EWP & Crane Certification for the Mining Industry

Why mining accelerates equipment fatigue

A boom lift working on a mine site accumulates structural fatigue at a rate that visual inspection alone cannot fully characterise. High-cycle articulation, sustained loading, ground vibration transmitted through the chassis and thermal cycling in extreme ambient temperatures all contribute to crack initiation at welds and highly stressed connections. The consequences of an undetected crack in a boom pivot or turret weld are catastrophic given the heights involved.

For this reason mining clients typically require non-destructive testing beyond the visual inspections adequate for lighter-duty environments. Magnetic particle inspection on ferromagnetic weldments, ultrasonic testing on critical thickness and pins, and dye penetrant testing on non-ferrous or machined surfaces reveal defects long before they become visible.

• Continuous duty cycles far exceeding general-industry usage
• Abrasive dust ingress into pins, bushes and hydraulic systems
• Corrosion from mine water and process chemicals
• Thermal and vibration fatigue at critical welds

Standards and site verification requirements

Elevated work platforms are inspected against AS 1418.10 and used under AS 2550.10, while mobile and crawler cranes follow the relevant AS 2550 parts and AS 1418 design references. On top of these statutory standards, most mine sites operate a fitness-for-service or verification-of-competence regime that requires documented engineering sign-off before a unit is permitted on site.

Our inspection reports are written to satisfy both layers. They demonstrate compliance with the applicable Australian Standard and provide the engineering detail — measured wear, NDT findings, structural assessment conclusions — that principal contractors require in their equipment verification packs.

Non-destructive testing programs for mining plant

For high-hour and high-consequence assets we recommend a structured NDT program rather than one-off testing. This means baselining critical welds and connections, then re-testing at defined intervals so fatigue crack growth can be tracked over time. Techniques are selected to suit the material and the defect type of concern: magnetic particle for surface and near-surface cracks in steel, ultrasonic for volumetric and thickness assessment, eddy current for surface cracks including under coatings, and dye penetrant for surface-breaking defects on non-magnetic materials.

Where testing reveals indications, we carry out a structural assessment to determine whether the defect is acceptable, requires monitoring, or mandates immediate withdrawal and repair. Repairs are followed by visual weld inspection and re-testing before the unit returns to service.

Cranes and lifting equipment underground and on surface

Mining relies heavily on mobile cranes, Franna-type pick-and-carry cranes and vehicle loading cranes for maintenance, construction and materials handling. These units carry their own inspection regime under the AS 2550 series, including proof load testing where structural repairs or modifications have been carried out. Underground applications add confined-environment and diesel-particulate considerations that influence how and when inspections are scheduled.

Load testing and proof load testing verify that a crane performs safely at its rated capacity after major inspection, repair or modification. We conduct these tests with calibrated equipment and document the results as part of the certification package.

Shutdown and turnaround coordination

Mine sites concentrate maintenance into planned shutdowns, and access and lifting plant must be certified and available for the intense work windows these represent. We coordinate inspection and NDT schedules against shutdown calendars so that every unit required for the turnaround is verified and current before work begins, and we mobilise for emergency inspections when unplanned events ground a critical asset mid-campaign.

Incident and failure investigation

When a component fails or an incident occurs, mining operations need a root-cause answer that satisfies internal investigation and, where required, the regulator. Our engineers conduct incident and failure investigations combining metallurgical evidence, NDT, load history and design review to establish the failure mechanism and recommend corrective action across the wider fleet where a systemic cause is identified.