Free crane load test record template

Q: 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. Under the model WHS Regulations, tower cranes and mobile cranes with a rated capacity greater than 10 tonnes must be registered (Schedule 5), and the application must include "a statement that the item of plant has been inspected by a competent person and assessed by that person as being safe to operate" (regulation 266(2)(h)); a current load test record supports that statement. In the United States, OSHA requires a load test after each tower crane erection (29 CFR 1926.1435(f)(3)) and before a new or reinstalled derrick is first used (29 CFR 1926.1436(g)(3)). After a repair or modification that affects safe operation, 29 CFR 1926.1412 requires an inspection by a qualified person that "must include functional testing", not a load test. ASME B30.5 (Mobile and Locomotive Cranes) is an industry standard, not an OSHA regulation, although OSHA adopts listed parts of its 2004 edition for mobile and locomotive cranes made on or after 8 November 2010 (29 CFR 1926.1433(b)).

Q: 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 sets no load test percentage; its inspections call for functional testing. Where OSHA does set a figure, it depends on the equipment. For a new or reinstalled derrick in construction, test loads must be "at least 100% and no more than 110% of the rated capacity" unless the manufacturer or a qualified person recommends otherwise (29 CFR 1926.1436(g)(3)(i)). In general industry, test loads for crawler, locomotive and truck cranes "shall not exceed 110 percent of the rated load at any selected working radius" (29 CFR 1910.180(e)(2)(ii)), and for overhead and gantry cranes they "shall not be more than 125 percent of the rated load unless otherwise recommended by the manufacturer" (29 CFR 1910.179(k)(2)). Always follow the crane manufacturer test procedure and the current edition of the applicable standard for the specific crane type.

Q: 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 29 CFR 1926.1412 requires a qualified person to inspect a crane after a repair or modification that affects safe operation, and 29 CFR 1926.1436(g)(3) requires a competent person to load test a new or reinstalled derrick and determine "that the test has been passed". The crane operator and dogger involved in the test should also sign as witnesses to confirm the test sequence.

Q: 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.

Q: 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 (PDF-ready). Captures proof load, dynamic test, SWL verification and competent person sign-off.

Updated 25 Sept 2026

Crane Load Test Record

Proof load and operational load test record. Test to the crane manufacturer's procedure and the standard that applies, such as AS 2550.

Live form

0 of 26 checks

Site / projectCrane ID / registrationMake / model / serialSWL / WLL (kg)

Set-up & conditions

1Crane on level ground with full outrigger extension

2Outrigger pads correctly sized for ground bearing

3Wind speed within manufacturer limits (<9.8 m/s)

4Exclusion zone established and barricaded

5Test load weight verified by weighbridge or load cell

Static load test

6Test load lifted clear of ground (100-300 mm)

7Load held for prescribed duration (10 min per AS 2550)

8Deflection / settlement reading recorded

9Recovery checked on release of load

Dynamic function tests

10Hoist raise tested with rated load

11Hoist lower tested with rated load

12Slew left and right tested with rated load

13Travel tested where applicable

14Load moment indicator response verified

15Anti-two-block device tested

Brake hold tests

16Hoist brake holds load for 10 min with no drift

17Slew brake holds against rated load

18Travel brake holds on incline (if applicable)

19Emergency stop tested under load

20Stopping distance recorded

Post-test structural inspection

21Boom welds checked for cracks or deformation

22Turntable bolts and pins inspected

23Counterweight attachment verified

24Hook throat and safety latch checked

25Wire rope and sheaves inspected

26Competent person sign-off completed

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Updated 25 September 2026

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Key takeaways

The MapTrack crane load test record template contains 26 checks across 5 sections. Sections covered: Set-up & conditions, Static load test, Dynamic function tests, Brake hold tests, Post-test structural inspection.

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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 that apply to it, such as AS 2550 in Australia, before the crane is returned to service or registered for use on a new site. In the United States, OSHA's crane inspection rule, 29 CFR 1926.1412, sets no load test: the inspections it requires after a modification, repair or adjustment that affects safe operation, and at least every 12 months, must each include functional testing. OSHA does require a load test after each tower crane erection (29 CFR 1926.1435(f)(3)) and before a new or reinstalled derrick is first used (29 CFR 1926.1436(g)(3)).

Load 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. Under the model WHS Regulations, tower cranes (including self-erecting tower cranes) and mobile cranes with a rated capacity greater than 10 tonnes must be registered (Part 5.3 and Schedule 5), and the application must include "a statement that the item of plant has been inspected by a competent person and assessed by that person as being safe to operate" (regulation 266(2)(h)). A current load test record is useful evidence for that inspection. 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 baseline practice 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 evidence: records the load test where AS 2550, the manufacturer or OSHA calls for one, such as after each US tower crane erection (29 CFR 1926.1435(f)(3)); OSHA 29 CFR 1926.1412 itself requires functional testing, not a load test
Registration evidence: supports the competent person inspection statement that a registration application needs under the model WHS Regulations (regulation 266(2)(h)), for tower cranes and mobile cranes with a rated capacity greater than 10 tonnes (Schedule 5)
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.
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 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 from the crane manufacturer's procedure and the standard that applies (typically 110 to 125 percent of SWL per AS 2550). OSHA 29 CFR 1926.1412 sets no load test percentage; for a US tower crane after erection, 29 CFR 1926.1435(f)(3)(ii) says the test "must be conducted in accordance with the manufacturer's instructions when available", or to written load test procedures from a registered professional engineer where they are not. 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 typically carried out 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. Whether each one is a legal requirement depends on the jurisdiction, the crane type and the manufacturer's procedure. 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.

