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Free gantry crane inspection checklist
Free gantry crane inspection checklist (PDF-ready). Covers legs, end trucks, wheels, rails, ropes, hooks and travel limits. Safe use: AS 2550.3.
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The fields in the printable form, in a view that fits your screen.
- Crane ID / serial
- Registration number
- Capacity (tonnes)
- Span (m)
- Gauge (m)
- Inspection type
- Inspector name and licence
- Date and time
Structure & travel path
Hoist drum, rope & sheaves
Brakes
Power supply & controls
Function & load testing
Declaration & Sign-Off
I confirm that all items have been inspected/completed as indicated above. Any defects or concerns have been noted and reported.
Completed By
Printed name · Signature · Date
Reviewed / Approved By
Printed name · Signature · Date
The MapTrack gantry crane inspection checklist contains 25 checks across 5 sections.
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Short answer
A gantry crane inspection checklist records checks on the legs and sill beams, end trucks, rails or tyres, girder, trolley and hoist, wire ropes, hook block, brakes, limits and anti-collision devices. Operators do a pre-start check each shift; deeper inspections follow the manufacturer and the crane management plan. Regulation 213 of the model WHS Regulations requires inspection by a competent person, and AS 2550.3:2025 covers safe use.
Checked against AS 2550.3:2025 on by the MapTrack templates team. How we check templates
Key takeaways
- The MapTrack gantry crane inspection checklist contains 25 checks across 5 sections. Sections covered: Structure & travel path, Hoist drum, rope & sheaves, Brakes, Power supply & controls, Function & load testing.
- Reg 213 requires competent-person inspection following the manufacturer's recommendations, or a competent person's if none exist; annual inspection applies only where neither is practicable.
- Inspect hoist ropes to AS 2759 Section 13 and discard them on the Section 14 criteria, recording diameter and broken wires.
- Some crane designs must be registered under Part 5.3 and Schedule 5; record the design registration number on the checklist.
- In the US, OSHA 29 CFR 1910.179 sets frequent and periodic inspections for overhead and gantry cranes.
What is a gantry crane inspection checklist?
A gantry crane inspection checklist is a structured record used by riggers, crane supervisors and maintenance teams to confirm that a gantry crane is safe to operate before, during and after each shift. Unlike an overhead bridge crane that runs on elevated runway beams, a gantry crane carries its load on legs that sit on the ground, travelling on floor-mounted rails (rail-mounted gantry, RMG) or on rubber tyres (rubber-tyred gantry, RTG). The checklist walks the inspector through the main wear and failure points: the legs and sill beams, end-truck wheels, rail or tyre condition, span and gauge, the bridge girder, the trolley and hoist, wire ropes, the hook block, the festoon or cable reel, brakes, limit switches, anti-collision sensors and the operator interface. It is the everyday tool that turns AS 2550.3 from a standard on a shelf into something a yard actually does each morning.
Under the WHS Regulations 2011, Part 5.1 requires a gantry crane to be maintained and inspected by a competent person (regulation 213), and the design of a gantry crane with a safe working load greater than 5 tonnes, or of any gantry crane designed to handle molten metal or Schedule 11 hazardous chemicals, must be registered (Part 5.3 and Schedule 5). A record of each inspection, the maintenance done and any defect found is how the PCBU shows that duty was met. AS 2550.3 sets out the safe-use requirements for bridge, gantry and portal cranes, including the inspection regime, while AS 1418.3 covers design and AS 2759 governs the wire rope on the hoist and any pendant ropes. In container terminals and intermodal yards, RTG and RMG operations also need to consider signal continuity, twistlock interlocks and anti-collision between adjacent cranes. A printed checklist supports a daily pre-start; a digital record in MapTrack ties each tick to a crane asset, a defect log and the next scheduled service so the audit trail is intact when a regulator or insurer asks for it.
Learn more about compliance and inspections in MapTrack.
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Benefits of using this gantry crane inspection checklist
- Operator accountability: Every pre-start, monthly and annual check is signed against the operator or competent person who completed it.
- AS 2550.3 reference: check the form against AS 2550.3, the safe-use standard for bridge, gantry and portal cranes, before an audit.
- Defect visibility: Faults raised on a wheel, rope or brake are linked to the crane record rather than buried in a paper pile in the foreman office.
- Yard-wide consistency: Two RTGs, four RMGs and a precast gantry all get inspected against the same baseline rather than the operator memory of last shift.
- Insurance and incident readiness: A complete inspection history shortens the response time after a near-miss and supports the PCBU due-diligence position.
- Service planning: Daily defects flow into the maintenance plan so the 250, 500 and 1000-hour services target the right wear points.
- Lifecycle records: Wheel changes, rail welds, rope changes and structural repairs sit against the asset for the full life of the crane.
What to include in a gantry crane inspection checklist
- Crane identification: serial number, registration, capacity, span and gauge.
- Legs and sill beams: visual structural check for cracks, dents, paint loss and bolt tightness.
- End trucks and wheels: flange wear, tread profile, bearing noise and equaliser play.
