Workshop and processing plant overhead cranes are often the oldest lifting equipment on site. Many are past the design working period assumed in AS 1418.3, running on runways that have never been surveyed, with hoists that have been swapped without engineering review. AS 2550.3 expects a documented assessment before a crane continues beyond its design working period.
We inspect bridge, gantry, semi-gantry and monorail cranes and their runways to AS 2550.1 and AS 2550.3, including annual inspections, design working period assessments and post-relocation inspections.
Inspection checklist areas
- Bridge girders and end carriages
- Visual and MT inspection of girder-to-end-carriage connections, diaphragm and stiffener welds, camber check, end carriage wheel and bearing condition, buffers.
- Runway, rails and supports
- Rail wear, alignment and gauge survey, rail clip and splice condition, runway beam and bracket welds, column connections, end stops, with reference to AS 1418.18.
- Hoist and trolley
- Hoist gearbox, brake adjustment and lining, rope or chain condition to AS 2759 or manufacturer criteria, drum grooves and anchorage, hook and block, trolley wheels and guide rollers.
- Electrical and controls
- Downshop conductors or festoon, pendant or remote control function and emergency stop, limit switches (hoist upper and lower, long and cross travel), overload protection, isolation.
- Safety devices and identification
- Rated capacity markings, warning devices, anti-collision where multiple cranes share a runway, access platforms and walkways to AS 1657.
- Design working period
- Assessment of duty group, cycles and hours against the design working period, and documented recommendation on major inspection or continued service.
Known failure modes
Girder and end carriage connection cracking
Fatigue at the bolted or welded girder-to-end-carriage joint under repeated hoist and travel loads.
Hoist brake failure
Worn or maladjusted brakes allowing load drift or drop.
Runway derailment or rail failure
Rail misalignment, gauge spread, worn wheel flanges or failed clips causing wheel climb or derailment.
Rope or chain failure
Hoist rope or load chain worn beyond discard criteria, or incorrectly reeved after replacement.
Uncontrolled travel
Limit switch or brake failure allowing the crane to strike end stops or adjacent cranes.
Applicable standards and regulations
| Reference | Title | Relevance |
|---|---|---|
| AS 2550.1 | Cranes, hoists and winches — Safe use — General requirements | Inspection regime and records for all cranes. |
| AS 2550.3 | Cranes, hoists and winches — Safe use — Bridge, gantry and portal cranes | Type-specific inspection and design working period assessment requirements. |
| AS 1418.1 and AS 1418.3 | Cranes — General requirements; Bridge, gantry and portal cranes | Design basis including duty classification and design working period. |
| AS 1418.18 | Cranes — Crane runways and monorails | Design and tolerance basis for runway and rail inspection. |
| AS 2759 | Steel wire rope — Use, operation and maintenance | Discard criteria for hoist ropes. |
| AS 1657 | Fixed platforms, walkways, stairways and ladders | Crane access platforms and walkways. |
Inspection intervals
- Annual inspection
- At intervals not exceeding 12 months by a competent person (AS 2550.1).
- Design working period assessment
- Before continuing in service beyond the design working period established under AS 1418.3 for the crane's classification, a major inspection or documented assessment is required under AS 2550.3.
When to inspect
- Annual inspection due
- Crane approaching or past its design working period
- After hoist replacement, relocation, re-rating or runway modification
- Following an overload, load drop or collision with end stops
- Before commissioning a second crane on a shared runway
Frequently asked questions
How do I know if my overhead crane is past its design working period?
The design working period depends on the crane's classification under AS 1418.3 (duty group and load spectrum) and the accumulated cycles and hours. We assess the classification, usage records and condition, and document whether a major inspection is due and what it must cover.
Is the runway included in the inspection?
Yes. Rail wear, alignment and gauge, clips, splices, runway beams and their connections are inspected with reference to AS 1418.18, because runway defects cause derailments and accelerate wheel and end carriage damage.
What about monorails and jib cranes in workshops?
Monorail hoists and workshop jib cranes are inspected under the same AS 2550 framework, with attention to the monorail beam, end stops, trolley and the jib pivot and wall or column connection.