Comprehensive procedures for safe mobile crane operations covering lift planning, ground preparation, powerline safety, and load control

Mobile Crane Safe Work Method Statement

WHS Act 2011 Compliant | AS 2550 Safe Use Standards Aligned
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Mobile crane operations form the backbone of material handling and positioning work across Australian construction sites, from residential developments to major infrastructure projects. This Safe Work Method Statement provides comprehensive procedures for operating hydraulic mobile cranes, covering critical safety aspects including detailed lift planning, ground assessment and preparation, powerline hazard management, outrigger deployment, load control, and emergency procedures that protect workers and ensure regulatory compliance.

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Overview

What this SWMS covers

Mobile cranes represent the most versatile and widely used lifting equipment in Australian construction, providing the capability to lift and position heavy loads ranging from a few tonnes to several hundred tonnes across diverse project types. These hydraulic cranes feature telescopic booms that extend from compact transport configurations to working lengths exceeding 60 metres, carrier-mounted on wheeled chassis enabling rapid relocation between sites and positioning at multiple locations within large projects, outrigger stabilization systems that provide stable working platforms independent of chassis suspension, sophisticated load moment indicator systems monitoring crane capacity throughout operational envelope, and operator cabins providing protected working environments with comprehensive control and monitoring systems. The operational scope of mobile cranes encompasses virtually all construction sectors. In residential construction, mobile cranes position roof trusses, lift precast concrete elements, handle steel beams, and place HVAC equipment. Commercial construction projects utilize mobile cranes for structural steel erection, curtain wall panel installation, mechanical equipment lifts, and material handling throughout construction phases. Infrastructure projects depend on mobile cranes for bridge beam installation, precast segmental construction, utility equipment positioning, and specialized heavy lifts. Industrial projects require mobile cranes for process equipment installation, tank and vessel positioning, pipe rack assembly, and maintenance shutdowns where equipment replacement occurs. The mobility of these cranes allows contractors to efficiently serve multiple projects, rapidly deploying equipment where lifting requirements arise. Mobile crane operations involve significantly more complexity than simply 'picking and placing' loads. Every lift requires comprehensive planning addressing load characteristics including weight verification through manufacturer data or physical weighing, dimensional analysis affecting lift radius and clearances, center of gravity determination influencing rigging design, and attachment point identification for secure load connections. Ground conditions at crane setup locations must be thoroughly assessed for bearing capacity, levelness, stability, and proximity to underground services or structures that might be affected by ground loading. Environmental factors including wind speed, temperature extremes affecting hydraulic systems, precipitation affecting visibility and ground conditions, and lighting for night operations must be evaluated and controlled. Proximity hazards such as overhead powerlines, adjacent structures, public access areas, and other site operations require careful identification and implementation of specific control measures. The operation of mobile cranes creates interaction between multiple parties with distinct responsibilities but interdependent actions. The crane operator holds overall responsibility for safe crane operation within rated capacity and manufacturer specifications, maintaining control of all crane movements and monitoring load moment systems. Dogmen or riggers direct crane operations through hand signals or radio communication, attach loads using appropriate rigging techniques, and ensure loads are properly secured before lifting. Spotters provide visual guidance to operators for load positioning, observe clearances to obstacles or hazards, and maintain awareness of ground personnel locations. Site supervisors coordinate overall lifting operations, verify lift planning documentation, ensure appropriate personnel are assigned, and maintain authority to stop operations if safety concerns arise. Principal contractors maintain overarching safety responsibility ensuring appropriate SWMS documentation exists, verifying contractor licensing and insurance, and coordinating crane operations with other site activities. The regulatory framework governing mobile crane operations is comprehensive and stringently enforced. Under the Work Health and Safety Act 2011 and supporting regulations, mobile crane operations are classified as high-risk construction work triggering mandatory requirements including preparation and implementation of detailed SWMS before work commences, verification that operators hold appropriate high-risk work licences, confirmation of crane registration and current inspection certification, notification to work health and safety regulators for certain types of lifting work, and implementation of specific safety controls addressing identified hazards. Australian Standard AS 2550.5 (Cranes, hoists and winches—Safe use: Mobile and tower cranes) provides technical requirements for safe mobile crane operations including lift planning procedures, load calculation methods, stability verification requirements, operational limits based on environmental conditions, and maintenance and inspection regimes. These regulatory and technical requirements create a framework where systematic planning, qualified personnel, appropriate equipment, and rigorous procedures combine to minimize the substantial risks inherent in lifting operations.

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Why this SWMS matters

Mobile crane operations consistently feature in serious incident and fatality statistics across Australian construction, with crane-related deaths occurring regularly despite decades of safety focus and regulatory attention. The potential for catastrophic incidents involving crane collapses, load drops, powerline contacts, and workers being struck by loads or equipment creates an imperative for comprehensive safety documentation and control implementation. Safe Work Method Statements for mobile crane operations are not administrative formalities but critical safety tools that prevent predictable and preventable deaths and serious injuries. The consequences of inadequate mobile crane safety extend far beyond the immediate incident victims. Crane collapses have killed multiple workers simultaneously, with catastrophic failures involving boom collapses or tip-overs crushing ground personnel, operators, and workers in adjacent areas. Load drops from rigging failures or operator errors have resulted in workers being struck by falling materials weighing tonnes, with unsurvivable impacts. Powerline contacts have electrocuted crane operators and ground personnel, with electrical arcing causing fatal injuries even when direct contact does not occur. The scale of these incidents creates ripple effects throughout the construction industry, affecting worker families, traumatizing incident witnesses, devastating contracting businesses through prosecution and civil liability, and imposing substantial regulatory attention on construction sectors where serious crane incidents occur. From a legal and regulatory perspective, mobile crane operations trigger some of the most stringent requirements under Australian work health and safety legislation. The Work Health and Safety Act 2011 Section 27 requires persons conducting a business or undertaking to ensure, so far as is reasonably practicable, that workers and other persons are not exposed to health and safety risks arising from high-risk construction work. For mobile crane operations, this duty includes ensuring competent licensed operators perform all crane operations, that comprehensive lift planning occurs before work commences, that ground conditions and environmental factors are assessed and controlled, that proximity hazards including powerlines are identified and appropriate clearances maintained, and that appropriate rigging equipment and techniques are used for all lifts. Failure to meet these obligations attracts significant penalties, with maximum fines exceeding $3.6 million for corporations and $600,000 for individuals, alongside potential criminal prosecution for serious breaches. Australian Standard AS 2550.5 provides the technical framework that courts and regulators reference when assessing whether mobile crane operations met appropriate safety standards. The standard specifies requirements for lift planning including documentation of load weights, crane capacities, ground conditions, and hazard controls. It defines operational limits based on wind speed, with operations typically prohibited when wind exceeds 12.5 metres per second (approximately 45 km/h) due to load instability and crane overloading risks. It establishes inspection and maintenance requirements including daily pre-operational checks, periodic inspections at specified intervals, and major inspections with load testing at maximum two-year intervals. Compliance with AS 2550.5 is generally considered demonstrating reasonable practicability under WHS legislation, while departures from standard requirements without documented risk assessment and alternative controls may be considered negligent. The economic consequences of mobile crane incidents extend well beyond regulatory penalties. Crane damage from collapses, tip-overs, or contact incidents can total millions of dollars for large capacity equipment, with repair times extending weeks or months affecting project schedules. Property damage to buildings, structures, or adjacent property from crane collapses or load drops creates substantial civil liability exposure. Project delays from stop-work orders following incidents, investigation periods, and regulatory approval to resume operations can extend weeks affecting project critical paths. Insurance premiums increase substantially following crane incidents, particularly if investigations reveal inadequate safety systems or SWMS documentation. Client relationships suffer irreparable damage when crane incidents affect their projects, with principal contractors often terminating subcontractors following serious safety breaches. Worker compensation claims for injured personnel, alongside common law damages claims that can exceed millions of dollars for serious injuries, create long-term financial liabilities that can devastate contracting businesses. The reputational damage from crane incidents can effectively end construction businesses. News media coverage of crane collapses, fatalities, or major incidents creates public awareness that affects client willingness to engage contractors, principal contractor prequalification decisions, and regulatory scrutiny on future projects. Work health and safety regulators maintain focus on contractors involved in previous incidents, conducting more frequent inspections and detailed safety system audits. Insurance underwriters may decline coverage or impose prohibitive premiums following serious incidents. Workers may refuse employment with contractors perceived as having poor safety cultures, creating recruitment challenges in competitive labor markets. The cascade of reputational, regulatory, insurance, and client relationship consequences can force businesses into insolvency even when direct incident costs are manageable. From a worker protection perspective, comprehensive SWMS documentation creates the procedural framework that prevents crane incidents. When lift plans are properly prepared, operators and ground crews understand the specific hazards affecting each lift and the controls that prevent incidents. When ground assessment is thorough, crane tip-overs from inadequate bearing capacity are prevented. When powerline clearances are verified and maintained, electrocution deaths are eliminated. When environmental limits are enforced, wind-related load control losses and crane overloading are avoided. The SWMS transforms abstract regulatory requirements into concrete operational procedures that workers can implement, creating the practical bridge between safety obligations and safe outcomes.

