Comprehensive Crane Inspection and Regulatory Requirements Guide

Compliance & Regulations, Plant Inspection November 8, 2024

Cranes are critical assets for heavy industries, such as mining, energy, construction, manufacturing, and logistics. They not only lift materials but are also the productivity centre of entire operations.

If you’re into building skyscrapers, moving massive shipping containers, or mining resources, cranes are essential to getting the job done. However, their sheer size and operational complexity also mean they pose significant safety risks if not maintained properly.

Crane inspection and maintenance are critical to not only meet industry and regulatory requirements, but also to minimise risks and protect both workers and equipment.

Furthermore, Section 19 of the Work Health and Safety Act 2020 states that a person Conducting a Business or Undertaking (PCBU) has a primary duty of care to ensure, so far as reasonably practicable, the health and safety of workers engaged, or caused to be engaged by that person or if the PCBU influences and directs work activities undertaken by the worker.  The PCBU must also ensure procedures are in place for the provision and maintenance of safe plant at the workplace.

In industries where a single malfunction can halt project progress, proactive crane inspection and maintenance are the unseen drivers of success.

Here, we’ll explore the importance of regular crane inspection and maintenance, with a focus on Australian Standards and best practices for any person with management or control of an item of plant such as cranes.

Why Is Crane Inspection Important?

For any person with management or control of plant, crane inspections are a strategic business practice that protects people, equipment, the environment and the bottom line.

A well-maintained crane can prevent costly accidents, extend operational life, and keep projects on schedule. Here’s why regular crane inspections are crucial for any business that uses these items of registered plant.

Compliance With Work Health and Safety (WHS) Regulations

In Australia, businesses must comply with stringent industry and work health and safety (WHS) regulations and standards. These regulations and standards mandate crane inspections and maintenance be carried out by a competent person to ensure the crane meets the required safety and operational standards set by industry and regulatory bodies.

Failure to adhere to these industry standards and WHS regulations can result in hefty fines, legal action, and even shutdowns. Inspections of crane assets help identify potential hazards before they become an uncontrolled risk in the workplace. If the risk is left uncontrolled, you may be exposed to legal action if a serious incident occurs in the workplace.

Prevention of Workplace Accidents

Accidents involving cranes can be catastrophic, resulting in severe injuries or fatalities, as well as property damage. No-one has the luxury to say, “I wish I had attended to that crane inspection earlier”.

Regular inspections ensure that all components are functioning correctly. This reduces the likelihood of mechanical failures and ensures the required crane servicing is accomplished.

A regular crane inspection program provides the management plan businesses require to assess and manage the risks of plant in the workplace and address issues such as electrical faults, malfunctioning brakes, safety and warning devices, or addressing wire rope and boom structural damage early on. This enables prevention of incidents that could endanger lives and disrupt operations.

Extending Equipment Lifespan

Like any piece of heavy machinery, cranes are susceptible to wear over their working design life. Regular inspections and maintenance extend the lifespan of cranes through the identification of and by addressing wear and tear (through crane servicing) before it leads to major mechanical failures.

Keeping parts well-lubricated, replacing worn-out components, and ensuring faults are rectified, are all steps that help maintain or possibly extend the cranes working design life, enabling businesses to save on capital costs of expensive early replacements.

Reducing Downtime and Costs through Preventative Maintenance.

Unplanned downtime due to crane failure can be costly, especially for businesses operating on tight project timelines.

A preventative maintenance program for cranes should be implemented, taking into careful consideration the manufacturers recommendations, the working environment and the frequency and severity of use.

Routine inspections catch minor issues before they escalate into bigger, costlier problems. Regular maintenance also contributes to better performance, so operations are efficient and the financial impact of outages is reduced.

Crane Inspection Requirements

Regular inspections ensure that cranes remain safe, efficient, and compliant with regulatory and industry standards.  It is important to note that there are regulatory duties imposed on designers, manufacturers, suppliers and operators of cranes to ensure the crane is being maintained and is safe to use.

Pre-Operational Inspections

Pre-operational inspections should be conducted before use of any crane. This daily routine involves checking essential crane components, such as hoist ropes, sheaves, hooks, boom and brakes for any visible signs of wear or damage. A pre-operational inspection should also include a thorough assessment of the crane set up area including ground conditions and the crane working area.

Operators should also verify that all safety and warning devices, like limit switches and emergency stop buttons, are functioning correctly. By adhering to a checklist for pre-start and post-start inspections before every operation, businesses can manage risks and prevent accidents caused by unnoticed mechanical issues.

Routine Inspections

Routine inspections are generally performed every 90 days although a competent person may recommend that routine inspections are carried out more frequently.

