Crane inspections under the AS 2550 series aren't optional. For bridge, gantry and jib cranes, AS 2550.3:2025 sets a layered regime: pre-operational checks, routine inspection and servicing at 4–12 week intervals depending on duty class, periodic inspections at least every 2–4 years, and a major assessment as the crane approaches its design working period — generally 10 years for mechanisms and 25 years for the structure. Whether you bought your crane from us or from another supplier, Sorian provides the engineer-led inspection and the documentation pack that satisfies the regulator.
Major inspection — the '10-year major' (AS 2550.3)
AS 2550.3:2025 requires a major assessment when the crane approaches the design limits of its mechanisms or structure. For most industrial cranes the mechanisms' design life is 10 years unless the manufacturer specified otherwise — which is where the "10-year major" comes from. It falls due earlier where actual duty has been heavier than the design assumed, and it is also triggered by periodic-inspection recommendations, a notable increase in defects, significant deterioration, or when a crane is recommissioned or repurposed. A second-hand crane with no operating history requires a major assessment before it is used at all. 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 — generally 25 years for the structure — AS 2550.3:2025 requires an assessment for continued use to determine whether the crane can stay in service, and on what conditions. Where the design life is unknown, assessments default to 10-year intervals for mechanisms and 25-year intervals for the structure. An assessment is also required after any overload exceeding 10% of rated capacity. 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.
Runway inspections
Your runway has its own inspection schedule. AS 2550.3:2025 requires crane runways to be routinely inspected and maintained — at maximum intervals ranging from 5 years for light-duty cranes (A1–A2) down to 1 year for the heaviest duty (A8) — plus periodic inspections by an accredited inspection body every 3–5 years depending on class. Rail joint gaps, weld cracking and rail alignment are specific checklist items. We inspect runways as part of every crane inspection engagement, or as a standalone service.
Keep your crane's usage and maintenance records. Under AS 2550.3:2025, if duty history is unknown the assessing engineer must apply a worst-case duty factor (f1 = 1.5), which can halve the crane's assessed remaining life on paper. Records also transfer with ownership — they are part of the asset's value when you sell.
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 the applicable AS 2550 parts (AS 2550.1 general; AS 2550.3 bridge, gantry and portal cranes). 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 inspection against the applicable AS 2550 parts 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 the applicable AS 2550 parts (AS 2550.1 general; AS 2550.3 bridge, gantry and portal cranes)
- 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 the applicable AS 2550 parts (AS 2550.1 general; AS 2550.3 bridge, gantry and portal cranes)
- 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.
Our Victoria service partner — Crane Reliability
For hands-on servicing and inspections across Victoria, Sorian works alongside Crane Reliability, founded by Barry Young. Barry brings more than 25 years in the Australian crane industry — built working for established names in the field before starting his own business — and services and inspects all makes and models of overhead cranes and hoists to AS 2550.
For our Victoria customers it's the best of both: Sorian's engineer-led design and major-inspection sign-off, backed by a seasoned local team that handles everything from 12-weekly periodic maintenance and independent third-party inspections through to commissioning, decommissioning and major inspection works.
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 require for crane inspections?
For bridge and gantry cranes, AS 2550.3:2025 sets four inspection levels: pre-operational checks each shift; routine inspection and servicing at recommended intervals of 12 weeks (classes A1–A4), 8 weeks (A5–A6) or 4 weeks (A7–A8); periodic inspections by an inspection body conforming to AS/NZS ISO/IEC 17020, at intervals not exceeding 4 years for cranes classified A4 and below, or 2 years above A4; and a major assessment as the crane approaches its design limits. Owners must keep usage and maintenance records — if duty history is unknown, assessments must assume worst case.
When does my crane need a 10-year major inspection?
Commonly around 10 years for most industrial cranes, or earlier if the crane has consumed its design working period faster than rated. A crane specified at duty class M5 but cycling at M7 rates is consuming design life roughly four times faster — a nominal 10-year design working period can be used up in under 3 years. 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.
Crane service by city and inspection type
City-specific service pages with local response notes, suburbs covered and applicable WHS regulator details: Crane service Melbourne · Sydney · Brisbane · Perth · Adelaide. For inspection-specific guides see the 10-yearly major inspection pillar page and annual crane inspection page.