Reinforce licensing, insurance, and regulator expectations for Mobile Crane Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Crane Tip-Over from Inadequate Ground Conditions or Outrigger Failure

High

Mobile crane tip-over incidents represent one of the most catastrophic failure modes in construction, occurring when ground beneath outriggers fails to support crane and load weight, when outriggers are inadequately deployed or positioned, when operations exceed crane stability limits for the specific configuration, or when ground conditions change during operations due to weather, excavation, or loading from adjacent activities. Ground failure typically manifests as progressive settlement of one or more outrigger positions, creating unlevel crane conditions that redistribute load to remaining outriggers exceeding their individual capacity and triggering rapid cascade failure. Inadequate outrigger deployment where outriggers are not fully extended, are positioned at different extensions creating asymmetric stability, or are not properly locked in deployed positions allows crane movement or outrigger retraction during loaded operations with immediate stability loss. Operations beyond stability limits occur when operators exceed load chart capacities for specific boom configurations and radii, when side-loading occurs from attempting to drag loads horizontally, when dynamic loading from rapid movements or sudden stops exceeds static load calculations, or when wind loading on suspended loads creates additional overturning moments not accounted in lift planning. Underground voids from services, old excavations, basements, or deteriorated infrastructure can create sudden ground collapse when crane loading exceeds remaining ground strength over voids. The consequences of crane tip-over include crushing of operators in crane cabins during boom impact, ground personnel crushed by overturning crane components or falling loads, property damage to adjacent structures or vehicles, and potential progressive collapse if cranes contact buildings or other cranes during tip-over.

Contact with Overhead Powerlines Causing Electrocution

High

Overhead powerline contact incidents involving mobile cranes are consistently fatal or cause life-altering injuries, occurring when crane booms, jibs, or suspended loads approach or contact energized electrical conductors. Electrical hazards exist even without direct contact through electrical arcing that can occur when cranes approach within minimum clearance distances—for high voltage transmission lines, arcing can occur across air gaps of several meters. Contact incidents occur through multiple scenarios including operators misjudging clearances to powerlines during boom movements, spotters failing to observe or communicate powerline proximity, loads swinging toward powerlines during slewing or positioning movements, wind affecting suspended load position causing drift toward powerlines, and graduated creep where operators progressively encroach on powerline clearances throughout operations becoming desensitized to proximity risks. The electrical current path from powerline contact typically flows through crane boom and structure to ground through outriggers, but operators in crane cabins can be electrocuted if they attempt to exit equipment while it remains energized or if cabin components become energized. Ground personnel touching cranes or suspended loads connected to energized cranes complete electrical circuits to ground experiencing fatal electrocution. Electrical faults can also ignite hydraulic fluids or create explosive conditions. The minimum clearance distances specified in WHS regulations—typically 3 metres for powerlines up to 132kV and 6 metres for higher voltages—must be maintained by all crane components, suspended loads, and rigging throughout all operations, yet these clearances are frequently violated through inadequate planning, poor communication, or operator error.

Load Drop from Rigging Failure or Exceeding Crane Capacity

High

Suspended load drops resulting from rigging component failure or operation beyond crane rated capacity create immediate hazards for workers positioned below, near, or in the intended landing area of loads. Rigging failures occur through multiple mechanisms including slings, chains, or wire ropes failing due to wear, damage, corrosion, or loading beyond working load limits, shackles or connecting hardware failing from overload, deformation, or inadequate rated capacity, hooks opening or failing when subjected to side-loading or when safety latches are absent or defective, and edge protection failures where sharp corners cut through synthetic slings or cause wire rope strand failures. Exceeding crane capacity occurs when actual load weight exceeds operator assumptions or lift plan calculations, when boom configuration, extension, or operational radius exceeds load chart limits for the lifted load, when dynamic loading from rapid movements multiplies static load weight beyond capacity, or when combined environmental loads such as wind on suspended loads adds to crane loading beyond capacity limits. Load drops from significant heights create extreme impact forces—a 1-tonne load dropped from 10 metres impacts with approximately 100 kN of force, sufficient to cause fatal injuries or substantial property damage. Workers positioned in landing zones preparing for load arrival face particular risk as they may have limited visibility of suspended loads approaching from above and limited escape routes if rigging failures occur during final positioning. The unpredictability of rigging failures—components can appear serviceable yet fail catastrophically under load—means all suspended load areas must be treated as potential drop zones requiring exclusion controls.

Workers Struck by Moving Crane Components or Slewing Superstructure

High

The movement of crane components during operations creates multiple strike hazards where workers can be crushed, struck, or trapped between moving crane parts and fixed objects. Slewing crane superstructures rotate through 360-degree arcs creating sweep paths that can strike workers who enter crane operating envelopes, trap workers between rotating counterweights and structures or vehicles, or push workers into obstacles or edges. Extending and retracting boom sections create strike hazards when booms contact workers during movement, when jib attachment or removal operations position workers in boom travel paths, or when boom deflection under load causes unexpected contact with structures or personnel. Outrigger deployment and retraction creates crush points between extending outriggers and ground, structures, or equipment, and between outrigger components and crane chassis during deployment sequences. Hook blocks and load blocks swinging during crane movements or load positioning can strike workers in their path, with significant momentum from multi-tonne hook assemblies creating severe impacts. The confined nature of many construction sites creates limited clearances between operating cranes and site boundaries, structures, material stockpiles, and other work areas, reducing available separation distances and increasing likelihood of crane-worker contact. Workers focused on other tasks such as rigging loads, positioning landing zones, or performing adjacent work may not maintain awareness of crane movement hazards, particularly when multiple cranes or lifting operations occur simultaneously. The scale and mass of crane components means even slow movements create crushing forces that cause fatal or serious injuries when workers are caught.

Ground Personnel Entering Suspended Load Drop Zones or Swing Paths

High

Workers entering areas beneath suspended loads or within potential swing paths of loads being moved create immediate fatal hazard exposure should rigging failures, load control loss, or crane malfunctions occur. This hazard manifests through several common scenarios including workers positioning themselves in load landing zones before loads are fully landed and secured, attempting to guide loads by hand contact while loads remain suspended and crane-supported, entering beneath loads to remove rigging or adjust load position before crane weight transfer to landing surface is complete, and crossing beneath active load paths during multi-lift operations or when returning from completed tasks. The temptation to enter suspended load areas is driven by operational efficiency pressures—workers attempt to expedite landing operations by pre-positioning in landing zones, reduce crane time by commencing load securing activities before loads are fully landed, or take shortcuts across sites by passing under suspended loads rather than walking around exclusion zones. Communication failures where workers are not aware loads are suspended above them, particularly in congested sites with multiple operations, place workers in drop zones without their knowledge or consent. The consequences of load drops on workers are typically fatal given the mass of construction materials—roof trusses, steel beams, precast concrete elements, and mechanical equipment commonly weigh multiple tonnes creating unsurvivable impacts. Even smaller loads such as material bundles or equipment assemblies weighing hundreds of kilograms cause serious crush injuries when dropped on workers. The critical principle that must be enforced is absolute prohibition on workers positioning beneath or within swing paths of suspended loads until loads are fully landed, weight transferred to landing surfaces, and crane hook tension released.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Comprehensive Ground Assessment and Preparation Before Crane Setup

Elimination

Thorough ground assessment and preparation eliminates the primary cause of crane tip-over incidents by ensuring ground bearing capacity is adequate, surface conditions are stable and level, and all underground hazards are identified and protected before crane outrigger deployment.