- Rails or tyres: rail head wear, joint gaps, fastener condition; tyre pressure, tread and cuts for RTG.
- Bridge girder and tie beams: deflection, weld integrity, lateral bracing and inspection-walkway handrails.
- Trolley and hoist: cross-travel wheels, gearbox oil, drum condition and trolley rail wear.
- Wire ropes and reeving: broken wires per lay, diameter, lubrication and termination per AS 2759.
- Hook block, sheaves and safety latch: throat wear, latch function, sheave groove profile and bearing freeplay.
- Brakes: hoist, long-travel and cross-travel brake function, pad wear and stopping distance.
- Limit switches and overload: upper, lower, end-of-travel and load-moment or overload device function.
- Anti-collision and proximity: end-stops, buffers and adjacent-crane proximity sensors where fitted.
- Electrical and festoon: festoon cable, drag chain or cable reel, earth continuity and emergency stops.
- Cab, controls and load test: control labelling, visibility, audible warning, dynamic test lift to rated capacity where required.
How to use this gantry crane inspection checklist
Confirm the inspection scope and isolate where needed.
Identify whether this is a daily pre-start, monthly, quarterly or annual inspection. For anything beyond a pre-start, lock and tag the crane out, isolate power and put barriers around the legs to keep yard traffic clear.
Walk the structure and travel path.
Start at one leg, work around the sill beams, end trucks and travel rails or tyres. Look for fresh paint loss, cracking near welds, bent ladders, damaged handrails and rail joints that have spread or lifted.
Inspect the hoist, ropes and hook.
Climb the access platform with a second person on the ground. Measure rope diameter, count broken wires per lay length to AS 2759, check the drum spooling, sheaves, hook throat, safety latch and any swivel.
Test the controls, brakes and safety devices.
With the area clear, run no-load travel and hoist motions, prove the upper, lower and end-of-travel limits, test the overload device, anti-two-block if fitted, e-stops and audible warning. Confirm brake stopping distance against the manufacturer spec.
Conduct a load function check where required.
For annual and post-repair inspections, perform a test lift at SWL per AS 2550.3. Watch for unusual noise from the gearbox, slewing ring or end trucks, and confirm the load-holding brake holds the rated load without drift.
Record defects and sign off.
Capture every defect with a photo, severity rating and a corrective action. Sign the inspection record, log the next inspection due date and update the crane record. In MapTrack the inspection links to the crane asset, generates the defect work order and schedules the next service tier automatically.
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How often should you complete this checklist?
AS 2550.3:2025 covers the safe use of gantry cranes; check its current edition for the inspection tiers and intervals, and follow the manufacturer recommendations as regulation 213 requires. This checklist uses a tiered regime that yards can formalise in their crane management plan. A pre-start visual and functional check is done by the operator at the start of every shift. A more detailed monthly inspection covers ropes, brakes and limit switches. A quarterly inspection adds structural and electrical checks, and an annual inspection by a competent person covers the full asset including a load function test. The AS 2550.3 major assessment, made against the crane's design working period, reviews fatigue life and structural integrity, particularly on RTG and RMG cranes that cycle many times a day. Any incident, overload event, wind event above the rated in-service speed, or repair to a load-bearing component triggers an out-of-cycle inspection before the crane returns to service. In MapTrack each tier is scheduled per crane and reminds the right person when it is due.
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Frequently asked questions
Practical answers about the form, record keeping and using MapTrack.
AS 2550.3 covers the safe use of bridge, gantry and portal cranes, including the inspection and maintenance regime. AS 1418.3 covers their design and manufacture, and AS 2759 covers the steel wire rope on the hoist. The PCBU also has duties under Part 5.1 of the WHS Regulations, which requires maintenance and inspection by a competent person (regulation 213), and the design of a gantry crane with a safe working load greater than 5 tonnes must be registered (Part 5.3 and Schedule 5). The crane itself is not an item of plant that must be registered, so the record duty in regulation 237 does not apply to it, but keeping inspection and maintenance records for the life of the crane is still the practical way to show the regulation 213 duty was met.
Link to this answerPre-start at every shift by the operator, monthly checks on ropes, brakes and limits, quarterly structural and electrical, and a full annual inspection by a competent person. The AS 2550.3 major assessment, made against the design working period, reviews structural and fatigue life, particularly on high-cycle RTG and RMG cranes. Any overload, impact or storm event triggers an out-of-cycle inspection before the crane returns to service.
Link to this answerA bridge crane runs on elevated runway beams fixed to the building structure, so the inspection focuses on the runway, end trucks and roof bracing. A gantry crane carries its own legs to the ground on floor rails or rubber tyres, so the inspection adds floor rail condition, sill beams, tyre condition for RTG and yard travel path. The hoist, trolley and rope checks are similar across both.
Link to this answerDaily pre-start checks can be done by the licensed operator. Monthly and quarterly inspections should be done by a person trained in the inspection procedure. The annual inspection and the AS 2550.3 major assessment must be done by a competent person, such as an OEM-trained technician or a crane inspector with the training, qualifications or experience to inspect that crane.
