Crane inspections under AS 2550.1 aren't optional. The major inspection at 10 years and the assessment at end of design working period (typically 25 years for industrial cranes) are mandated for any crane in service. Whether you bought your crane from us or from another supplier, Sorian provides the engineer-led inspection and the documentation pack that makes the difference between an inspection that satisfies the regulator and one that doesn't.
10-year major inspection (AS 2550.1)
AS 2550.1 mandates a major inspection at 10 years from date of manufacture, or earlier where the crane's actual duty cycle has accelerated wear. The inspection involves partial disassembly of critical components, NDT (non-destructive testing) of fatigue-prone areas, dimensional measurement of ropes, wheels and wear plates against discard limits, electrical insulation and earth-bond testing, a full proof load test where access permits, and a structural assessment against current specification.
Common findings: undersized brake torque, drum and bottom-block wear, wire rope reaching discard limits, contactor wear from cranes spec'd at one duty class but operating at a higher one, base plate anchor corrosion. Every finding is documented with photographic evidence, measurement against the discard criteria, and a remedial works schedule prioritising safety-critical items.
25-year design working period assessment
At the end of the crane's design working period — typically 25 years for industrial cranes — AS 2550.1 requires a comprehensive assessment to determine whether the crane can be returned to service or must be retired or refurbished. This is more thorough than the 10-year major: full structural NDT, fatigue review against actual duty cycle history, calculation of remaining design life, and a fitness-for-continued-service determination.
Outcomes fall into one of four buckets: cleared for continued service (typically with a defined re-inspection interval), conditional clearance pending remedial work, major refurbishment required (often replacing fatigue-critical components like the bridge girder), or retirement recommended. Most cranes can continue in service post-DWP with appropriate refurbishment if the structure is sound — the assessment tells you which path applies, and what it costs.
Third-party / independent inspections
When you need an inspection from someone who didn't supply or install the crane — for due diligence, insurance, sale or purchase, regulatory compliance, dispute resolution, or simply a second opinion — Sorian provides independent inspections under AS 2550.1. We have no commercial relationship with the crane's manufacturer or installer; the report goes to you alone, with no commercial bias toward repair work, replacement parts or retrofits.
Common engagements:
- Pre-purchase inspection — used cranes, asset transfers, business sales. Covers structural condition, remaining design life, compliance gaps, and fair-market refurbishment cost.
- Post-incident assessment — after dropped loads, runway collisions or operator error. Determines structural damage, fatigue impact, and whether the crane can be returned to service.
- Insurance renewal — many insurers require a current AS 2550.1 inspection from an independent engineer at policy renewal.
- End-of-lease handover — establishes condition and remaining service life at handover from outgoing tenant or operator.
- Dispute resolution — second-opinion inspections where the original installer's findings are contested.
What's in the inspection report
Every inspection comes with a complete documentation pack:
- Inspection scope and methodology to AS 2550.1
- Photographic record of all inspected components
- NDT results where applicable — magnetic particle, dye penetrant, ultrasonic
- Wear measurement against discard limits — ropes, wheels, brakes, hooks
- Electrical insulation resistance and earth-bond test results
- Load test record where conducted
- Structural assessment and fatigue review against actual duty history
- Defect register prioritised by safety criticality
- Remedial works schedule with cost estimates and timelines
- Fitness-for-continued-service determination
- Engineer's signed compliance statement against AS 2550.1
- Recommended next inspection interval
Why engineer-led inspections matter
Generic crane inspection services often subcontract to fitters or maintenance technicians. That's fine for routine 6-monthly checks where the question is straightforward. It falls down on the 10-year major and 25-year DWP inspections, where the question shifts from "is anything obviously broken" to "is this crane fit for another decade of service" — a fatigue and design-life question that needs an engineer.
Sorian inspections are signed off by a qualified mechanical engineer. The same person who specifies new cranes against AS 1418 understands what the crane was designed for, what's normal wear after a given duty history, and what's a developing problem. When defects are borderline, when fatigue calculation is needed, or when an insurer or regulator wants a second opinion, the engineer's sign-off is what makes the report stand up.
Crane servicing & inspections — Melbourne, Sydney, Brisbane, Perth, Adelaide
Sorian Cranes services and inspects cranes nationally. Common engagements: 10-year major inspections on EOT bridge cranes in fabrication shops; 25-year DWP assessments on water-authority and infrastructure cranes; third-party pre-purchase inspections on used jib and gantry cranes; post-incident assessments after dropped loads or collisions. We work directly with metropolitan customers in Melbourne, Sydney, Brisbane, Perth and Adelaide, and with regional operators in Geelong, Newcastle, Townsville, Mackay and the Hunter Valley. National engagements are project-managed end-to-end from our Melbourne office.
Frequently asked questions
What does AS 2550.1 require for crane inspections?
AS 2550.1 mandates inspection regimes across the full service life: routine pre-shift checks, an annual thorough examination, a major inspection at 10 years (or earlier where duty cycle is high), and a design working period assessment at end-of-design-life (typically 25 years). Owners are responsible for ensuring inspections are carried out by competent persons; major and DWP inspections require an engineer's sign-off.
When does my crane need a 10-year major inspection?
10 years from date of manufacture for most cranes, or earlier if the crane has reached its rated design working period faster due to higher-than-rated duty cycle. If your crane was specified at duty class M5 but operating at M7 cycles, the major inspection may be due in 7 or 8 years rather than 10. We assess actual duty cycle as part of the inspection.
What happens if my crane fails the 25-year DWP assessment?
The DWP assessment determines remaining design life. Outcomes are: cleared for continued service (with a defined re-inspection interval), conditional clearance pending remedial work, major refurbishment required (often replacing fatigue-critical components), or retirement recommended. Most cranes can continue in service post-DWP with appropriate refurbishment if the structure is sound — the assessment tells you which path applies.
Can you inspect a crane you didn't supply?
Yes — that's specifically what our third-party inspection service is for. We inspect cranes from any manufacturer or installer, with no commercial relationship that would bias the report. Common in pre-purchase due diligence, insurance renewals, post-incident assessments, and disputes. The report is yours and goes only to you.
Do you service cranes outside major capitals?
Yes. We inspect and service cranes nationally — Melbourne, Sydney, Brisbane, Perth, Adelaide, Hobart, Darwin, Canberra and regional sites across Australia. Regional engagements are project-managed end-to-end from our Melbourne office, including scheduling, freight of test equipment and any required access works.