Implementation

1. Engage geotechnical engineers or qualified ground assessment specialists to evaluate bearing capacity at proposed crane setup locations for projects involving large cranes, extended duration positioning, or questionable ground conditions 2. Review site plans and service location information identifying underground services, basements, old excavations, wells, septic systems, or other subsurface features that may create voids or weak zones 3. Conduct dial-before-you-dig service location requests and obtain underground service location information from utility providers 4. Use non-destructive service location techniques including ground-penetrating radar or electromagnetic locators to verify underground service locations at crane setup positions 5. Probe or excavate trial pits at outrigger positions to verify ground conditions, identify fill materials, assess soil type and moisture content, and confirm absence of underground voids 6. Prepare crane setup areas by removing topsoil, vegetation, and unsuitable fill materials exposing competent load-bearing material 7. Install crane pad preparation consisting of compacted crushed rock, road base, or engineered fill providing stable working platform with adequate bearing capacity 8. Provide timber cribbing, steel outrigger mats, or engineered crane pads beneath all outrigger positions distributing concentrated outrigger loads across adequate ground area 9. Size outrigger mats appropriately for crane capacity and ground conditions—minimum 900mm x 900mm x 75mm timber mats for typical mobile cranes on competent ground, or larger/multiple mats for high-capacity cranes or soft ground 10. Ensure all crane setup areas are level within manufacturer specifications (typically maximum 1% grade) using surveying equipment to verify levelness 11. Document ground assessment findings, preparation activities, and outrigger mat installations with photographs and written records included in lift planning documentation

Detailed Lift Planning Documentation for All Lifting Operations

Administrative

Comprehensive lift planning forces systematic consideration of all factors affecting safe crane operations, documenting load characteristics, crane configuration, ground conditions, hazards, personnel responsibilities, and emergency procedures before work commences.

Implementation

1. Prepare written lift plans for all mobile crane operations addressing specific lift requirements, or prepare general lift plans for repetitive similar lifts with site-specific variations documented 2. Document load information including actual load weight verified through manufacturer specifications, bill of materials calculations, or physical weighing—never estimate load weights 3. Specify load dimensions, center of gravity location, and rigging attachment points with diagrams or photographs showing how load will be rigged 4. Identify crane specifications including make, model, capacity rating, boom length, jib configuration if applicable, and load chart capacity for the specific operational configuration 5. Calculate required boom length, operational radius, and boom angle for the lift, verifying crane capacity at these parameters exceeds load weight with adequate margin 6. Document ground conditions at crane setup location including bearing capacity assessment, ground preparation requirements, and outrigger mat specifications 7. Identify all proximity hazards including overhead powerlines with voltage and minimum clearance distances, adjacent structures or cranes with required clearances, underground services requiring protection, and public areas requiring exclusion controls 8. Specify environmental limits for the operation including maximum wind speed (typically 12.5 m/s), visibility requirements, temperature limitations affecting hydraulic systems, and prohibition of operations during electrical storms 9. Assign personnel responsibilities including crane operator with licence verification, dogman/rigger with qualification confirmation, spotters for blind lift areas, and competent supervisor 10. Establish communication methods including radio channels, hand signal standards, or alternative communication if line-of-sight communication is used 11. Define exclusion zones preventing unauthorized access to crane operating area, suspended load paths, and landing zones 12. Document emergency procedures including load lowering protocols, evacuation routes, emergency contact information, and incident response procedures 13. Obtain lift plan approval from competent supervisor or site management before mobilizing crane equipment 14. Conduct pre-lift toolbox meetings with all involved personnel reviewing lift plan requirements and confirming understanding

Verification of Powerline Clearances and Implementation of Exclusion Zones

Elimination

Ensuring mobile cranes maintain minimum clearance distances from overhead powerlines eliminates electrocution hazards by preventing electrical contact or arcing. Where clearances cannot be maintained, powerline de-energization eliminates the electrical hazard entirely.

Implementation

1. Identify all overhead powerlines within crane operating areas during site assessment, documenting powerline locations on site plans and lift plans 2. Confirm powerline voltage with electricity network operators—never assume voltage from visual inspection as appearance does not reliably indicate voltage 3. Establish minimum clearance distances based on confirmed voltage: 3 metres for powerlines up to 132kV, 6 metres for powerlines 132-330kV, or 6 metres for any powerline where voltage cannot be confirmed 4. Measure distances from proposed crane setup locations to powerlines verifying that maximum boom extension, jib length, load height, and potential load swing will maintain minimum clearances throughout all operations 5. If minimum clearances cannot be maintained, request powerline de-energization and isolation from electricity network operator, obtaining written confirmation of de-energization before operations commence 6. Install physical barriers or exclusion zone markings at ground level corresponding to minimum clearance distances from powerlines, preventing crane setup within exclusion areas 7. Appoint dedicated powerline spotters with sole responsibility of monitoring clearances to powerlines throughout crane operations, with authority to immediately stop operations if clearances are violated 8. Provide powerline spotter training covering minimum clearance requirements, electrical arcing risks, communication protocols, and emergency procedures 9. Install visual warning systems such as brightly colored bunting or flags at crane boom positions corresponding to minimum clearance distances, providing operators visual reference of clearance margins 10. Include powerline clearance requirements in lift plan documentation and pre-lift toolbox meetings 11. Prohibit crane operations during high winds or conditions that may cause increased suspended load swing toward powerlines 12. If powerline contact occurs, implement emergency procedures requiring operator to remain in crane cabin until electricity network operator confirms de-energization, prohibiting anyone from touching crane or suspended load, and establishing wide exclusion zones around crane for emergency responder access only

Mandatory Exclusion Zones Preventing Access to Suspended Load Areas

Engineering

Physical exclusion zones using barriers, fencing, or designated restricted areas prevent workers from entering beneath suspended loads or within potential load swing paths, eliminating struck-by hazards from load drops or loss of load control.

Implementation

1. Establish exclusion zones encompassing all areas where suspended loads may be positioned during travel from pick-up to landing locations 2. Size exclusion zones to account for maximum potential load swing based on lift height and expected wind conditions—typically minimum 5-metre radius around suspended load positions, or greater for high lifts or windy conditions 3. Install physical barriers using safety fencing, barrier tape, or traffic barriers preventing unauthorized access to exclusion zones 4. Post prominent signage at exclusion zone boundaries displaying overhead loads warnings, prohibition of unauthorized entry, and emergency contact information 5. Assign personnel to monitor exclusion zones and prevent unauthorized entry during active lifting operations, particularly in areas where public or other trades may attempt to access excluded areas 6. Communicate exclusion zone locations and requirements to all site personnel through toolbox meetings, site inductions, and daily pre-start briefings 7. Maintain exclusion zones throughout lifting operations until loads are fully landed, weight is transferred to landing surfaces, and crane hook tension is released 8. Prohibit workers from entering landing zones to guide loads until loads are within 300mm of final landing position and travel speed is minimal 9. Require positive communication between dogman and crane operator before any personnel enter exclusion zones or approach loads 10. Document exclusion zone locations on lift plans and site plans for emergency responder reference

Crane Operator Licensing Verification and Competency Assessment

Administrative

Ensuring all crane operators hold current appropriate high-risk work licences and demonstrate competency in operating the specific crane type prevents incidents arising from inadequate operator knowledge, skill, or understanding of crane capabilities and limitations.