These inspections may include:

• Verifying fluid levels, lubrication of moving parts and inspection of filter elements.
• Checking all operational functions for control of speed, smoothness and motion limits and sensors.
• Checking for unusual noises during operation.
• Ensuring that all electrical components are in proper working condition.
• Inspections of all critical crane components.
• Inspections of crane signage and control markings.

Routine checks are key to spotting early signs of deterioration and can often be performed by trained operators or maintenance personnel.

Periodic Third-Party Inspections.

Each crane shall undergo a periodic third-party inspection to provide independent advice on whether the level of maintenance and repairs are in accordance with industry standards.

These inspections are conducted on an annual basis and provide a detailed examination of the entire crane, typically conducted by a certified professional or competent person who is not directly involved in the maintenance of the crane being inspected.

This involves a comprehensive check of the crane’s:

• Structural integrity
• Mechanical components
• Electrical systems
• Load Moment Indicator and calibration
• Crane safety and warning devices

The goal of annual crane inspections is to ensure that the crane complies with all relevant safety standards and is operating within its designed capacity.

An annual inspection report is often required for compliance with Australian safety regulations, making this a critical task from a legal and operational position.

Major Crane Inspection

A major crane inspection is an extensive and thorough examination required for cranes that have been in continuous service typically for a period of 10 years.

During this inspection, the cranes critical components are stripped down and paint and grease is removed to allow a complete and thorough inspection. This might include inspecting the structural welds and boom sections, slew ring and load-bearing parts for fatigue or corrosion using inspection methods such as non-destructive testing.

A major crane inspection is critical for ensuring long-term safety and reliability, and any major repairs or part replacements are typically carried out during this process to prepare the crane for continued service.

Crane Type-Based Inspection Requirements

Crane inspection requirements vary depending on the type of crane and its operational conditions. The design, purpose, and usage frequency of different cranes determine how often inspections should be performed and what specific parts need more attention.

Let’s explore the various crane types and why their inspection demands differ.

Bridge and gantry cranes are typically used in industrial environments like factories and warehouses. They operate on overhead runways and are designed to lift heavy loads over large areas. These cranes are ideal for indoor use, where high load precision and control are essential.

Inspection Requirements:

Bridge and gantry cranes require regular structural inspections due to the high stresses placed on their girders and hoisting mechanisms. These cranes typically undergo frequent checks for wear on the trolley, hoist, and rails, as these components endure heavy operational loads. As they are often used in repetitive tasks, daily inspections focusing on operational components like brakes, hoist drum, wire rope, hook block, and electrical control systems are critical.

➜ Learn more & download our guide on Bridge and Gantry Crane Inspection Requirements

The fact that they are used across various industries, such as mining, energy, construction, and infrastructure projects, demonstrates the versatility of mobile cranes.

Mobile cranes are often used for lifting and transporting materials over short distances. They can be mounted on trucks or crawler tracks, making them easy to move to different sites.

Inspection Requirements:
The mobile nature of these cranes exposes them to varying ground conditions and stresses. This is why frequent checks of the hydraulic systems, outriggers, and load charts are necessary. Their ability to move on public roads also implies compliance with both crane safety regulations and road safety standards are required. Regular inspections of tires, outriggers, and mobility-related components are required in addition to typical crane component checks.

➜ Learn more & download our guide on Mobile Crane Inspection Requirements

Tower cranes are fixed to the ground and used predominantly in high-rise building construction, where they lift and move heavy materials vertically and horizontally.

Inspection Requirements:
Tower cranes face significant wind and environmental exposure because of their height. Inspection requirements include regular structural assessments, particularly of the tower sections and mast components. Bolted connections, the slewing system, and the base foundation are all subject to stress and wear, making frequent inspection crucial for safety. Additionally, as these cranes often remain in one place for extended periods, regular inspections of electrical and hydraulic systems are essential to prevent malfunctions. Comprehensive pre-erection and commissioning inspections of tower cranes should also be undertaken.

Crane-lifted workboxes are used to safely lift personnel to heights for tasks like maintenance or inspection work. These boxes are attached to cranes and must meet strict safety standards to protect workers while operating at height.

Inspection Requirements:
Workbox inspections focus on the integrity of the attachment points, safety harness systems, and load-handling devices. As workboxes are designed to lift people, safety standards are more stringent, with a focus on ensuring there are no weak points in the structural integrity of the workbox and its connections to the crane. Regular testing of emergency procedures and fall arrest systems is also mandatory.

➜ Learn more & download our guide on Workbox Inspection Requirements

Operating while mounted on trucks, vehicle loading cranes are used to load and unload heavy materials from the vehicle itself. These are commonly used in industries such as logistics, transport, and construction where goods need to be moved frequently between locations.

Inspection Requirements:
Vehicle loading cranes experience significant movement, and subsequently regular checks of their hydraulic systems and stability components are required. Inspections often include tests for wear on the lifting arms, stabilisers, and joints. The integration of the crane with the truck chassis must also be regularly inspected to ensure safe lifting operations.

