No two major inspections are alike, and neither are their costs. Under AS 2550.10, the 10-year major inspection is the deepest check in the regime, and its scope flexes with the machine in front of the assessor. Understanding what drives the cost helps owners budget realistically and read a quote for what it is. This guide walks through the factors that move the number, without putting a figure against any of them — because the honest answer is that the machine, its history and its condition decide that.
Machine type and size
The single biggest cost driver is the machine itself. A compact scissor lift and a large truck-mounted boom are separated by orders of magnitude in structure, hydraulics and complexity, and the inspection effort scales with them.
The physical characteristics that matter include:
- Platform type — vertical and scissor machines are generally simpler to strip and reassemble than articulating or telescopic booms.
- Reach and boom sections — more boom sections mean more pins, more welds and more critical joints to disassemble and examine.
- Slew and turntable arrangements — larger rotating structures carry more critical components to measure and reinstate.
- Access difficulty — machines where structural members are buried behind covers, counterweights or bodywork take longer to open up.
The extent of strip-down
A major inspection is not a service; it is a re-verification that demands access to components that are hidden during normal operation. The depth of disassembly required is a direct labour cost.
Where a machine has been kept clean, well documented and mechanically tidy, a competent major inspection provider can open it up, examine what needs examining and reassemble it efficiently. Where fasteners are seized, greased joints are packed with grime, or previous repairs make removal awkward, the same tear-down consumes far more labour before any assessment even begins.
The extent of non-destructive testing
Critical welds and structural members cannot be signed off on appearance alone, so non-destructive testing (NDT) forms part of a thorough major inspection. The volume and type of NDT specified for a given machine affects the cost.
- The number of critical welds and members that require testing rather than visual assessment.
- The NDT method used — surface methods and volumetric methods carry different setup, consumable and interpretation effort.
- Surface preparation — coatings, paint and corrosion often need removing before a weld can be tested and recoated afterwards.
- Accessibility of the areas being tested, which can require additional disassembly purely to reach them.
What the tear-down uncovers
A quote for a major inspection is an estimate of the inspection effort — not a fixed price for the machine's future. The condition discovered once the machine is open is often what determines the final outcome. Worn pins and bushes, a slew ring at the end of its life, cylinders that no longer hold, cracked structure or life-expired safety components all translate into parts and additional labour that could not be known before disassembly.
This is why a reputable provider will separate the inspection itself from any rectification work, and why an older, harder-worked machine tends to reveal more than a lightly used one. The findings are also the substance of a sound keep-versus-replace decision.
Parts, logistics and documentation
The takeaway is that a credible estimate depends on real information about the machine. Giving your major inspection provider accurate details — make, model, year of manufacture, service history and known issues — produces a more reliable quote than a blanket figure ever could.
Beyond labour and testing, several practical factors shape the total:
- Parts availability — components for current models are usually straightforward, while parts for older or discontinued machines can carry longer lead times and greater effort to source.
- Transport — getting a large or immobile machine to and from a workshop, and any rigging required to handle it, adds to the cost.
- Recertification and documentation — the engineering assessment, NDT reports and logbook certification that make the inspection defensible take time to prepare properly.
- Whether the work is done in a workshop or on site, which changes the equipment, access and containment required.
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.