EWP Major Rebuilds
A major rebuild brings an ageing or damaged elevated work platform back to a certified, working condition rather than writing it off. It goes far beyond routine repair — the machine is assessed, stripped down where needed, and its structural, hydraulic and electrical systems restored so it can be recertified and returned to service with confidence.
We coordinate rebuilds end to end: engineering assessment, structural and weld repairs, hydraulic and electrical overhaul, NDT and load testing, and the recertification that lets the unit go back to work compliant. It is the sensible alternative to replacement when a machine is fundamentally sound but has reached the point where a deeper intervention is due.
Built For
- Fleet owners deciding between rebuild and replacement
- Operators with machines failed or flagged at major inspection
- Hire companies keeping high-value units in service longer
- Government, council and utility fleets with capital constraints
- Owners of damaged plant needing structural restoration
Equipment & Coverage
- Telescopic and knuckle boom lifts
- Scissor lifts and spider lifts
- Truck-mounted EWPs, cherry pickers and bucket trucks
- Insulated EWPs and their dielectric components
- Structural, hydraulic and electrical systems throughout
The Process
Engineering assessment
We assess the machine to establish whether a rebuild is viable and what it needs — structure, hydraulics, electrics and safety systems — with an honest view on rebuild versus replacement.
Strip-down & structural repair
Safety-critical components are dismantled and examined for wear, fatigue and corrosion, and structural and weld repairs are carried out where the assessment calls for them.
Hydraulic & electrical rebuild
Cylinders, valves, hoses, control systems and wiring are overhauled or replaced so the machine's power and control systems perform as designed.
NDT, load test & recertify
Weld inspections and NDT verify structural integrity, load and stability testing confirms performance, and the unit is reassembled, recertified and documented.
Compliance & Standards
A major rebuild is carried out to return a machine to the safe-use and structural standards of AS 2550.10 for equipment designed to AS/NZS 1418.10. Weld inspections and NDT verify the integrity of repaired structure, load and stability testing confirms the machine performs to its rating, and recertification with an engineering report evidences that the rebuilt unit is safe to operate. Nothing is signed off that has not been assessed and tested — the recertification reflects the actual condition of the rebuilt machine.
Why EWP Australia
- Ageing or damaged plant returned to a certified condition instead of retired
- Engineering assessment gives an honest rebuild-versus-replace picture
- Structural, hydraulic and electrical rebuild coordinated end to end
- Weld inspections, NDT and load testing to verify integrity and performance
- Recertification and documentation so the unit goes straight back to work compliant
Common Questions
When is a major rebuild required?
A rebuild is worth considering when a machine has significant structural wear, corrosion or fatigue, has been damaged, or has failed or been flagged at a major inspection. It suits fundamentally sound units where restoring the machine is more sensible than replacing it — the engineering assessment tells you which situation you are in.
How do you decide between a rebuild and replacement?
We start with an engineering assessment of the structure and major systems, then weigh the scope of work against the machine's value and remaining life. The assessment gives you an honest basis for the decision rather than committing you to a rebuild before the extent of the work is known.
What does a rebuild cover?
Depending on the assessment it can include structural and weld repairs, hydraulic overhaul of cylinders, valves and hoses, electrical and control system rebuild, and replacement of worn safety-critical components. NDT and load testing then verify the result before recertification.
Is the machine recertified after a rebuild?
Yes. Weld inspections and NDT verify the repaired structure, load and stability testing confirms performance to the machine's rating, and the unit is recertified with documentation and an engineering report so it can return to service compliant.
Do you rebuild insulated EWPs?
Yes. Insulated units can be rebuilt, and their dielectric components are assessed and tested as part of the work so the insulation that protects crews near live apparatus is verified before the machine returns to live-line duties.
Can I see examples of previous rebuilds?
Project examples relevant to your equipment type are available on request — get in touch with the make, model and scope you are considering and we will talk you through comparable work.
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