Free gantry crane inspection checklist

• 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.
• 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.

Learn more about compliance and inspections in MapTrack.

• Operator accountability: Every pre-start, monthly and annual check is signed against the operator or competent person who completed it.
• AS 2550.5 alignment: The checklist mirrors the safe-use clauses for bridge, gantry and portal cranes so audits are straightforward.
• 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.

• 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.

1. 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.

2. 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.

3. 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.

4. 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.

5. Conduct a load function check where required.

   For annual and post-repair inspections, perform a test lift at SWL per AS 2550.5. Watch for unusual noise from the gearbox, slewing ring or end trucks, and confirm the load-holding brake holds the rated load without drift.

6. 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.

Practical answers about the form, record keeping and using MapTrack.

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.

• AS 2550.5 - Cranes, hoists and winches (Bridge, gantry and portal cranes - Safe use)
• AS 1418.3 - Cranes, hoists and winches (Bridge, gantry, portal cranes and jib cranes - Design)
• AS 2759 - Steel wire rope - Use, inspection and discard criteria
• WHS Regulations 2011 - Chapter 5, Part 5.1 (Registration and inspection of plant)
• OSHA 1910.179 - Overhead and gantry cranes

• Model WHS Regulations (Safe Work Australia)
• OSHA 29 CFR Part 1910, Occupational Safety and Health Standards
• 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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