➜ Learn more & download our guide on Vehicle Loading Crane Inspection Requirements

Inspection Requirements of Crane Parts

Each part of a crane plays a unique role in its operation, and being familiar with the different inspection requirements for each component is essential to maintain safety and functionality.

The inspection frequency and focus areas vary depending on the part’s function, how it is used, and the stresses it endures.

The crane hoist is responsible for lifting and lowering loads. It consists of several key components, including the hook, drum, and lifting mechanism.

Inspection Requirements:
Hoist inspections focus on the wear and tear of ropes, drums, and braking systems. Inspectors check for fraying, corrosion, and any signs of misalignment. Daily visual inspections are recommended, while more thorough mechanical checks should be carried out during routine inspections.

The wire rope transfers the force from the hoist to the load. It is critical for supporting and lifting heavy materials.

Inspection Requirements:
Wire rope inspections are essential to identify issues such as kinking, bird-caging, or fraying. Due to the immense loads that wire ropes endure, regular inspections are required, and ropes must be replaced when they reach the manufacturer’s recommended wear limits. Lubrication and cleanliness checks also ensure the longevity of wire ropes.

The crane’s structure, including its boom, mast, jib, girders, and supports, provides stability and strength for lifting operations.

Inspection Requirements:
Structural inspections focus on detecting cracks, corrosion, or deformation in critical components. Given the stresses cranes face from loads and environmental factors, frequent structural assessments are essential to avoid catastrophic failures. Non-destructive testing (NDT) methods, such as ultrasonic testing, are often used to assess the internal integrity of materials.

Hydraulic systems power the movements of many cranes, controlling lifting, lowering, and rotating actions.

Inspection Requirements:
Hydraulic system inspections focus on identifying leaks, pressure losses, or contamination in the fluid. Regular checks of hoses, cylinders, and pumps help ensure smooth operation. Hydraulic systems are prone to wear and therefore require routine fluid checks and component replacements to prevent system failure.

Electrical systems control the operation of crane movements and include wiring, control panels, and safety interlocks.

Inspection Requirements:
Electrical systems must be inspected for insulation wear, loose connections, and proper grounding. Inspectors often perform tests on the functionality of control systems, emergency stop buttons, and overload sensors. Regular inspection helps ensure reliable operation and prevents electrical faults that could lead to equipment malfunctions or accidents.

Crane Inspection Methods

Various inspection methods are used to assess the safety and functionality of crane components. These methods range from visual checks to advanced non-destructive testing (NDT) techniques, each suited to specific parts and conditions.

Visual Inspection

A visual inspection is a simple, yet effective method of identifying obvious signs of wear, damage, or corrosion.

Application:
The visual inspection method is typically performed during routine and pre-operational checks. Visual inspections are the first line of defence against potential issues and are essential for spotting obvious damage, such as frayed wires or leaking hydraulic lines.

Non-Destructive Testing (NDT)
NDT methods allow for the inspection of crane components without damaging them. These tests include ultrasonic testing, magnetic particle testing and radiography.

Application:
NDT is commonly used for structural inspections. It allows inspectors to detect internal flaws, such as cracks or corrosion that might not be visible externally. It’s particularly useful for inspecting the crane frame, boom, and critical load-bearing parts.

Load Testing

A load test involves applying a load to the crane to ensure it can handle its maximum rated capacity. The test weight needs to ideally weigh between 100% and 125% of the crane’s maximum rated capacity or fall within the weight range recommended by the original equipment manufacturer (OEM).

Application:
Load tests are typically performed during annual or major lifting equipment and crane inspections to verify a cranes lifting capability. This method helps ensure the crane’s mechanical components, such as the hoist, brakes, and structure, can safely operate under load lifting conditions.

Regulations Governing Crane Safety and Maintenance in Australia

In Australia, the safety and maintenance of cranes are governed by a set of stringent laws and standards designed to protect workers and the public.

Crane safety is governed by work health and safety (WHS) regulations, which mandate strict guidelines for the operation, inspection, and maintenance of cranes. These regulations are critical for ensuring compliance and maintaining the safe operation of cranes in industrial settings.

Work Health and Safety (WHS) Regulations

WHS laws outline the duties  of crane owners, operators, maintenance teams and inspection services providers. Compliance with these regulations ensures that cranes are inspected regularly, maintained according to industry standards, and operated by qualified personnel.

Key regulations include the WHS Act, WHS Regulations, and the Australian Standards for cranes. Compliance with AS 2550.1 and AS 1418 is mandatory. These Standards incorporate the safe use of cranes and cover all available methods and frequencies for inspecting and maintaining your crane asset.

