In the lifting industry, even the smallest oversight can have catastrophic results. Routine pre-use checks and scheduled thorough examinations are more than paperwork – they are lifesavers.
For example, on a Melbourne construction site in 2018, a crane’s concrete bucket dropped when a missing split-pin allowed the hoist assembly to fail, killing one worker and crippling another. WorkSafe Victoria noted that careful inspections “never occurred,” and that a reasonably practicable check of that pin could have prevented the tragedy. This article explains how simple checks and competent inspections, backed by proper training, safeguard Australian and New Zealand lifting operations against similar failures.
Daily Pre-use Checks and Scheduled Examinations
Lifting equipment inspection typically involves three levels: pre-use, interim, and thorough examinations. The first level is the pre-use check, performed by the operator before each lift. This is a quick visual inspection for obvious defects – damaged hooks, deformed links, missing markings, abnormal noises or changes in performance. Any problems found must be reported immediately to maintenance teams. These routine checks form the first line of defence: in a Western Australia mine incident (2014), a cracked sheave was missed during a pre-start check and later catastrophically failed, narrowly missing a worker.
Between pre-use checks and thorough examinations, interim inspections (also called frequent inspections) are conducted. Their frequency and scope are based on a risk assessment and may coincide with routine maintenance or follow repairs. Interim inspections zoom in on high-stress or wear-prone parts (for example, hooks, pins, brakes, ropes) that could fail before the next major exam. Finally, a thorough examination (or periodic inspection) is an in-depth check carried out by a qualified, independent inspector. This thorough exam often includes measurements, testing or non-destructive evaluation, ensuring the equipment is safe for continued use. Standards such as AS2550.4 (tower cranes) and AS2550.1 (general) specify that thorough exams be done at defined intervals depending on equipment and conditions.
Competent Inspectors and Training
By law, a thorough examination must be done by a competent person – someone with the training, experience and ability to spot defects and understand relevant standards. For example, AS2550.1 2020 requires a competent person to inspect lifting equipment, and inspection reports must be kept. A competent inspector can be an accredited third-party examiner, or a LEEA-certified Lifting Inspector. LEEA’s guidance emphasises that if a defect is found during a thorough exam, it often points to a flaw in the inspection or maintenance regime,, underscoring the need for inspectors who know what to look for.
LEEA supports competency through training and membership. All LEEA members and accredited companies undergo regular technical audits and training updates to ensure inspectors and users stay sharp. The association offers courses focused on rigging safety, inspection techniques and thorough examination of lifting gear. Users are encouraged to look for the LEEA logo on inspectors or service providers – a badge of competence and industry-best practice. Together, these measures mean inspections are not just a formality but an effective safety check on lifting equipment.
Duty Holder Responsibilities (AUS/NZ Law)
Under both Australia’s Work Health & Safety Act and New Zealand’s Health and Safety at Work Act, the person conducting a business or undertaking (PCBU) has primary responsibility for plant safety. This includes cranes, hoists, slings and all lifting accessories. The duty holder must ensure, so far as is reasonably practicable, that the equipment is safe and subject to proper testing and inspection. They must provide information, training and instruction to staff, maintain the equipment, and ensure inspection reports are recorded. Importantly, WHS law dictates that these duties cannot be transferred – a PCBU remains responsible even if inspections are subcontracted to others.
In New Zealand, crane controllers are explicitly required to ensure cranes have current inspection certificates issued by recognised inspection bodies. In Australia, regulations often prescribe periodic major inspections for registered cranes. For example, WorkSafe guidance notes that major crane examinations must include detailed visual inspections of all structural and wear components (brakes, ropes, sheaves, etc.) for corrosion and wear. Duty holders must also keep records of all tests, inspections and maintenance, and act promptly to remedy any defects identified.
Real-World Incidents: When Checks Fail
• Victoria 2018: A tower crane’s concrete bucket fell to the ground after a missing split-pin in the hoist assembly worked loose. One worker was killed and another critically injured. The operator was fined $400,000; WorkSafe investigators noted that a thorough inspection when the crane was installed would have caught the missing pin.
• Queensland 2025: A tower crane’s hoist rope and hook assembly collapsed and dropped 10 metres. Investigations found significant corrosion on a swivel bolt due to harsh coastal conditions – corrosion that should have been detected during inspections. The crane had passed its annual check just two months earlier, highlighting the importance of competent, detailed examinations and perhaps more frequent checks in adverse environments.
• Western Australia 2014: At a mine site, a mobile crane sheave (rooster sheave) suddenly failed while slewing under load. A post-incident review found that the sheave had pre-existing damage that daily pre-use checks had failed to identify. The two-kilogram nylon fragment narrowly missed a rigger below. This case shows how even routine operator checks must be thorough.
• New Zealand 2022: A Rotorua precast yard used a homemade mobile crane (converted from an old log skidder) with no formal inspection certificate or safety devices. A 17-year-old worker was struck by a swinging 412kg beam and badly injured. WorkSafe NZ observed “the crane should not have been operational” and warned businesses to “regularly check all
their equipment” – especially older
or modified gear.
Each of these incidents stemmed from missed or improper inspections. In every case, diligent checks by trained personnel could have identified the fault before it became catastrophic. In the words of one NZ regulator, “businesses must manage their risks. This includes regularly checking all their equipment to check it’s fit for purpose and compliant”.
LEEA Guidance, Membership and Support
LEEA’s Code of Practice (COPSULE) is a free resource that lays out best practice for lifting inspections worldwide. Section 1 of the latest COPSULE covers inspection intervals, roles (users, maintenance staff, examiners) and responsibilities. By consulting COPSULE (alongside local standards), Australian and New Zealand businesses can align with global best practices.
LEEA membership further helps users meet their obligations: members gain access to expert advice, regular technical updates and tailored training on lifting safety. Whether through LEEA’s accredited courses or its library of guidance documents, lifting operators can ensure they understand and fulfill the inspection and maintenance duties required by law.
‘Small checks’ at the start of each lift and scheduled thorough examinations have big safety payoffs. Operators, supervisors and duty holders in Australia and New Zealand must implement robust inspection regimes. Working with competent inspectors (for example, those trained via LEEA) and following regulators’ codes ensures compliance with WorkSafe/Victoria, SafeWork NSW and WorkSafe NZ expectations. As one regulator put it, ensuring lifting equipment is safe is a fundamental duty of care. By treating routine inspections as integral to all lifting operations, companies turn liability into assurance – preventing the next preventable accident.