When is a crane load test legally required in Australia and the United States?

In Australia AS 2550 (Cranes hoists and winches safe use) and AS 1418 (design and manufacture) require a proof load test after manufacture after major structural repair after replacement of a major load-bearing component and after any modification that affects rated capacity. Plant registration under WHS Regulations 2011 Chapter 5 Part 5.1 typically requires evidence of the current load test certificate. In the United States OSHA 29 CFR 1926.1412(f) requires post-assembly load testing for assembled mobile cranes and a re-load test after major modification or repair. ASME B30.5 provides further industry guidance for mobile cranes.

What proof load percentage is used for a crane load test?

The proof load is typically set between 110 and 125 percent of safe working load depending on the standard and the test purpose. AS 1418.1 and AS 2550 generally specify 125 percent for new cranes during commissioning and 110 to 125 percent for in-service re-tests after repair or modification. OSHA 29 CFR 1926.1412(f) requires a 100 percent rated capacity functional test for assembled cranes with manufacturer or qualified person guidance on overload testing. Always follow the crane manufacturer test procedure and the current edition of the applicable standard for the specific crane type.

Who can supervise and sign a crane load test record?

A crane load test must be supervised and signed by a competent person as defined under the relevant standard. In Australia this is generally a licensed assessor or a competent person with relevant engineering qualifications and demonstrated crane experience. For mobile cranes the supervisor is often an inspection assessor accredited under the National Association of Testing Authorities (NATA) framework or by the crane manufacturer. In the United States OSHA defines the qualified person standard for load testing. The crane operator and dogger involved in the test should also sign as witnesses to confirm the test sequence.

How is the test load verified before the lift?

The test load weight must be verified using one of three methods: a calibrated weighbridge a calibrated electronic load cell suspended in the rigging or a set of certified test weights with current calibration certificates. Calculating the weight from drawings or estimated densities is not acceptable for a formal load test. The verified weight is recorded on the load test record with the calibration certificate reference for the weighing equipment. This traceability is essential because the percentage of rated capacity claimed by the test is only valid if the actual load weight is known.

What invalidates a crane load test?

Common reasons a load test may be considered invalid include: the test load was not independently verified by a weighbridge or load cell the proof load was below the percentage required by the standard the test was not held for the prescribed duration the structural inspection after the test was incomplete or undocumented the supervisor was not a competent person under the applicable standard or the crane configuration during the test (boom length counterweight outrigger setup) did not match the rated capacity being tested. Any of these flaws can result in the record being rejected during a regulator audit or insurance review.

Free crane load test record template

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Free crane load test record template (PDF-ready). Captures proof load, dynamic test, SWL verification and AS 2550 / OSHA 1926.1412 sign-off.

Jarrod Milford

Commercial Director

Updated 18 May 2026

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Updated 18 May 2026

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What is a crane load test record template?

A crane load test record is a structured form used to document the results of a proof load test or operational load test on a crane after manufacture, major repair, modification or scheduled re-certification. It captures the test load value (typically 110 to 125 percent of safe working load), the test procedure (static proof, dynamic functional, rated load run), deflection or settlement readings, brake holding tests, structural inspection results and the signature of the competent person or licensed assessor who supervised the test. The record provides documented evidence that the crane has been tested to the requirements of AS 2550 in Australia and OSHA 29 CFR 1926.1412(f) in the United States before the crane is returned to service or registered for use on a new site.\n\nLoad testing is one of the most safety-critical events in a crane's life cycle. The test confirms that the boom, jib, hoist drum, wire rope, hook block, structural welds and slew ring can sustain loads beyond the rated capacity without permanent deformation or failure. A single missed load test after a major repair can mask a hairline crack in a structural weld that later fails under normal load and drops the suspended weight. Australian WHS Regulations 2011 Chapter 5 Part 5.1 classifies cranes as registrable plant, and the registration evidence package requires a current load test certificate. Insurers, principal contractors and crane hire customers routinely require sight of the load test record before a crane is allowed on site. Maintaining a clean and traceable load test record per asset is therefore a baseline obligation for every crane fleet operator.