Implementation

1. Verify all crane operators hold current high-risk work licence for mobile crane operations appropriate to crane capacity and type, issued by state or territory work health and safety regulator 2. Confirm licence class covers the specific crane being operated—CN class for non-slewing cranes, C2 class for slewing cranes over 60 tonnes capacity, C1 class for cranes up to 100 tonnes, or C0 class for cranes exceeding 100 tonnes 3. Check licence expiry dates ensuring licences are current throughout planned operation period 4. Maintain copies of operator licences on site and available for inspection by work health and safety regulators 5. Verify operators are familiar with the specific crane make and model being operated, particularly for operators who regularly operate different crane types or manufacturers 6. Require operators to demonstrate understanding of load chart interpretation for the specific crane, including capacity variations with boom configuration, radius, and jib usage 7. Confirm operators understand site-specific hazards including powerlines, ground conditions, environmental limits, and exclusion zone requirements through pre-start briefings 8. Verify operators hold current medical certificates if required by licensing authority, typically including vision, hearing, and general health assessments 9. Prohibit operators from performing operations beyond their licence class or crane type experience 10. Implement competency monitoring through supervisor observation of crane operations, verifying smooth control operation, proper load moment indicator monitoring, and adherence to lift planning procedures

Comprehensive Pre-Operational Crane Inspections

Administrative

Thorough pre-operational inspections identify crane defects, worn components, or system malfunctions before operations commence, preventing equipment failures during loaded operations when consequences are catastrophic.

Implementation

1. Conduct daily pre-operational inspections by qualified crane operators before each shift or operational period using standardized inspection checklists 2. Inspect structural components including boom sections for cracks, deformation, or damage, boom extension mechanisms for proper operation and wear, jib connections and pins if jib is installed, and hook blocks for cracks, wear, or deformed components 3. Examine outrigger systems including hydraulic cylinders for leaks or damage, outrigger extension mechanisms for proper locking engagement, outrigger pads for cracks or deformation, and leveling systems for accurate operation 4. Check all hydraulic systems including hydraulic fluid levels in reservoir, hoses for leaks, bulging, chafing, or deterioration, hydraulic fittings for security and leak-free connections, and hydraulic filters for scheduled replacement 5. Test all crane safety systems including load moment indicator displays for proper function and alarm testing, over-load protection systems for activation at appropriate thresholds, anti-two-block systems preventing hook block contact with boom tip, and emergency shutdown systems for immediate response 6. Verify all crane controls operate smoothly including boom hoist for smooth extension and retraction, load winch for controlled raising and lowering, slew mechanism for smooth rotation without binding, and outrigger controls for proper extension and retraction 7. Inspect wire ropes including boom hoist ropes and load line for broken wires, kinks, bird-caging, or corrosion, confirming wire ropes are within Safe Work Australia Code of Practice retirement criteria 8. Check all rigging equipment including hooks for cracks or deformation, slings for cuts, abrasions, or damage, shackles for wear or deformation, and certification tags showing equipment is within service date 9. Document all inspections with dated checklists signed by inspector 10. Remove defective equipment from service immediately, tagging as unsafe and arranging repairs by qualified crane technicians before returning to service 11. Maintain inspection records on site throughout crane operations and retain for minimum five years for regulatory compliance and liability protection

Environmental Monitoring and Operational Limits

Administrative

Monitoring and enforcing environmental limits including wind speed, visibility, and precipitation prevents crane operations under conditions that compromise load control, stability, or operator ability to maintain safe operations.

Implementation

1. Install weather monitoring equipment on site measuring wind speed, visibility, and precipitation, or access reliable weather information from Bureau of Meteorology services 2. Establish maximum wind speed limits for crane operations based on AS 2550 recommendations—typically 12.5 metres per second (45 km/h) for general operations, or lower limits for high-surface-area loads susceptible to wind loading 3. Monitor wind speed continuously during crane operations using anemometers positioned at appropriate height and location representative of crane operating level 4. Implement immediate work cessation procedures when wind speeds approach or exceed limits, requiring load lowering to ground or secure interim position 5. Establish visibility requirements ensuring operators can clearly observe suspended loads, ground personnel, and obstacles throughout load paths 6. Prohibit crane operations during fog, heavy rain, or dust conditions reducing visibility below safe levels 7. Define temperature limitations for crane operations based on manufacturer specifications—typically prohibiting operations below -20°C or above +40°C where hydraulic system performance is compromised 8. Prohibit crane operations during electrical storms or when lightning is observed within 10 kilometers due to lightning strike risk to cranes and personnel 9. Assess site lighting adequacy for night operations ensuring sufficient illumination for load visibility, rigging inspection, ground condition assessment, and operator control monitoring 10. Document environmental monitoring results in daily operations records 11. Communicate environmental limits to all crane operators, supervisors, and personnel through lift planning documentation and pre-start briefings 12. Empower any worker to stop operations if environmental conditions exceed safe limits regardless of schedule pressures or client demands

Download complete control procedures

Personal protective equipment

Requirement: Type 1 or Type 2 safety helmet conforming to AS/NZS 1801:1997

When: Required for all personnel in crane operational areas including operators exiting cranes, dogmen, riggers, spotters, and workers near lifting operations to protect from falling objects and overhead hazards

Requirement: Steel-capped safety boots meeting AS/NZS 2210.3:2009 with ankle support and slip-resistant soles

When: Required for all personnel working in crane operational areas to protect feet from dropped objects, crushing hazards, and provide secure footing on construction sites

Requirement: Class D day/night high visibility vest, jacket, or coveralls conforming to AS/NZS 4602.1:2011

When: Required for all personnel working near crane operations to ensure visibility to crane operators, plant operators, and prevent personnel being struck by moving equipment

Requirement: Heavy-duty work gloves providing grip, abrasion protection, and cut resistance, conforming to AS/NZS 2161.2:2005

When: Required for dogmen and riggers handling wire ropes, chains, slings, and rigging equipment to prevent hand injuries and improve grip on equipment

Requirement: Impact-resistant safety glasses meeting AS/NZS 1337.1:2010 with side shields, or for dusty conditions, goggles providing sealed eye protection

When: Required when rigging loads, working in positions where dust or debris may be dislodged, or when environmental conditions create eye hazards

Requirement: Earplugs or earmuffs rated for noise reduction appropriate to operational noise levels, meeting AS/NZS 1270:2002

When: Required for personnel working near operating cranes when noise levels exceed 85 dB(A), particularly for extended periods near diesel engines or hydraulic systems

Requirement: Broad-brimmed hat, sunscreen SPF 50+, long-sleeved shirt, and long pants for outdoor crane operations

When: Required for all personnel working outdoors during crane operations to protect against UV exposure and prevent heat stress in Australian conditions

Inspections & checks

Before work starts

  • ✓Verify crane operator holds current high-risk work licence appropriate for crane class and capacity being operated
  • ✓Confirm crane has current registration and inspection certification from competent person within required timeframes
  • ✓Review lift plan documentation including load weights, crane capacity verification, ground conditions, hazards, and emergency procedures
  • ✓Conduct site assessment confirming overhead powerlines identified with voltage confirmed and minimum clearances verified
  • ✓Inspect ground conditions at crane setup location verifying preparation, levelness, and outrigger mat installations match specifications
  • ✓Perform comprehensive pre-operational crane inspection using checklist covering structure, hydraulics, safety systems, wire ropes, and controls
  • ✓Verify all rigging equipment including slings, shackles, and hooks are within service dates and show no visible damage
  • ✓Test communication systems between crane operator and dogman/spotters confirming reliable operation
  • ✓Establish exclusion zones with physical barriers preventing unauthorized access to crane operating area and suspended load paths
  • ✓Conduct pre-lift toolbox meeting with all personnel reviewing lift plan, responsibilities, communication protocols, and emergency procedures
  • ✓Check weather conditions including wind speed, visibility, and precipitation confirming operations are within environmental limits
  • ✓Verify emergency response equipment and first aid facilities are available and emergency contact information is posted

