Last reviewed by Rohan Allen, B.Eng (Mech), Director — Sorian Cranes. May 2026.
What is a 10-yearly major inspection?
The 10-yearly major inspection is a deep structural, mechanical and electrical assessment of an in-service crane, performed by a competent engineer to verify the crane remains safe and fit for continued use. It's distinct from your annual or quarterly maintenance inspection — those check operational function and obvious wear. The major inspection looks for what those routine checks can't see: fatigue cracks in welded joints, latent wear in load-path components, insulation degradation in motors and contactors, and accumulated damage that determines the crane's residual life.
The "10-year" interval comes from AS 2550.1 as a default upper limit between major inspections, but the actual trigger date depends on the duty class your crane was designed to under AS 1418. A high-duty crane (Class A6 or higher) operating near rated load with frequent lifts can reach end-of-design-life in 5-7 years. A lightly-loaded jib used a few times a week may comfortably exceed 10 years. The right answer is in your original design documentation — check the duty class and the calculated design life.
The legal framework
Three layers stack to make the major inspection a hard requirement, not an optional one:
- WHS Regulations (state-based): Each Australian state and territory's Work Health and Safety Regulations require persons conducting a business or undertaking (PCBUs) to ensure plant is inspected and maintained in accordance with the manufacturer's recommendations and applicable Australian Standards. Most state regulators reference AS 2550 directly.
- AS 2550 series: AS 2550.1 sets the framework for safe in-service use, including inspection intervals. The product-specific parts (AS 2550.5 for mobile cranes, AS 2550.13 for building maintenance units, etc.) apply additional crane-specific requirements.
- Insurance and contractual: Most workplace insurance policies require compliance with applicable safety standards. A crane operating past its required major inspection is unlikely to be covered if it causes injury or property damage. Many EPCs and large industrial customers require evidence of recent major inspection as a condition of supply contracts.
The combined effect: a crane operating past its inspection date exposes the business to regulatory enforcement, voids insurance, and creates personal liability for company officers under the Corporations Act and WHS legislation.
What gets inspected
A complete major inspection covers structural, mechanical, electrical and documentation domains. The exact scope depends on crane type, but for a typical electric overhead travelling (EOT) bridge crane the inspector will work through:
Structural assessment
- Visual inspection of main girders, end carriages, runway beam and crab structure
- Non-destructive testing (NDT) on critical welded connections — typically magnetic particle inspection (MPI) for ferrous welds or dye penetrant inspection (DPI) for surface flaws
- Measurement of girder camber and any loss of designed pre-camber under no-load
- Inspection for fatigue cracks at high-stress locations: end-carriage to girder connections, trolley wheel spans, drum mounting flanges
- Bolt-tension verification on safety-critical connections
Mechanical inspection
- Wheel measurements — flange wear, tread profile, ovality
- Brake inspection, lining wear and operational test
- Drive gearbox examination — oil sample for metal content, backlash measurement, seal condition
- Hoist drum inspection — rope groove wear, drum-end flange cracks, mounting
- Hook inspection — throat opening measurement, NDT for cracks, rotation freedom and locking
- Wire rope inspection per AS 2759 — broken wires per lay length, diameter reduction, lay-length growth
- For chain hoists: chain elongation measurement against original pitch, surface wear, side plate condition
Electrical inspection
- Insulation resistance testing (megger) of motors and main supply
- Earth bond verification across the crane structure
- Function test of all controls including pendant, radio remote, limit switches
- Operation of upper and lower hoist limits, bridge end-of-travel limits, slew limits
- Emergency stop function and isolator operation
- Overload protection device test against rated load
Documentation review
- Original design and manufacturing documentation
- Maintenance log since installation
- Previous inspection reports
- Modification register — any changes to original design
- Operator licensing records and pre-start checklists
Load test (where specified)
- Static load test, typically at 1.25× safe working load (SWL)
- Dynamic load test, typically at 1.10× SWL
- Deflection measurement under load and recovery to no-load datum
Who can perform a major inspection
AS 2550 requires the inspection to be performed by a "competent person." In practice this means a chartered mechanical or structural engineer with crane-specific experience, or a specialist inspection company employing such engineers. NDT components — MPI, DPI, ultrasonic testing — must be performed by a technician certified to AS 3998 or an equivalent recognised qualification.
Critically, the inspector should be independent of the day-to-day maintenance contractor. There's an obvious conflict of interest if the company maintaining your crane is also assessing whether their maintenance has been adequate. Best practice is to engage a separate engineering firm for the major inspection, even if your routine maintenance contractor is technically capable. The final report must be signed by a qualified engineer who takes professional responsibility for the residual-life assessment.
What it costs
Cost varies with crane size, complexity, access and whether NDT findings drive rectification work. Indicative ranges across the Australian market for a clean inspection (no major defects found):
| Small jib or workstation crane (under 2 t) | $2,500 – $5,000 |
| Single-girder EOT bridge crane (2 – 10 t) | $5,000 – $12,000 |
| Double-girder EOT bridge crane (10 – 50 t) | $12,000 – $25,000 |
| Large gantry, portal or specialised crane (50 t+) | $20,000+ |
| Witnessed load test (additional) | $1,500 – $5,000 |
Costs rise meaningfully if NDT reveals defects requiring rectification, if the crane needs to be partially dismantled for access (e.g. removing a drum to inspect bearings), or if your facility requires the crane to be moved or scaffolded for inspector access. We quote each inspection on actual scope rather than off the table above — send through the basics and we'll come back with a fixed-price quote, usually within one business day, that explicitly lists what's included and what triggers an additional charge.