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Benefits of using this crane load test record template

Proof of capacity: documents that the crane has carried 110 to 125 percent of safe working load without permanent deformation before returning to service
Regulatory compliance: satisfies AS 2550 and OSHA 29 CFR 1926.1412(f) requirements for load testing after manufacture major repair or modification
Registration evidence: provides the documented load test certificate required for plant registration under WHS Regulations 2011 Chapter 5 Part 5.1
Liability protection: a signed record by a competent person or licensed assessor demonstrates due diligence during incident investigations and insurance claims
Hire-out readiness: principal contractors and crane hire customers typically require sight of a current load test record before allowing a crane on site
Asset history: a load test record per crane builds a longitudinal performance dataset that supports trend analysis on structural deflection and brake wear

Benefits of digitising forms in MapTrack

When you digitise crane records 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).
Escalate critical hazards instantly to safety managers via push notification.
Maintain an auditable safety register that satisfies WHS regulator requests.
Correlate incident trends across sites with built-in safety analytics.

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What to include in a crane load test record template

This crane load test record template covers 9 key areas:

Crane details: type make model serial number SWL/WLL boom length jib configuration counterweight and registration number
Test environment: site address date weather conditions wind speed ground bearing assessment and outrigger pad layout
Test load details: nominal proof load percentage test load weight (verified by weighbridge or calibrated cell) attachment method and rigging configuration
Static proof test: load held for prescribed time (typically 10 minutes per AS 2550) deflection or settlement reading and recovery on release
Dynamic functional test: hoist raise and lower slew left and right travel and brake-set under load with results for each function
Rated load operational run: full operating cycle at SWL through the working radii with no abnormal noise vibration or load drift
Brake test: hoist brake holding test slew brake travel brake and emergency stop response time recorded under load
Structural inspection: post-test visual inspection of boom welds turntable bolts pins outriggers hook and wire rope for cracks deformation or shifts
Personnel and sign-off: name and competency of test supervisor crane operator dogger and witness/assessor with signatures dates and licence numbers

How to use this crane load test record template

Plan the test and verify the test load: confirm the required proof load percentage (typically 110 to 125 percent of SWL per AS 2550 or 100 percent per OSHA 1926.1412(f)). Verify the actual test load weight using a weighbridge calibrated load cell or certified test weights. Document the verified weight on the record before the test commences so the result is traceable
Set up the crane in the worst-case test configuration: position the crane on level ground with full outrigger extension and pads. Configure the boom and jib for the planned test radii. Cordon off the exclusion zone and confirm wind speed is within manufacturer limits typically below 9.8 metres per second for the test
Conduct the static proof test: lift the test load to a clear height typically 100 to 300 millimetres above the ground and hold for the prescribed duration usually 10 minutes per AS 2550. Record any deflection settlement or drift in the load over the hold period and the recovery after the load is released
Perform the dynamic functional test: with rated load attached operate every motion (hoist raise hoist lower slew left slew right travel boom telescope) through its full working envelope. Verify smooth operation no abnormal noise no vibration and correct response of load moment indicator anti-two-block and limit switches at each cut-out
Test the brakes and emergency stops under load: lift rated load to a safe height release the controls and confirm the hoist brake holds the load without drift for 10 minutes. Apply the emergency stop during a slew and travel motion under load and record stopping distance and any roll-back of the suspended load
Conduct the post-test structural inspection and complete sign-off: with the test load removed visually and physically inspect boom welds turntable bolts pins counterweight attachment hook wire rope and sheaves for any cracks deformation or shifting. The competent person or licensed assessor signs the record dates it and attaches the test certificate to the crane log book and digital asset record

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How often should you complete this record?

A crane load test is required after manufacture (commissioning) after any major structural repair after a major component replacement (hoist gearbox slew drive boom section) after a modification that alters the rated capacity and after an overload event or incident affecting structural integrity. Under AS 2550 most crane types also require a periodic load test as part of the major inspection cycle typically every 10 years with the test repeated more frequently if the crane operates in a corrosive or high-cycle environment.\n\nOSHA 29 CFR 1926.1412(f) requires a post-assembly load test for assembled mobile crane components and a re-load test after major modification or repair. Many principal contractors and crane hire fleets perform an interim functional load check at every annual major inspection even when a full proof load test is not strictly required so the load chart capacity is verified in service. In MapTrack the load test record can be attached to the crane asset with automated reminders set against hours condition and calendar intervals.

Frequently asked questions

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS 2550
AS 1418
OSHA 29 CFR 1926.1412(f)
ASME B30.5
WHS Regulations 2011 Chapter 5

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