During work

  • ✓Monitor load moment indicator displays continuously throughout all crane operations, ensuring crane remains well within rated capacity
  • ✓Observe outrigger positions and ground conditions for any settlement, movement, or distress indicating inadequate ground bearing
  • ✓Maintain continuous communication between crane operator and dogman/spotters throughout load movements
  • ✓Monitor suspended load stability and control, observing for load swing, rotation, or instability requiring operational adjustments
  • ✓Verify clearances to overhead powerlines are maintained throughout all boom movements and load positioning
  • ✓Observe exclusion zones remain intact with no unauthorized personnel entering suspended load areas or crane operating envelope
  • ✓Monitor environmental conditions including wind speed increases, visibility deterioration, or approaching storms requiring operations cessation
  • ✓Check rigging connections remain secure throughout lift operations, particularly after any load repositioning or directional changes
  • ✓Verify crane remains level throughout operations with no evidence of outrigger settlement or crane tilting
  • ✓Observe all personnel maintain safe distances from crane slew paths, counterweight swing areas, and moving crane components
  • ✓Monitor crane operational sounds and performance for any unusual noises, vibrations, or responses indicating developing mechanical issues
  • ✓Document any incidents, near-misses, communication difficulties, or equipment anomalies for post-operational review

After work

  • ✓Conduct post-operational crane inspection checking for damage, fluid leaks, unusual wear, or components requiring maintenance
  • ✓Verify all loads have been safely landed and rigging equipment removed from crane hook before securing crane
  • ✓Retract and secure crane boom to safe configuration if crane will remain on site between operational periods
  • ✓Inspect outrigger positions and ground beneath outriggers for settlement, rutting, or surface damage indicating ground capacity concerns
  • ✓Remove exclusion zone barriers and signage if crane operations are complete, or secure exclusion areas if operations will resume
  • ✓Debrief with all operational personnel identifying hazards encountered, operational issues, equipment performance concerns, and procedural improvements
  • ✓Document operational details including lifts completed, loads handled, any incidents or near-misses, environmental conditions, and crane performance
  • ✓Report any ground settlement, crane defects, or safety concerns to site management and crane maintenance personnel
  • ✓Review lift plan accuracy comparing actual operational parameters with planned configurations, identifying any variances requiring investigation
  • ✓Arrange crane maintenance or repairs if any defects or performance issues were identified during operations
  • ✓Retain all operational records, inspection checklists, and incident documentation for regulatory compliance and continuous improvement

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

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1

Prepare Comprehensive Lift Plan and Obtain Approvals

Before mobilizing mobile crane equipment to site, prepare detailed lift plan documentation addressing all aspects of the planned lifting operations. Begin with accurate load information by obtaining load weight from manufacturer specifications, structural engineering drawings, or bill of materials—never estimate load weights. Document load dimensions and center of gravity location as these affect rigging design and crane capacity requirements. Identify required crane specifications including boom length needed to reach from crane setup position to load landing location, operational radius from crane center of rotation to load position, and boom angle for the lift. Consult crane load charts for the specific crane make and model determining crane capacity at the required boom length, radius, and configuration, ensuring capacity exceeds load weight by adequate margin (typically minimum 20% for contingency). Select appropriate crane setup location considering proximity to load pick-up point, ground conditions and bearing capacity, clearances to overhead powerlines and structures, and access for crane travel to and from site. Document ground preparation requirements including removal of unsuitable materials, installation of crane pads or working platforms, and outrigger mat specifications based on ground conditions. Identify all proximity hazards including overhead powerlines documenting voltage and minimum clearance distances, adjacent structures requiring clearance verification, underground services requiring protection or exposure, and public areas requiring exclusion controls or traffic management. Specify environmental limits for the operation including maximum wind speed (typically 12.5 m/s per AS 2550 recommendations), visibility requirements, and prohibition of operations during electrical storms. Assign specific personnel responsibilities listing crane operator with licence verification, dogman/rigger with qualifications, spotters for blind areas or powerline monitoring, and competent supervisor overseeing operations. Submit completed lift plan to site management or principal contractor for review and approval before mobilizing crane equipment.

Safety considerations

Lift planning must address actual site conditions and specific lift requirements—generic lift plans are inadequate for mobile crane operations where ground conditions, powerline proximity, and load characteristics vary significantly between sites and lifts.

2

Assess and Prepare Ground Conditions at Crane Setup Location

Before crane arrival, thoroughly assess and prepare ground conditions at the planned crane setup location to ensure adequate bearing capacity and stable working platform. Request dial-before-you-dig service location information and underground service plans from utility providers identifying electrical, gas, water, telecommunications, and sewer services in the crane setup area. Conduct non-destructive service location using ground-penetrating radar or electromagnetic locators to verify underground service positions and ensure outrigger positions will not load services directly. Probe or excavate trial pits at each planned outrigger position to verify ground material type, identify fill or imported materials, assess moisture content, and confirm absence of underground voids or services. If ground conditions are questionable, soft, or contain fill materials, engage geotechnical engineers to assess bearing capacity and specify ground preparation requirements. Remove topsoil, organic materials, and any unsuitable fill exposing competent load-bearing material—typically removal of 200-300mm of surface materials is required. Install crane pad preparation consisting of compacted crushed rock, road base, or engineered fill to create stable working platform with adequate bearing capacity. Compact crane pad materials in 150-200mm layers using appropriate compaction equipment achieving specified compaction density (typically 95% Modified Proctor). Grade and level crane setup area ensuring surface is level within crane manufacturer specifications—typically maximum 1% grade (1:100) in any direction. Install outrigger mats at each outrigger position sized appropriately for crane capacity and ground conditions—minimum 900mm x 900mm x 75mm hardwood timber mats for typical mobile cranes on competent prepared ground, or larger mats, multiple layers, or engineered steel mats for high-capacity cranes or marginal ground conditions. Position outrigger mats precisely at planned outrigger locations verified through measuring from reference points. Ensure all outrigger mats are level and make full contact with prepared ground surface. Document ground preparation activities with photographs showing before, during, and after preparation conditions, material types installed, compaction verification if applicable, and final outrigger mat positions.

Safety considerations

Inadequate ground preparation is the primary cause of crane tip-over incidents. The cost of thorough ground assessment and preparation is trivial compared to catastrophic consequences of ground failure under loaded crane operations.

3

Establish Powerline Exclusion Zones and Clearance Controls

If overhead powerlines are present within potential crane operating areas, implement comprehensive controls ensuring minimum clearance distances are maintained throughout all operations. Identify all overhead powerlines visible from crane setup location, along crane travel routes, and within maximum boom extension radius. Contact electricity network operators to confirm powerline voltage—never assume voltage from visual inspection as low-voltage and high-voltage powerlines may appear similar. Determine minimum clearance distances based on confirmed voltage: 3 metres for powerlines up to 132,000 volts, or 6 metres for powerlines 132,000-330,000 volts, or 6 metres if powerline voltage cannot be confirmed. Measure from proposed crane setup positions to powerlines verifying that boom fully extended to maximum length, plus maximum load height, plus potential load swing allowance, will maintain minimum clearances in all boom positions. If measurements indicate clearances cannot be maintained throughout required operations, request powerline de-energization from electricity network operator, obtaining written confirmation of de-energization and isolation before operations proceed. If powerlines will remain energized, install physical ground barriers or fencing at positions corresponding to minimum clearance distances from powerlines, creating exclusion zones that prevent crane setup within unsafe proximity. Position high-visibility markers such as bunting or flags on powerline spans making powerlines more visible to crane operators. Appoint dedicated powerline spotter with sole responsibility for monitoring clearances to powerlines throughout operations, positioned where they can observe boom position relative to powerlines and equipped with communication equipment for immediate contact with crane operator. Provide powerline spotter training covering minimum clearance requirements, electrical arcing risks, authority to immediately stop operations if clearances are compromised, and emergency procedures if powerline contact occurs. Brief crane operator on powerline locations, required clearances, spotter communication protocols, and prohibition on boom movements toward powerlines. Document powerline locations, voltages, clearance distances, and control measures in lift plan documentation. Include powerline hazards and controls in pre-start toolbox meetings with all site personnel.

