Workshop plant and lifting gear inspections: what a fab shop should track
How Australian fab shops should separate plant, lifting gear and test-and-tag due dates, what AS 2550 guidance commonly says about crane intervals, and the pre-use checks that catch most failures.
Fab shops mix three different registers into one drawer: workshop plant (bandsaw, press, overhead crane), lifting gear (slings, chains, shackles, plate clamps) and electrical test-and-tag. They have different rules and different due dates. Mixing them is how overdue gear stays on the floor.
The short answer
- The WHS Regulations require a PCBU to manage risks from plant and to maintain it so it stays safe. Inspection intervals come from the manufacturer, a competent person and relevant Standards (for cranes, the AS 2550 series is the usual reference).
- For many cranes and hoists, industry guidance on AS 2550.1 points to pre-use checks, routine inspections at intervals not longer than 3 months, and periodic third-party inspections at intervals not longer than 12 months, adjusted for duty and environment. Part-specific standards (for example AS 2550.3 for bridge and gantry cranes) can set different intervals.
- Lifting gear needs a pre-use check by the user every time, plus periodic inspection by a competent person at the interval in the manufacturer's instructions or the applicable sling/chain Standard.
- Electrical test-and-tag is a separate system (see our test-and-tag guide). Don't use the crane's annual date as the lead's due date.
What to track on one shop register
- Plant: ID, make/model, serial, location, last service, next service, who is competent to operate it, and any registration number if it is registrable plant.
- Lifting gear: ID/tag number, type (chain sling, synthetic, wire rope, shackle), WLL, last inspection, next inspection, and whether it is quarantined.
- Electrical portable equipment: asset ID, test date, next test date, outcome (pass/fail), tester.
Colour-coding overdue rows (red) beats a paper folder nobody opens.
Pre-use checks that catch most failures
- Slings: cuts, heat damage, stretched links, missing tags, bent hooks, cracked latches.
- Shackles and clamps: correct pin, worn threads, jaw damage, wrong WLL for the lift.
- Crane/hoist: limit switches, brakes, obvious rope or chain damage, unusual noise, load chart readable.
If it fails the pre-use check, quarantine it. Do not "use it for light lifts".
Questions the other guides don't answer
Is a 3-month / 12-month rule law?
The WHS laws require plant to be maintained and inspected as needed to manage risk. The 3-month routine and 12-month third-party figures commonly quoted for cranes come from guidance on AS 2550.1 Table F1. Your crane's part-standard, manufacturer and a competent person can set a different interval. Read the Standard that applies to your crane.
Do synthetic slings go on the same cycle as chain?
Often not. Follow the manufacturer and the applicable Standard for that sling type. Synthetic gear fails differently (UV, cuts, chemical attack) and may need shorter intervals in a fab shop.
Who is a "competent person" for lifting gear?
Someone who has acquired the knowledge and skills to inspect that gear through training, qualification or experience. Many shops use an external inspection company for periodic checks and keep pre-use checks with the crew.
What about registrable plant?
Some plant (certain cranes, pressure equipment, lifts) must be design-registered and/or item-registered with the state regulator. Check your state's registrable plant list. Registration does not replace day-to-day inspection.
Quick answers
How often should workshop cranes be inspected in Australia?
Follow the manufacturer and the applicable AS 2550 part. Guidance on AS 2550.1 commonly references pre-use checks, routine inspections at intervals not longer than 3 months, and periodic third-party inspections at intervals not longer than 12 months, adjusted for duty and environment.
Do slings need inspecting every time before use?
Yes. Pre-use checks by the user catch most damage. Periodic inspections by a competent person are additional, at the interval set by the manufacturer or applicable Standard.
Should plant, lifting gear and test-and-tag share one due date?
No. They are different systems with different intervals. One register with separate due-date columns is fine; one shared date is how overdue gear gets missed.
Does plant registration replace inspections?
No. Design or item registration with the regulator is separate from the PCBU's duty to maintain and inspect plant so it stays safe to use.
Sources
- Safe Work Australia – Plant
- Safe Work Australia – Managing risks of plant in the workplace
- Konecranes AU – Inspections for overhead cranes and hoists (AS 2550.1 interval summary)
- Standards Australia store – AS 2550.1 Cranes, hoists and winches – Safe use – General requirements
Related guides
- Plant pre-start checklist template
- Electrical test and tag in Australia
- Toolbox talk topics
- Site induction checklist
- Fabrication ITP guide
General information only, summarised from the official sources above as at the review date. It isn't legal, WHS or engineering advice. Rules change and your situation may differ, so check the source or ask a professional.