliaSold by the publisher |
| Cranes, hoists and winches - Safe use, Part 5: Mobile cranesMaintenance, inspection and repair of mobile cranes. | AS 2550.5:2016 |
| Standards AustraliaSold by the publisher |
| Cranes, hoists and winches - Safe use, Part 4: Tower cranes including self-erecting tower cranesSafe use of tower cranes, including self-erecting tower cranes. | AS 2550.4:2025 | Whole instrument | Standards AustraliaSold by the publisher |
| Cranes, hoists and winches - Safe use, Part 3: Bridge, gantry, portal (including container cranes), jib cranes and monorail beamsMaintenance and inspection of bridge, gantry and jib cranes, which regulation 235 does not cover. | AS 2550.3:2025 |
| Standards AustraliaSold by the publisher |
| Non-destructive testing - Qualification and certification of NDT personnelQualification and certification of the NDT personnel who test welds and pins. | AS/NZS ISO 9712:2023 | Whole instrument | Standards Australia and Standards New ZealandSold 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)
Major inspection of registered mobile and tower cranes, who may do it and what it covers, records for registered plant, and which cranes need registering.
- reg 235: Registered mobile and tower cranes need a major inspection at the manufacturer's design life end, else per competent person advice, else every 10 years.
- Part 5.2: Additional duties for registered plant and plant designs, including major crane inspections and records.
- reg 237: Records of tests, inspections, maintenance and alterations must be kept for plant required to be registered.
- Schedule 5: Plant requiring registration: plant designs (Part 1) and items of plant (Part 2), such as boilers and tower cranes.
- reg 235(4): For major inspections, the competent person must have the knowledge and skills and be registered under a professional engineers registration law, or be determined competent by the regulator.
- reg 235(6): A major inspection examines all critical components of the crane, stripping down and removing paint, grease and corrosion if necessary, and checks the crane operates effectively and safely.
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
Major assessment of a crane for continued use, maintenance and inspection records, and personnel competency.
- Section 9: Major assessment of a crane for continued use or changed operation.
- 7.5: Records of maintenance, inspection and repair.
- 1.7: Competency of personnel involved with cranes, hoists and winches.
Standards AustraliaSold by the publisher
Cranes, hoists and winches - Safe use, Part 5: Mobile cranes
Edition: AS 2550.5:2016
Maintenance, inspection and repair of mobile cranes.
- Section 7: Maintenance, inspection and repair of mobile cranes.
Standards AustraliaSold by the publisher
Cranes, hoists and winches - Safe use, Part 4: Tower cranes including self-erecting tower cranes
Edition: AS 2550.4:2025
Safe use of tower cranes, including self-erecting tower cranes.
Standards AustraliaSold by the publisher
Cranes, hoists and winches - Safe use, Part 3: Bridge, gantry, portal (including container cranes), jib cranes and monorail beams
Edition: AS 2550.3:2025
Maintenance and inspection of bridge, gantry and jib cranes, which regulation 235 does not cover.
- Section 14: Maintenance, inspection and repair of bridge, gantry, portal and jib cranes.
Standards AustraliaSold by the publisher
Non-destructive testing - Qualification and certification of NDT personnel
Edition: AS/NZS ISO 9712:2023
Qualification and certification of the NDT personnel who test welds and pins.
Standards Australia and Standards New ZealandSold by the publisher
Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.
- Model WHS Regulations (Safe Work Australia)
- AS 2550 series, Cranes, hoists and winches, safe use (Standards Australia listing)
MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.
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The MapTrack crane 10-year major inspection checklist contains 50 checks across 8 sections.
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- MapTrack. (2026). Crane 10-year major inspection checklist [Checklist template]. Retrieved from https://www.maptrack.com/templates/crane-10-year-inspection
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<p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Crane 10-year major 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;">Pre-inspection documentation: serial number verification, maintenance history, WHS regulator registration, manufacturer manual and critical component list.</li>
<li style="margin:4px 0;">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.</li>
<li style="margin:4px 0;">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.</li>
<li style="margin:4px 0;">Hydraulic system: cylinder condition, system pressures, hoses and fittings, oil condition, control valves, filter condition.</li>
<li style="margin:4px 0;">Electrical and control systems: wiring and connectors, control circuits, slip rings and collector brushes, lighting and warning devices, power supply cables.</li>
<li style="margin:4px 0;">Safety devices: RCI/LMI accuracy, limit switches, anti-two-block device, emergency stops, anemometer (tower cranes), overload protection, boom backstop.</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/crane-10-year-inspection" style="color:#071D49;font-weight:600;text-decoration:none;">Crane 10-year major inspection checklist</a> by MapTrack</p>
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