Safety considerations

Overhead powerline contact incidents are consistently fatal or cause life-altering injuries. Clearance verification and spotter assignment are fundamental controls that must never be omitted or compromised regardless of schedule pressures.

4

Position Crane and Deploy Outriggers on Prepared Mats

With ground preparation complete and outrigger mats positioned, carefully position the mobile crane at the planned setup location. Use crane transport mode traveling on tires to approach crane setup position, maintaining awareness of ground conditions, surface grades, and overhead clearances during travel. Position crane base centrally relative to planned outrigger positions, allowing equal outrigger extension on all sides within available space. Verify crane orientation aligns with planned boom direction to load pick-up and landing locations. Deploy outriggers according to crane manufacturer specifications and lift plan requirements. Extend all outriggers fully and equally unless asymmetric extension is specifically planned and verified for stability—note that many crane load charts assume full outrigger extension and capacity is significantly reduced with partial extension. Position outriggers precisely on prepared outrigger mats, ensuring outrigger pads make full contact with mat surfaces without overhanging mat edges. Observe that all outrigger mats remain in contact with ground without tipping, rocking, or edge loading. Begin extending outriggers to take weight off crane tires, raising chassis clear of tire contact—crane manufacturers typically specify raising chassis 100-200mm above tire contact providing clearance for suspension movement. Monitor that outrigger deployment is symmetrical without disproportionate extension on any side. Lock all outriggers in deployed position using mechanical locks or pins—never rely solely on hydraulic pressure to maintain outrigger extension. Use crane leveling indicators (typically bubble levels or digital inclinometers in cab) to verify crane is level within manufacturer specifications—most cranes require level within 1-2 degrees in both longitudinal and transverse directions. If crane is not level, identify which outrigger position requires adjustment. For high positions, retract outrigger slightly; for low positions, insert additional cribbing beneath outrigger mat to raise that corner. Make incremental adjustments working around crane until level is achieved. Re-verify all outriggers remain fully extended and locked after leveling adjustments. Document crane positioning with photographs showing outrigger deployment on mats, level verification, and overall crane setup relative to ground conditions and nearby structures.

Safety considerations

Proper outrigger deployment and crane leveling are fundamental stability controls. Partially extended outriggers, unlevel crane positioning, or outriggers not centered on mats significantly reduce crane stability and can result in tip-over during loaded operations.

5

Conduct Pre-Operational Crane Inspection

Before commencing lifting operations, perform comprehensive pre-operational inspection of all crane systems verifying mechanical integrity and safety system functionality. Use standardized inspection checklist covering all critical crane components. Inspect boom structural components walking full boom length observing for cracks, deformation, corrosion, or damage to boom sections, particular attention to welds, connection points, and areas of previous repair. Check boom extension mechanisms for smooth operation without binding, excessive play, or unusual noises. If crane includes jib, inspect jib structure, connection pins, and attachment hardware. Examine all wire ropes including boom hoist rope and load line using Safe Work Australia Code of Practice retirement criteria: no more than 10% broken wires in any lay length, no crown breaks or core protrusion, no kinks or bird-caging, no excessive corrosion or wear. Verify wire rope reeving is correct per manufacturer specifications with proper rope wraps on drums. Inspect hook blocks for cracks, wear, or deformation, checking that safety latches operate properly and close securely. Test all hydraulic systems by operating each function observing smooth operation without jerking, cavitation noises, or slow response. Check hydraulic hoses for leaks, bulging, chafing against structural components, or deterioration of hose material. Verify hydraulic fluid levels in reservoir are within specified range. Test crane safety systems including load moment indicator by observing display functionality, verifying rated capacity limiter activates appropriate alarm levels, testing anti-two-block system by raising hook block toward boom tip until system activates preventing contact. Operate all crane controls verifying proper response including boom hoist for extension and retraction, load winch for raising and lowering, slew for rotation in both directions, and outrigger controls if operation requires outrigger adjustment. Check all crane instruments including boom angle indicator, load radius indicator, and wind speed indicator if equipped. Inspect operator cabin confirming mirrors provide adequate visibility, all required warning labels are present and legible, fire extinguisher is current and accessible, and communication equipment operates properly. Document inspection findings on checklist with date and inspector signature. Immediately address any defects identified, removing crane from service if safety-critical defects exist until repairs by qualified technicians are completed.

Safety considerations

Pre-operational inspections identify defects before they cause failures during loaded operations. Equipment failures under load create extreme hazards with limited response options—prevention through inspection is the only reliable control.

6

Establish Exclusion Zones and Conduct Pre-Lift Briefing

Before commencing lifting operations, establish comprehensive exclusion zones and conduct pre-lift briefing with all personnel involved in the operation. Determine exclusion zone boundaries encompassing crane operating envelope including maximum boom slew radius, counterweight swing path, suspended load travel path from pick-up to landing location, and landing zone area. Size exclusion zones accounting for potential load swing based on lift height and wind conditions—typically minimum 5-metre radius around anticipated suspended load positions, or greater for high lifts or windy conditions. Install physical exclusion zone barriers using safety fencing, plastic barriers, bunting, or traffic management barriers preventing unauthorized entry. Ensure barriers are substantial enough that they will not be easily moved or ignored—in areas with public access or multiple trades working, solid fencing with gates is more effective than bunting. Post prominent signage at all exclusion zone entry points displaying overhead loads warnings, danger crane operations notifications, prohibition of unauthorized entry, and emergency contact information. Assign personnel to monitor exclusion zones during operations preventing unauthorized entry, particularly important in congested sites or areas with public access. Convene pre-lift briefing with all personnel involved including crane operator, dogman/rigger, spotters, supervisors, and workers in adjacent areas who may be affected. Review lift plan covering load weight and dimensions, rigging method to be used, crane configuration and capacity verification, load path from pick-up to landing, ground conditions and outrigger deployment, identified hazards including powerlines, environmental limits for the operation, and emergency procedures. Assign specific responsibilities confirming crane operator understands load control requirements, dogman understands rigging and signaling responsibilities, spotters understand observation positions and communication requirements, and all personnel understand exclusion zone boundaries and prohibition of entry. Establish communication protocols specifying radio channel if radios will be used, hand signal standards if line-of-sight communication is used, and emergency stop signals that any person can use to immediately halt operations. Verify all participants understand briefing content by requesting confirmation and answering questions. Document briefing attendance with sign-on sheet listing all participants.

Safety considerations

Pre-lift briefings ensure all personnel understand their roles, hazards, and controls before work commences. Many crane incidents result from communication failures or personnel entering hazard zones—briefings establish shared understanding preventing these failures.

7

Attach Load with Appropriate Rigging Techniques

With crane positioned, inspected, and exclusion zones established, proceed with load rigging using appropriate techniques and equipment for the specific load characteristics. Select rigging equipment with working load limits exceeding load weight by minimum 5:1 safety factor for synthetic slings or 6:1 for wire rope slings. Choose rigging configuration appropriate to load geometry—single-leg slings for loads with central lifting points and known center of gravity, two-leg or four-leg sling configurations for loads requiring balanced support or with offset centers of gravity, or specialized lifting beams and spreader bars for loads requiring specific lift point geometry. Inspect the specific load being rigged observing for sharp edges requiring edge protection or wire rope slings instead of synthetic slings, protruding elements that may interfere with rigging or cause load imbalance during lift, manufacturer-specified lifting points that must be used, and load marking or documentation indicating weight and center of gravity. If load weight is uncertain, use conservative assumptions or conduct test lift raising load barely clear of ground to assess actual crane loading. Attach rigging to designated lifting points ensuring slings seat fully on load bearing surfaces without riding on edges or corners, sling angles do not exceed 60 degrees from vertical (more acute angles cause significant force multiplication), shackles are installed with pins through structural load bearing points not through sling loops, and all rigging connections are secured with appropriate hardware properly tightened. Verify load attachment security by conducting test lift raising load approximately 100mm clear of ground, holding position while observing load behavior for balance and stability, checking that rigging connections remain secure without shifting or slings sliding on load surfaces, and confirming load does not tilt, rotate, or behave unpredictably. Communicate with crane operator throughout rigging procedures using agreed signals or radio communication. Position dogman clear of potential load swing paths before signaling operator to commence main lift. Verify no personnel are positioned beneath load or in potential swing paths before load is raised to full lift height.

