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Typical vs IDC Inspection Methodology

Typical Inspection Methodology

Cranes are designed for a finite lifetime duty, which is given in load cycles and loading intensity and is not principally related to calendar working time.

What does a typical inspection look like?

  • Most companies who provide major inspection activities provide a single stage process based on the calendar life, without any consideration of the actual crane duty.
  • To ensure this approach complies with the OHS Regulations and WorkSafe guidance a detailed and thorough assessment is required.
  • Typically the crane is fully disassembled and critical components subject to fatigue are replaced.
  • CICA estimates that the average major inspection in accordance with the Australian Standards costs $80,000.
Accidents & Prosecutions Do Occur In Australia …
Accidents & prosecutions do occur in Australia …

In 2012 a worker was killed in Rockhampton following the structural failure of an overhead crane. From 1999 to 2004 there were 27 crane related prosecutions against both employers and individuals, including managers.

Our Inspection Methodology

We adopt a staged methodology which ensures the crane owner and manager’s duty of care is met while minimising cost and allowing significant expenditure to be amortised over the life of the crane. We achieve this by focusing on the actual crane duty.

Undertake a desktop review of crane’s inspection and service history.

At this point three possibilities exist for most cranes:

  • Complete a deferred major inspection review.
  • Complete a deferred major inspection with overhaul activities scheduled over the future life of the crane based on individual component design life.
  • Complete a typical overhaul based major inspection with the scope tailored to suit the cranes individual component design life.

Detailed review of crane history and design life.

  • Assess crane structural and mechanical condition (in conjunction with CraneSafe ‘Green Sticker’ inspection & NDT of crane) to validate crane life assessment.
  • Test functional performance.
  • Prepare report & certification (generally  for a 5 year design life extension).

If the crane’s design life has been reached a more detailed inspection, design review and replacement of components is required. Disassembly and inspection or replacement of critical components may be required.

For example:

  • Crane boom removal.
  • Extension / retraction rope replacement.

Often it may be more cost effective to incorporate major inspection activities into the future. Maximising the design life of individual components and systems.

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