Link to this answerThe structural, hoist, brake and rope checks are common, but RTGs add tyre pressure, tread depth, cuts and steering function, plus the diesel-electric powerpack and emissions checks. RMGs add rail head wear, rail joint condition, rail fastener torque and crane-to-rail alignment. Most yards keep a single checklist with conditional sections so the right items are filled in for each crane type.
Link to this answerYes. This gantry crane inspection checklist is completely free to download and use, and it downloads as a ready-to-print PDF. No MapTrack account is required. It suits riggers, crane supervisors and maintenance teams running RTG, RMG and precast gantry cranes against AS 2550.3. If you later want to move off paper and spreadsheets, MapTrack turns this into a live digital inspection: pre-starts completed on a phone at the crane, defects raised against each gantry by serial number with photos, automated reminders for the monthly, quarterly and annual tiers, and a complete timestamped audit trail, so nothing slips through across your yard. Start free at maptrack.com/free-trial or book a demo.
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 |
|---|---|---|---|
| Cranes, hoists and winches - Safe use, Part 3: Bridge, gantry, portal (including container cranes), jib cranes and monorail beamsSafe use of bridge, gantry and portal cranes, including maintenance, inspection and repair, and crane runways. | AS 2550.3:2025 |
| Standards AustraliaSold by the publisher |
| Model Work Health and Safety RegulationsInspection by a competent person, lifting plant used within safe limits, and registration of listed plant designs. | 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) |
| Steel wire rope - Use, operation and maintenanceIn-service inspection of the hoist's steel wire rope and the criteria for discarding it. | AS 2759-2004 |
| Standards AustraliaSold by the publisher |
| Cranes, hoists and winches, Part 3: Bridge, gantry, portal (including container cranes) and jib cranesDesign and construction standard for bridge, gantry and portal cranes; the source of the design data the inspection checks against. | AS 1418.3:2024 | Whole instrument | Standards AustraliaSold by the publisher |
| 29 CFR Part 1910, Occupational Safety and Health StandardsUS rule for overhead and gantry cranes: frequent and periodic inspections, testing, maintenance and ropes. | Current eCFR text, up to date as of 2026-10-22 (read 2026-10-26) |
| US Occupational Safety and Health Administration (text via eCFR) |
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 of bridge, gantry and portal cranes, including maintenance, inspection and repair, and crane runways.
- 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)
Inspection by a competent person, lifting plant used within safe limits, and registration of listed plant 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.
- reg 219: Lifting plant must be designed for the load so far as reasonably practicable, with safeguards for alternatives, suitable lifting attachments, and use within safe working limits.
- 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)
Steel wire rope - Use, operation and maintenance
Edition: AS 2759-2004
In-service inspection of the hoist's steel wire rope and the criteria for discarding it.
- 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 and construction standard for bridge, gantry and portal cranes; the source of the design data the inspection checks against.
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 rule for overhead and gantry cranes: frequent and periodic inspections, testing, maintenance and ropes.
- 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.
- Model WHS Regulations (Safe Work Australia)
- AS 1418 series, Cranes, hoists and winches (Standards Australia listing)
- 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 gantry crane inspection checklist contains 25 checks across 5 sections.
- Short attribution
- MapTrack Gantry Crane Inspection Checklist, https://www.maptrack.com/templates/gantry-crane-inspection-checklist
- Reference list
- MapTrack. (2026). Gantry Crane Inspection Checklist [Checklist template]. Retrieved from https://www.maptrack.com/templates/gantry-crane-inspection-checklist
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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;">Gantry 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 identification: serial number, registration, capacity, span and gauge.</li>
<li style="margin:4px 0;">Legs and sill beams: visual structural check for cracks, dents, paint loss and bolt tightness.</li>
<li style="margin:4px 0;">End trucks and wheels: flange wear, tread profile, bearing noise and equaliser play.</li>
<li style="margin:4px 0;">Rails or tyres: rail head wear, joint gaps, fastener condition; tyre pressure, tread and cuts for RTG.</li>
<li style="margin:4px 0;">Bridge girder and tie beams: deflection, weld integrity, lateral bracing and inspection-walkway handrails.</li>
<li style="margin:4px 0;">Trolley and hoist: cross-travel wheels, gearbox oil, drum condition and trolley rail wear.</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/gantry-crane-inspection-checklist" style="color:#071D49;font-weight:600;text-decoration:none;">Gantry Crane Inspection Checklist</a> by MapTrack</p>
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About the author
Co-Founder & Commercial Director
Jarrod has spent over a decade in technology consulting and asset management, including roles at Accenture (mining and heavy industry) and CGI as an Asset Management Consultant. He co-founded MapTrack and built and scaled its original platform, then rebuilt it with Lachlan and Alex from thousands of customer conversations and 300+ user research sessions with field teams. His consulting background gives him deep insight into the operational and compliance challenges facing asset-intensive Australian businesses.
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