Safety considerations

Rigging failures cause load drops with catastrophic consequences. Rigorous rigging inspection, proper sling selection, and verification of load attachment security before full lift prevent the majority of rigging failure incidents.

8

Execute Lift with Continuous Load Control and Monitoring

With load securely rigged and all safety controls verified, execute lifting operation following lift plan and maintaining constant awareness of crane capacity, stability, and hazard clearances. Operator initiates lift by smoothly engaging load winch raising boom to take tension in rigging, pausing when load weight transfers to crane but before load lifts from ground. Monitor load moment indicator display confirming crane loading is well within rated capacity for current boom configuration—typically aim to operate at 70-80% of rated capacity providing adequate margin for dynamic loading or environmental factors. Continue raising load slowly, lifting clear of ground approximately 300mm, pausing to verify load stability and rigging security before continuing. Observe load does not tilt or rotate indicating improper center of gravity or inadequate rigging, slings remain properly seated without shifting on load surfaces, and crane remains level without observable outrigger settlement. If test lift reveals issues, lower load back to ground and rectify problems before continuing. Once test lift confirms load control, continue raising to clearance height sufficient for travel to landing location—typically 500mm to 1 metre above obstacles in load path. Maintain controlled load movements avoiding rapid winch speed changes that create dynamic loading and shock loads on crane, rigging, and load attachments. For load travel, coordinate boom extension, slewing, and winch operation maintaining smooth controlled movements. Continuously monitor load moment indicator throughout all crane operations ensuring displayed capacity percentage does not exceed approximately 80% rated capacity. Observe ground conditions around outriggers throughout operation looking for settlement, rutting, or mat movement indicating possible bearing capacity exceedance. Maintain communication with spotters as load travels toward landing location, receiving clearance information relative to obstacles, structures, or hazards. As load approaches landing zone, reduce travel speed and coordinate final positioning with landing zone spotter. Position load over intended landing position, then lower smoothly maintaining constant winch engagement without free-spooling. Land load gently making initial contact, then continue lowering transferring full weight to landing surface. Maintain slight tension in rigging until landing zone personnel confirm load is stable and secured before fully releasing tension for rigging removal.

Safety considerations

Controlled load movements throughout lifting operations prevent dynamic loading that can exceed crane capacity or cause load control loss. Operating within capacity margins and responding immediately to any unusual crane behavior prevents progression to catastrophic failures.

9

Monitor Environmental Conditions Throughout Operations

Throughout all crane operations, continuously monitor environmental conditions ensuring they remain within safe operational limits and implementing immediate work cessation if conditions deteriorate. Monitor wind speed using anemometer equipment positioned at height representative of crane boom operating level, not at ground level where wind speeds may be significantly lower than at elevated positions. Compare monitored wind speed against operational limits specified in lift plan—typically 12.5 metres per second (approximately 45 km/h) for general crane operations per AS 2550 recommendations, or lower limits for lifts with high surface area loads susceptible to wind loading such as wall panels, roof trusses, or sheet materials. Observe wind effects on suspended loads watching for load swing, rotation, or instability indicating wind impact. If wind conditions approach limits or if load behavior indicates excessive wind effects, implement graduated response beginning with pausing operations to reassess conditions, lowering loads to interim secure positions if wind continues, or fully landing all loads and securing crane if wind speed exceeds limits. Monitor visibility conditions ensuring operator can clearly observe suspended loads, ground personnel, rigging equipment, and obstacles throughout load paths. If fog, heavy rain, dust, or steam reduces visibility below levels where safe operations can be maintained, cease operations until visibility improves. Observe for approaching weather changes including darkening skies, increasing wind, lightning, or storm cells approaching site. Access Bureau of Meteorology weather warnings or site weather monitoring systems providing advance warning of deteriorating conditions. If electrical storms approach site indicated by lightning observations or thunder audible, implement immediate work cessation landing all loads and vacating crane operations—lightning strikes to cranes create extreme electrocution risk for operators and ground personnel. Monitor temperature conditions if operations occur during extreme heat or cold, ensuring hydraulic systems continue operating within normal parameters. Communicate environmental monitoring results to operators and supervisors, empowering any personnel to request operations cessation if they observe unsafe environmental conditions.

Safety considerations

Environmental conditions can change rapidly during construction projects. Continuous monitoring and willingness to cease operations when limits are approached prevents incidents arising from operating cranes in conditions beyond safe limits.

10

Complete Post-Operations Procedures and Documentation

After completing lifting operations for the day or when crane operations are finished, conduct systematic post-operational procedures ensuring equipment is secured, site is safe, and comprehensive documentation is completed. Conduct post-operational equipment inspection using same checklist format as pre-operational inspection, specifically looking for any damage sustained during operations, new hydraulic leaks that developed, unusual wear on components indicating potential issues, and any mechanical anomalies requiring maintenance attention. Document findings noting any items requiring repair or maintenance before next use. Verify all loads have been safely landed and rigging equipment removed from crane hook—never leave crane with loads suspended or rigging attached when operations cease. If crane will remain positioned on site between operational periods, retract boom to stable configuration, ensure outriggers remain deployed and locked providing stable base, and implement crane security measures preventing unauthorized operation such as removing ignition keys and installing cab locks. If crane must be relocated from site, plan demobilization sequence including rigging removal, boom retraction to transport configuration, outrigger retraction sequence, and travel route assessment for clearances and ground conditions. Inspect ground areas where outriggers were positioned looking for settlement, rutting, or damage indicating possible ground bearing capacity exceedance requiring investigation. Remove exclusion zone barriers if operations are complete, or secure barriers if operations will resume ensuring zones remain protected overnight or during non-operational periods. Conduct debriefing with all operational personnel including operator, dogmen, riggers, spotters, and supervisors discussing hazards encountered during operations, communication effectiveness and any issues that arose, equipment performance and any concerns, near-miss incidents or close calls requiring investigation, and procedural improvements for future similar operations. Document operational details in site records including lifts completed with brief descriptions, loads handled with weights if known, any incidents or unusual events that occurred, environmental conditions throughout operations including maximum wind speeds, crane performance observations, and ground conditions assessment. Report any ground settlement, structural concerns, or equipment defects to site management, principal contractor, and crane maintenance provider as appropriate. Review lift plan accuracy comparing actual operational parameters with planned configurations, noting any variances that required operational adjustments or plan modifications. File all documentation including lift plans, inspection checklists, briefing attendance records, and operational logs in project safety records for regulatory compliance and continuous improvement reference.

Safety considerations

Post-operational documentation captures lessons learned and identifies equipment issues before they cause failures in subsequent operations. Debriefing sessions provide opportunity to identify near-misses and implement improvements preventing actual incidents.

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Frequently asked questions

What crane operator licence do I need for mobile crane operations in Australia?