In the United States, OSHA 29 CFR 1926.1412 handles modifications and repairs through inspection, not load testing. After a modification that affects safe operation or capacity, or a repair or adjustment that relates to safe operation, a qualified person must inspect the crane before it is used again, and that inspection "must include functional testing" (paragraphs (a) and (b)). The annual/comprehensive inspection is the same: paragraph (f)(3) says it "must include functional testing to determine that the equipment as configured in the inspection is functioning properly". After assembly, paragraph (c) requires a qualified person to inspect the crane "to assure that it is configured in accordance with manufacturer equipment criteria". None of these paragraphs sets a load test or a test load percentage. OSHA does require one after each tower crane erection: "A load test using certified weights, or scaled weights using a certified scale with a current certificate of calibration, must be conducted after each erection" (29 CFR 1926.1435(f)(3)(i)). 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

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. Under the model WHS Regulations, tower cranes and mobile cranes with a rated capacity greater than 10 tonnes must be registered (Schedule 5), and the application must include "a statement that the item of plant has been inspected by a competent person and assessed by that person as being safe to operate" (regulation 266(2)(h)); a current load test record supports that statement. In the United States, OSHA requires a load test after each tower crane erection (29 CFR 1926.1435(f)(3)) and before a new or reinstalled derrick is first used (29 CFR 1926.1436(g)(3)). After a repair or modification that affects safe operation, 29 CFR 1926.1412 requires an inspection by a qualified person that "must include functional testing", not a load test. ASME B30.5 (Mobile and Locomotive Cranes) is an industry standard, not an OSHA regulation, although OSHA adopts listed parts of its 2004 edition for mobile and locomotive cranes made on or after 8 November 2010 (29 CFR 1926.1433(b)).

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 sets no load test percentage; its inspections call for functional testing. Where OSHA does set a figure, it depends on the equipment. For a new or reinstalled derrick in construction, test loads must be "at least 100% and no more than 110% of the rated capacity" unless the manufacturer or a qualified person recommends otherwise (29 CFR 1926.1436(g)(3)(i)). In general industry, test loads for crawler, locomotive and truck cranes "shall not exceed 110 percent of the rated load at any selected working radius" (29 CFR 1910.180(e)(2)(ii)), and for overhead and gantry cranes they "shall not be more than 125 percent of the rated load unless otherwise recommended by the manufacturer" (29 CFR 1910.179(k)(2)). Always follow the crane manufacturer test procedure and the current edition of the applicable standard for the specific crane type.

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 29 CFR 1926.1412 requires a qualified person to inspect a crane after a repair or modification that affects safe operation, and 29 CFR 1926.1436(g)(3) requires a competent person to load test a new or reinstalled derrick and determine "that the test has been passed". The crane operator and dogger involved in the test should also sign as witnesses to confirm the test sequence.

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.

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.

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.

AS 2550
AS 1418
OSHA 29 CFR 1926.1412 - Inspections (functional testing after a modification or repair and at the annual inspection)
OSHA 29 CFR 1926.1435(f)(3) - Tower crane load test after each erection
ASME B30.5 - Mobile and Locomotive Cranes (industry standard, not an OSHA regulation)
WHS Regulations 2011 Chapter 5

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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;">Crane load test record template</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 make model serial number SWL/WLL boom length jib configuration counterweight and registration number</li>
    <li style="margin:4px 0;">Test environment: site address date weather conditions wind speed ground bearing assessment and outrigger pad layout</li>
    <li style="margin:4px 0;">Test load details: nominal proof load percentage test load weight (verified by weighbridge or calibrated cell) attachment method and rigging configuration</li>
    <li style="margin:4px 0;">Static proof test: load held for prescribed time (typically 10 minutes per AS 2550) deflection or settlement reading and recovery on release</li>
    <li style="margin:4px 0;">Dynamic functional test: hoist raise and lower slew left and right travel and brake-set under load with results for each function</li>
    <li style="margin:4px 0;">Rated load operational run: full operating cycle at SWL through the working radii with no abnormal noise vibration or load drift</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-load-test-record-template" style="color:#071D49;font-weight:600;text-decoration:none;">Crane load test record template</a> by MapTrack</p>
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The MapTrack crane load test record template contains 26 checks across 5 sections.

Short attribution: MapTrack Crane load test record template, https://www.maptrack.com/templates/crane-load-test-record-template
Reference list: MapTrack. (2026). Crane load test record template [Checklist template]. Retrieved from https://www.maptrack.com/templates/crane-load-test-record-template

Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/crane-load-test-record-template.

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Free crane load test record template

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Key takeaways

What is a crane load test record template?

Benefits of using this crane load test record template

Benefits of digitising forms in MapTrack

Try MapTrack free for 30 days

What to include in a crane load test record template

How to use this crane load test record template

How often should you complete this record?

Frequently asked questions

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

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

Who can supervise and sign a crane load test record?

How is the test load verified before the lift?

What invalidates a crane load test?