Owners and operators of elevated work platforms hear a lot of inspection terms thrown around: pre-start, routine, annual, major, rebuild. They are not interchangeable, and getting them confused can leave a machine non-compliant without anyone realising. This guide walks through each type of inspection in plain language, so you know what applies to your equipment and when.
Pre-start checks: every shift
The simplest check happens before the machine is used each day. The operator walks around the unit, looks for obvious damage or leaks, tests controls and emergency functions, and records the result. It takes minutes, needs no specialist, and catches the problems that develop between formal inspections.
Routine inspections: at each service interval
Routine inspections happen alongside regular servicing and go deeper than the daily walk-around. A technician checks wear items, hydraulic condition, safety devices and structural components in more detail, and documents anything that needs attention before the next service.
Annual inspections: the yearly compliance check
Once a year, every EWP needs a formal, documented inspection carried out by a competent person. This is more thorough than routine checks: structural, mechanical, hydraulic and safety systems are all assessed against the applicable part of the AS 2550 series, and the results are recorded so the machine's compliance history stands up to a site audit.
The annual inspection is the one most often missed by owner-operators — a machine that is serviced regularly but never formally inspected each year is still non-compliant on paper.
Major inspections: the big milestone
At a set point in the machine's life, a major inspection is required. This is a teardown-level assessment: the machine is stripped far enough for inspectors to examine welds, pins, slew components and other safety-critical parts that cannot be seen in an annual inspection, often supported by non-destructive testing.
When the milestone falls depends on the equipment class and how the machine has been used — some classes reach it at five years, others at ten. That is why you will hear both '5-year major' and '10-year major' used: they are the same kind of inspection, triggered at different points for different classes of machine. If you are not sure which applies to yours, an inspector can confirm it from the machine's class, age and history.
Major rebuilds: renewal, not just assessment
A rebuild goes a step beyond the major inspection. Instead of only assessing and documenting condition, the machine is stripped down and actually renewed: worn components are replaced or remanufactured, structural repairs completed, the unit repainted, then load-tested and recertified with full documentation.
For a structurally sound machine, a rebuild effectively resets its service life — which is why many owners choose it over replacing a quality unit.
Pre-purchase inspections: before you buy
Separate from the compliance cycle, a pre-purchase inspection protects you when buying new or used equipment. An independent inspector assesses the machine's structure, hydraulics, safety systems and paperwork before money changes hands, so hidden defects or a broken compliance history do not become your problem after the sale.
How the types fit together
Quick reference — from lightest to deepest:
- Pre-start check — operator, every shift, minutes.
- Routine inspection — technician, at each service interval.
- Annual inspection — competent person, yearly, formally documented.
- Major inspection (5 or 10 year, depending on equipment class) — teardown assessment of safety-critical components.
- Major rebuild — full strip-down, component renewal, repaint and recertification.
- Pre-purchase inspection — independent condition check before buying, at any age.
This guide is general information prepared by EWP Australia and is grounded in publicly available Australian Standards and Safe Work Australia material. It is not a substitute for the current published edition of the relevant standard or for site-specific engineering advice. Always work from the current standard and consult a competent person for your specific equipment and application.