Mobile crane operator licence requirements in Australia depend on the crane capacity and configuration. For non-slewing mobile cranes (cranes with booms that telescope but do not rotate, such as many older style straight-boom cranes), operators require a CN (non-slewing mobile crane) licence regardless of capacity up to 60 tonnes. For modern hydraulic mobile cranes with slewing capability (boom rotates 360 degrees), operators require capacity-specific licences: C2 class for cranes over 60 tonnes up to 100 tonnes capacity, C1 class for cranes up to 100 tonnes, or C0 class for cranes exceeding 100 tonnes capacity. All crane operator licences are issued by state and territory work health and safety regulators such as WorkSafe after completion of nationally recognised training units and competency assessment. Licences must be renewed periodically, typically every 5 years, and operators must hold current licences at all times during crane operations. Operators must also hold current medical certificates demonstrating they meet health standards appropriate for crane operation including vision, hearing, and general fitness. Site managers and principal contractors must verify operator licensing before allowing crane operations, maintain copies of operator licences on site, and ensure operators do not exceed their licence class capacity limits. Operating cranes without appropriate licences or allowing unlicensed operators to operate equipment constitutes a serious breach of WHS regulations resulting in significant penalties for both operators and employers, potential criminal prosecution for serious incidents, and insurance coverage may be voided if incidents occur with unlicensed operators.

How do I calculate safe ground bearing capacity for mobile crane operations?

Ground bearing capacity calculations for mobile crane operations must be performed by qualified geotechnical engineers—crane operators, supervisors, or contractors should never attempt these calculations as errors result in catastrophic crane tip-over incidents. However, understanding the principles helps contractors recognize when professional assessment is critical. Ground bearing capacity depends on soil type (rock, clay, sand, silt), soil condition including moisture content and compaction state, depth to bedrock or firm bearing strata, and groundwater conditions. Soft clays may have bearing capacities as low as 50-100 kPa, while dense sands or gravels may support 200-300 kPa, and rock can support several thousand kPa. Mobile crane outriggers create concentrated point loads that must be distributed across sufficient ground area to remain within bearing capacity limits. A 50-tonne mobile crane operating at maximum capacity may create outrigger loads of 200-300 kN at each outrigger, which if applied to 0.1 square metre outrigger pads creates ground pressures of 2,000-3,000 kPa—far exceeding the bearing capacity of most soils. Timber outrigger mats distribute outrigger loads across larger ground areas reducing ground pressure. A 900mm x 900mm timber mat provides approximately 0.8 square metres bearing area, reducing ground pressure from the previous example to approximately 250-375 kPa, which exceeds capacity of soft soils but may be acceptable on dense sands or gravels. Geotechnical engineers assess ground conditions through site inspections, test pits, or soil boring programs, classify soil types and properties, calculate allowable bearing pressures with appropriate safety factors, and specify required ground preparation such as excavation of unsuitable materials, installation of engineered fill platforms, or use of specific outrigger mat configurations. Never attempt crane operations based on visual assessment or rules of thumb—ground failures occur suddenly with no warning, and consequences are catastrophic. The cost of geotechnical assessment is minor compared to crane tip-over consequences.

What is the maximum wind speed for safe mobile crane operations?

Maximum wind speed limits for mobile crane operations are specified in Australian Standard AS 2550.5 which recommends crane operations cease when wind speeds exceed 12.5 metres per second (equivalent to approximately 45 kilometres per hour or 24 knots). This limit applies to general crane operations with typical loads and assumes competent operator assessment. However, several factors may require lower wind speed limits for specific operations. Loads with large surface areas such as wall panels, roof trusses, steel sections with significant depth, or sheet materials experience substantial wind loading at lower wind speeds and may require reduced operational limits of 8-10 m/s. High-reach crane configurations with booms extended to maximum lengths are more susceptible to wind effects and may require reduced limits. Loads with irregular geometries that create unpredictable wind effects may require conservative limits. Crane manufacturers may specify wind limitations for specific crane models in operating manuals—these manufacturer limits must be followed. Wind speed monitoring must occur at heights representative of crane boom operating levels, not at ground level where wind speeds are significantly lower due to ground friction effects. Wind speed at height can be 30-50% higher than ground level measurements, meaning ground-level winds of 30 km/h may correspond to 45 km/h at boom height. Wind conditions vary throughout days—typically calmer conditions occur early morning and late evening, with strongest winds mid-afternoon. Approaching weather systems, storm fronts, or coastal sea breeze effects can cause rapid wind speed increases requiring continuous monitoring. If wind speeds approach operational limits, implement graduated response starting with pausing operations to assess conditions, reducing operational radius to maintain larger capacity margins, or fully ceasing operations and securing crane if winds exceed limits. Never continue operations in excessive wind due to schedule pressures—wind-related crane tip-overs and load drops are preventable through disciplined adherence to wind speed limitations.

What are the minimum clearance distances from overhead powerlines for mobile crane operations?

Minimum clearance distances from overhead powerlines for mobile crane operations in Australia are specified in Work Health and Safety Regulations and vary based on powerline voltage. For powerlines up to 132,000 volts (132 kV), the minimum clearance is 3 metres between any crane component (boom, jib, load, rigging, or crane structure) and powerline conductors. For powerlines between 132,000 and 330,000 volts, minimum clearance increases to 6 metres. If powerline voltage cannot be definitively confirmed, a minimum clearance of 6 metres must be maintained to account for worst-case high voltage scenarios. These clearances must be maintained in all directions (horizontal, vertical, diagonal) throughout all crane operations including boom extension, slewing, load travel, and any load swing or sway. The clearances account for electrical arcing potential where electrical current can arc across air gaps without direct physical contact—high voltage electricity can arc several metres through air to reach grounded objects, meaning crane operators and ground personnel can be electrocuted even without direct powerline contact. Clearance verification requires accurate measurement from proposed crane positions to powerlines, accounting for maximum boom extension, jib length if used, maximum load height, and potential load swing during movement. If minimum clearances cannot be maintained throughout all required crane operations, the only safe option is powerline de-energization and isolation by the electricity network operator before crane work commences. De-energization requests typically require several days notice and may incur costs, but these are trivial compared to electrocution consequences. Electricity network operators will attend site, isolate powerlines, install earthing connections, and provide written confirmation that powerlines are safe for crane proximity. Never assume powerlines are de-energized without written confirmation—treat all powerlines as energized unless electricity network operator provides documented de-energization confirmation. Install physical exclusion barriers on ground corresponding to minimum clearance distances, preventing crane setup within these zones. Appoint dedicated powerline spotters monitoring clearances throughout operations with authority to immediately stop crane operations if clearances are compromised.

What documentation must I keep on site during mobile crane operations?

Mobile crane operations require comprehensive documentation maintained on site and readily accessible for inspection by work health and safety regulators. Required documentation includes: crane registration certificates showing the crane has current registration with relevant authority and has passed periodic statutory inspections, typically required annually or every 18 months depending on jurisdiction; crane inspection records including most recent major inspection by competent person with load testing certification typically required every two years, periodic inspections at manufacturer-specified intervals typically monthly or quarterly, and daily pre-operational inspection checklists signed by operators; crane operator licences with current copies of all operators' high-risk work licences showing appropriate class for crane being operated, licence expiry dates, and any medical certificates required by licensing authority; comprehensive lift plan documentation addressing the specific lifts being performed including load weights and dimensions, crane capacity verification, ground assessment and preparation details, identified hazards and control measures, personnel responsibilities, communication protocols, and emergency procedures; rigging equipment certification with current inspection or proof-testing certificates for all slings, shackles, and lifting accessories showing compliance with Safe Work Australia Code of Practice requirements for periodic inspection and testing; Safe Work Method Statement for crane operations approved by principal contractor or site management addressing site-specific hazards and controls; ground assessment documentation including any geotechnical reports, bearing capacity calculations, or ground preparation specifications that informed crane setup decisions; powerline clearance documentation if overhead powerlines are present, including voltage confirmation from electricity network operators, clearance calculations, and de-energization confirmation if powerlines have been isolated; pre-start briefing attendance records showing all personnel involved in crane operations attended pre-lift briefings and understand their responsibilities; incident reports or near-miss documentation for any events occurring during crane operations; and environmental monitoring records including wind speed observations and decisions to cease operations due to environmental factors. All documentation should be maintained in organized site files, not loose papers scattered in vehicles or site sheds, and supervisors should know documentation location and be able to produce it immediately when inspectors request. Retain all crane operation documentation for minimum five years after project completion for regulatory compliance and liability protection purposes. Digital copies provide backup if site documentation is lost or damaged.

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