What happens if your crane fails
Failure outcomes range from minor to catastrophic. The inspector's report will categorise findings:
- Pass: No defects found. Crane recertified for the next inspection interval (typically 5-10 years).
- Pass with conditions: Minor defects identified that must be rectified within a specified timeframe. The crane can typically continue operating, sometimes at reduced capacity, until the conditions are addressed.
- Conditional re-certification after repair: Specific repairs required before the crane can return to service. Common examples: rope replacement, brake refurbishment, contactor replacement, NDT-confirmed weld repair.
- Failed — out of service: Critical structural defects, significant fatigue cracking, or accumulated wear beyond economic repair. The crane must be removed from service. Decision then becomes major refurbishment, reduced-capacity re-rating, or replacement.
The most common surprise for facility managers is finding out a crane that's been working "fine" has actually consumed most of its design life — particularly with high-duty cranes that have been progressively loaded harder over time as the business has grown. The major inspection is often the first time anyone has independently calculated where the crane sits against its original design assumptions.
How to prepare
You can reduce inspection cost and turnaround substantially with a few weeks of preparation:
- Pull together the documentation pack: original design drawings, manufacturer's manual, design certificate, maintenance log, previous inspection reports, modification register. Missing original documentation makes the inspector's job harder and the cost higher.
- Schedule downtime: the crane needs to be out of service for 1-3 days for a typical inspection. Plan around production schedules.
- Provide access: safe access to the crane structure, runway and high-level components. If scaffolding or a EWP is required, organise it in advance.
- Identify any known issues: tell the inspector upfront about any known noises, vibrations, intermittent faults or recent repairs. They'll find them anyway, but disclosure builds trust and saves time.
- Have your maintenance contractor available: they hold knowledge about quirks of the specific machine that's useful to the inspector.
Common findings
Across thousands of major inspections in the AU industrial sector, the most common findings cluster around:
- Fatigue cracking at end-carriage connections on cranes that have spent significant time near rated load
- Wheel flange wear beyond AS 2550 wear limits — usually a runway alignment issue manifesting as wheel damage
- Wire rope condition — usually replaceable but sometimes drums and sheaves need attention too
- Hook throat opening stretched beyond the manufacturer's wear limit — needs replacement
- Brake lining wear requiring replacement
- Insulation degradation in older motors and contactors
- Documentation gaps — modifications not formally engineered, missing maintenance records, lost original design documentation
The good news: most cranes pass with a few rectifications. The bad news: the rectifications are sometimes substantial, and many facilities haven't budgeted for them.
Talk to an engineer
Sorian Cranes is engineer-led. Our director is a chartered mechanical engineer with hands-on experience in AS 1418 design and AS 2550 inspection across Australian industry. We perform major inspections on overhead, jib, gantry and workstation cranes nationally, with a focus on producing reports that give you a defensible position with WorkSafe and a clear plan for what comes next.
Frequently asked questions
When does my crane need a 10-yearly major inspection?
A major inspection is typically required either every 10 years from the date of manufacture (or last major inspection), or earlier if the design life calculated under AS 1418 has been reached based on actual duty cycles. High-duty cranes operating near rated load or with frequent lifts may reach end-of-design-life well before 10 years. Check your crane's original design documentation for the calculated design life.
What happens if I don't do a 10-yearly major inspection?
Operating a crane past its required major inspection date is a breach of WHS regulations and AS 2550. Consequences include: WorkSafe enforcement notices, the crane being prohibited from use, insurance void in the event of an incident, and personal liability for officers if the crane fails causing injury or property damage. Beyond regulatory exposure, undetected fatigue cracks or worn components present a real safety risk.
What's the difference between an annual inspection and a 10-yearly major inspection?
Annual inspections are visual and functional — checking brakes, controls, hooks, ropes and obvious wear. They take a few hours and are usually done by your maintenance contractor. The 10-yearly major inspection is a deep structural and mechanical assessment including non-destructive testing (NDT) of welded connections, wear measurement of every load-path component, electrical insulation testing, and a residual-life calculation. It typically takes 1-3 days on site and produces a comprehensive engineering report.
How much does a 10-yearly major crane inspection cost in Australia?
Costs vary widely. Indicative Australian-market ranges: small jib or workstation crane $2,500-$5,000; single-girder EOT bridge crane $5,000-$12,000; double-girder EOT or large gantry $12,000-$25,000+. Costs rise if NDT reveals defects, if the crane needs partial dismantling for access, or if a witnessed load test is specified. Get a fixed-price quote that explicitly lists what's included before engaging.
Who can perform a 10-yearly major crane inspection?
AS 2550 requires the inspection to be performed by a competent person — typically a chartered mechanical or structural engineer, or a specialist crane inspection company employing such engineers. The inspector must be independent of day-to-day maintenance to ensure objectivity. NDT components must be performed by a technician certified to AS 3998 or equivalent. The final report must be signed by a qualified engineer who takes professional responsibility for the residual-life assessment.
Can the design life of my crane be extended past 10 years?
Yes — provided the major inspection demonstrates the crane is structurally sound and identifies the residual life. Many cranes pass their first 10-yearly inspection with no required works and receive an extension to the next inspection interval. Cranes with significant fatigue or high-duty service may receive a shorter extension or a list of components requiring replacement before continued use.