Crane Major Inspection
The overhaul-level structural inspection and recertification that returns an ageing crane to a known, documented condition.
The crane major inspection is the searching, overhaul-level examination that ageing lifting appliances require under the AS 2550 series. Like the EWP major inspection, it goes beyond periodic checks to strip, examine and non-destructively test the crane's safety-critical structure and mechanisms, establishing whether the machine is fit to continue in service. It is the point at which decades of accumulated fatigue and wear are confronted with engineering rigour rather than assumption.
What the crane major inspection covers
A major inspection reaches parts of the crane inaccessible during routine inspection. Booms, jibs, structural connections and the slew ring are exposed and examined, ropes and reeving are fully assessed, mechanisms are opened where required, and safety-critical welds are subjected to NDT. Component life limits set by the manufacturer are identified and actioned.
The trigger for a major inspection is typically the crane reaching a defined age or duty milestone, and the machine's logbook history is central to determining what is due and what has already been done.
- Structural examination of booms, jibs, connections and slew ring
- Full assessment of ropes, reeving, hooks and mechanisms
- NDT of safety-critical welds and highly-stressed members
- Identification and action of component life limits
- Review of logbook and full service history
Why the major inspection is necessary
Cranes accumulate fatigue over many years of lifting, and periodic inspection alone cannot reveal sub-surface cracking or the true condition of concealed structure and mechanisms. The major inspection exists to convert that hidden condition into documented fact, so an ageing crane can legitimately continue rather than being retired on suspicion or, worse, run on assumption.
For owners, the major inspection is what preserves the value and usability of a high-capital asset. For everyone on site, it is what underwrites confidence that the crane will not fail under load.
NDT and mechanism assessment
Safety-critical welds and members are examined by magnetic particle and ultrasonic methods, chosen and interpreted by the responsible engineer. Ropes are assessed against discard criteria, hooks measured for wear and deformation, and the slew ring and drive mechanisms evaluated for wear and integrity.
Because interpretation drives the recertification decision, NDT is planned as an integral part of the inspection rather than a bolt-on.
Load testing and recertification
Where the inspection or a repair requires it, load or proof-load testing demonstrates the crane performs to capacity after the major inspection. On satisfactory completion, we issue an engineer-signed recertification and update the crane's records so the next major inspection date is unambiguous.
Where defects are found, the report states precisely what must be rectified, and we re-attend to verify repairs before recertifying.
Documentation
The deliverable is a comprehensive, engineer-signed report and recertification designed to satisfy regulators, insurers and principal contractors, and to stand as the definitive record of the crane's condition at the milestone.
Frequently Asked Questions
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