Overhead Crane Inspections | Safe Lifting Australia

Ensure your overhead crane meets AS2550.1 standards with expert inspections by Safe Lifting Australia. Learn what’s involved, common faults, and how to stay compliant.

Matt Weight

6/13/20242 min read

Introduction

Overhead cranes are critical assets in workshops, factories, ports, and industrial sites across Australia. But like all lifting equipment, they require regular inspection and maintenance to stay compliant, safe, and reliable.

In this guide, we break down everything you need to know about overhead crane inspections, including frequency, Australian Standards (AS2550.1 and AS2550.3), what inspectors look for, and how to ensure you stay compliant — and avoid downtime or legal issues.

Why Overhead Crane Inspections Matter

A failure in an overhead crane system can result in serious injuries, structural damage, costly repairs, or project delays. Regular inspections:

Reduce the risk of failure and injury
Meet legal obligations under WHS legislation and AS2550.1
Improve the life and performance of your crane
Help plan maintenance and avoid unexpected downtime

Australian Standards and Legal Obligations

The key standards that govern crane inspections in Australia are:

AS 2550.1 – General requirements for safe use of cranes
AS 2550.3 – Specific to bridge and gantry cranes (overhead cranes)
AS 1418 – Covers crane design and manufacture

Under these standards, employers and crane owners must ensure:

Routine (daily/pre-start) inspections
Periodic inspections (3-monthly, 6-monthly, annually)
Major inspections (at 10 or 25 years, depending on duty)

What’s Included in an Overhead Crane Inspection?

Our experienced inspectors conduct a thorough review including:

🔧 Mechanical Checks

Hoist, trolley, and bridge operation
Load chain/wire rope condition and wear
Hook integrity, throat opening, and latch function
Gearbox oil leaks or abnormal noise

⚡ Electrical Checks

Control pendant or remote function
Emergency stops and limit switches
Earth continuity and insulation resistance
Overload protection devices

🔍 Structural Assessment

Inspection of bridge beams and end carriages
Checking for cracks, corrosion, or deformation
Fastener security and condition
Trolley rail alignment

📊 Documentation & Compliance

Logbook review and service history audit
Assessment of duty of use vs manufacturer rating
Identification of non-compliance or wear trends

Common Issues Found in Inspections

Our team regularly identifies these faults:

Missing or inoperative upper/lower hoist limit switches
Worn ropes, sheaves, or chains
Brakes not holding under load
Corroded or cracked structure
Non-functioning emergency stops
No proof of commissioning load test or major inspection

These issues may result in a crane being taken out of service or a stop-work order issued by regulators like SafeWork.

How Often Should Overhead Cranes Be Inspected?

Inspection intervals depend on use, environment, and duty rating. As a guide:

Daily/Pre-Start: Visual checks by operators
Quarterly (3-monthly): Periodic service/inspection
10-Year or Major Inspection: Overhaul in accordance with AS2550.1 or assessment with remnant life calculated.

What Happens If You’re Non-Compliant?

Failing to meet inspection requirements can lead to:

Prosecution under WHS legislation
Voided insurance coverage
Increased liability for injuries
Unplanned downtime or equipment failure

Why Choose Safe Lifting Australia?

At Safe Lifting Australia, we offer:

Certified overhead crane inspections across WA, Tasmania, and Australia-wide
Compliance with AS2550.1, AS2550.3, and manufacturer guidelines
Load testing, NDT, electrical testing, and major assessments
Full reporting and remediation guidance

Our team has real-world crane experience — not just a checklist. We work on overhead, jib, gantry, and monorail systems across mining, ports, manufacturing, and marine industries.