Key Regulatory Bodies

The key regulatory bodies overseeing crane safety and maintenance in Australia includes Safe Work Australia, which provides the framework for WHS laws, and state-specific safety authorities, comprising:

• WorkSafe in Victoria
• WorkSafe in Queensland
• SafeWork in New South Wales
• WorkSafe ACT
• WorkSafe Tasmania
• WorkSafe in Western Australia
• NT WorkSafe in the Northern Territory

These organisations enforce guidelines set by the Standards Australia (AS) and the International Organization for Standardization (ISO), which, in turn, detail the requirements for crane design, operation, and maintenance. They also investigate safety breaches related to crane operation and maintenance.

Regular audits and inspections from these bodies ensure that businesses meet all safety and operational requirements.

Australian Standards Applying to Cranes

Australian Standards are designed to guide the safe design, construction, and operation of cranes across various industries. Each crane type has its own set of guidelines that dictates everything from the engineering and structural integrity of the crane to its operational limitations and safety features.

Below is an overview of the key standards that apply to different types of cranes in Australia.

AS 1418: Cranes, Hoists, and Winches

The AS 1418 series outlines the design, construction, and safety requirements for various crane types. This code helps establish the minimum criteria needed for safe crane operation, maintenance, and inspections.

AS 2550: Cranes, Hoists, and Winches – Safe Use

The AS 2550 series complements AS 1418, focusing on the safe use of cranes.

While AS 1418 is focuses on design and construction, AS 2550 outlines practical use and maintenance requirements of cranes. This Standard specifies how cranes should be operated and inspected under working conditions.

Importance of Record Keeping

Effective record keeping is both a regulatory requirement and a critical aspect of crane maintenance and safety.

Detailed, accurate records allow asset managers and engineers to track the condition of equipment over time, spot patterns of wear or malfunction, and ensure that maintenance is carried out promptly. Without diligent record keeping, the risk of operational failures, accidents, and expensive repairs increases significantly.

WA WHS reg 237 Records of Plant, states that a person with management or control of any registered plant (cranes) in the workplace must keep a record of all tests, maintenance, and inspections, of plant for the period that the plant is used.

A failure to keep up-to-date records of crane hoist inspections could lead to missed signs of wear, resulting in mechanical failure during lifting operations. This not only puts workers at risk but can also lead to costly downtime and legal liabilities.

In contrast, proper record keeping can improve integrity by providing data that informs more proactive strategies, to ultimately increase crane lifespan and reduce costs.

It is for this very purpose that the AME Online Asset Inspection System (OAIS) was created. This is an advanced plant and asset management software and online information management system that helps users locate all available inspection reports, design registration documentation, manufacturer data reports and test certificates.

Training and Certification

Training and certification are foundational to ensuring that crane operators, inspectors, and maintenance personnel are competent in their roles.

The highly technical and potentially dangerous nature of crane operations makes proper training and certification not just advisable but legally required in Australia.

Workers responsible for crane operation and maintenance must undergo specialised training courses that cover safe handling, regulatory compliance, and emergency response procedures.

AME’s crane inspection awareness training is a specialised programme designed to help crane inspectors fulfil OH&S competency standards.

As one of the limited crane inspection training programs offered in Australia, AME created the course to address industry demands.

AME Crane Inspection, Testing and Compliance Services

When it comes to crane inspection, experience and expertise are invaluable.

At AME, we understand the critical role that cranes play in your operations, and our goal is to minimise downtime while ensuring that your equipment meets all safety and operational standards.

AME is a third-party inspection services provider, NATA accredited to ISO17020 to inspect Registerable Plant encompassing mobile cranes, bridge & gantry cranes, Elevated Work Platforms (EWPs), monorails, winches and hoists. We offer Annual Crane Inspections, Major Crane Inspections (10 year and 25 year), structural and mechanical inspections, Design Working Period calculations, asset audits and deliver solutions to regulatory non-compliances to ensure your entire portfolio meets the relevant WHS Regulations and Australian Standards.

AME can assist with maintaining the integrity and reliability of your assets through provision of Non-Destructive Testing services which include Ultrasonic Weld Inspections, Eddy Current Testing, Ultrasonic and Thickness Testing, Dye Penetrant Testing and Magnetic Particle Testing.

We compile Registerable Plant Registrations and Design Registration applications for cranes, hoists and lifting equipment in accordance with the WA WHS Regulations 2022.

AME has developed training courses to help you and your team build knowledge in compliance requisites for Cranes & Hoists in accordance with the WHS Mines Regulations 2022.

Our Team comprises specialised engineers and Crane SMEs who have backgrounds as crane technicians, crane operators, and WorkSafe high risk work license assessors, all possessing a deep knowledge of Australian standards and the WHS regulations.

By partnering with AME, you gain access to a team that prioritises safety, compliance, and operational efficiency, so your cranes remain reliable, functional, and safe, year after year.