25-Year Major Inspections for Overhead Cranes (Bridge & Gantry)

Older cranes demand more than a routine service. At 25 years, Standards require a major inspection and assessment for continued safe use — a deep dive into structure, runway rails, hoist/drive systems, and compliance. We deliver end-to-end 25-year inspections across Western Australia (Perth, Kwinana/AMC, Pilbara, Goldfields) and Australia-wide for mining and LNG sites.

What’s included (Scope)

1) Structure & Supporting Structure

• Visual + NDT of welds at fatigue-prone areas, corrosion mapping, thickness checks

• End carriages, connections, buffers, fasteners; supporting columns and frames

• Clearances, access, isolation hardware and guarding per the crane class/arrangement. (AS 2550.3 - 2002, AS 1418.3 - 1997)

2) Runway, Rails & Guidance

• Rail condition (burrs, flatting/mushrooming, spalling), joints & fixings, alignment

• Check deflection/track behaviour of runway supports for wheel tracking and flange binding risk. (AS 1418.18 - 2001)

• Confirmation that rails meet design intent and provide safe wheel guidance (wheel–rail interface checks).

3) Hoist, Trolley & Drives

• Gearboxes, couplings, brakes, wheels (tread/flange), matched-wheel tolerances

• Functional limits, emergency systems, isolation and interlocks.

4) Engineering Assessment & Records

• Duty history, abnormal events, tolerance checks, thickness/NDT reports

• Competent-person engineering report with repair recommendations and test plans. (AS 2550.3 - 2002, AS 2550.1 - 2011 Part 1)

Why a 25-Year Inspection?

• Required to verify continued safe use after long-term fatigue, corrosion and wear. (AS 2550.3 - 2002 Part 3)

• Confirms the crane can operate safely going forward or identifies rectification and upgrades before return to service. (AS 2550.1 - 2011 Part 1)

• Reduces downtime risk on critical production of assets and manufacturing (refineries, LNG trains, concentrators, ports etc).

Undertake your next 25-year inspection with Safe Lifting Australia.

• ISO 9001 certified systems

• DNV/API-qualified inspectors

• WA mining & LNG specialists
  📞 1300 141 109 • ✉️ service@safelifting.com.au

How we deliver (3 Steps)

1. Inspection & NDT — structure, runway, hoist/drives, electrical; disassembly/clean-down where required for thorough access. (AS 2550.3 - 2002 Part 3)

2. Engineering Assessment (AS 2550.1/.3 + AS 1418.1/.18) — suitability for continued safe use, upgrades to current practicable requirements, and inpsection|test plan.

3. Rectification & Re-verification — risk-ranked repairs, re-inspection and documentation prior to return to service. (AS 2550.1 - 2011 Part 1)

The Regularly Overlooked Item: Runway Rail Wear (the silent failure)

Runway rail geometry directly affects wheel guidance, derailment risk and bearing stress. Rails must be free from burrs/deformation that impair operation, and designed/maintained for the intended life.

Sectors & sites we serve

Western Australia (primary focus): Perth metro, Kwinana/AMC Henderson, Pilbara (Karratha, Port Hedland, Newman), Goldfields (Kalgoorlie).
Australia-wide heavy industry: Mining, LNG (onshore/offshore), ports, shipyards, steel/fabrication, defence.

Deliverables you receive

• Detailed inspection & NDT reports (photos, measurements, thickness/NDT maps)

• Engineering assessment & suitability for continued safe use statement

• Risk-ranked rectification schedule, parts list, and upgrade options

• Test plan and re-verification records for close-out

FAQs

Is the 25-year inspection mandatory?
It’s the pathway specified in AS 2550 to establish continued safe use when cranes reach that age or duty — combining major inspection + engineering assessment. (AS 2550.3 - 2002 Part 3)

How long does it take?
Depends on access, crane size/condition, and required disassembly. We stage works to minimise production impact. Expect 1 to 3 days for most cranes.

Do you work shutdowns?
Yes — shutdown-aligned scopes and night shifts for tier-one mining/LNG sites.