Cranes PDF

Draft
Code of Practice
CRANES
JUNE 2012
Draft for Public Comment
This draft model Code of Practice for managing risks associated with the use of cranes has
been developed to support the model Work Health and Safety (WHS) Act and Regulations
developed by Safe Work Australia under the Intergovernmental Agreement for Regulatory and
Operational Reform in Occupational Health and Safety.
Since 1 January 2012, six jurisdictions have implemented new WHS laws based on the model
WHS laws: Queensland, New South Wales, Tasmania (with a commencement date of 1
January 2013), the Northern Territory, the Australian Capital Territory and the Commonwealth.
The draft model Code of Practice aims to provide practical guidance to persons conducting a
business or undertaking who purchase, hire and use cranes in workplaces on how to manage
the health and safety risks associated with them. It includes information about specific control
measures required under the WHS Regulations.
Feedback is sought on whether the scope and application of this Code is appropriate including
whether it:
is helpful and easy to understand
reflects current state of knowledge and technological developments in relation to
managing the risks associated with cranes
has an appropriate level of information or is too detailed including whether the
information would be better dealt with in specific guidance rather than a code of practice
requires additional examples to provide clarification. If so, please provide relevant
examples that you think should be included.
In addition to the above, feedback is sought on the following issues:
1. Referencing technical standards (e.g. Australian Standards)

There are a wide range of Australian Standards that apply to cranes, which competent
persons should be aware of and apply as required, for example, in design and manufacture
or inspection and testing.
There is a view that codes of practice should not reference Australian Standards unless the
entire standard is relevant, as it places an expectation on duty holders to comply not only
with the code, but also with the referenced standard. Technical standards can be revised at
any time and they may or may not provide the most appropriate information in relation to
managing health and safety risks. Small businesses may have fewer resources to purchase
Australian Standards than larger businesses.
Comment is sought on whether it is necessary to reference particular technical standards in
the Code of Practice.
2. Structure of the material
This draft code is lengthy as it includes guidance that applies to various types of cranes, in
particular mobile and tower cranes. It also covers specific crane processes and activities
such as inspection and testing. Comment is sought on whether the material would be more
useful if it was contained in separate documents, for example:
a document on crane inspection, testing and maintenance
a document on crane operation
separate documents on specific types of cranes.
This Code reflects the requirements of the model WHS Regulations and it includes references
to specific regulations. Comments should not focus on the regulations themselves, but on the
guidance that is needed to comply with the WHS Regulations.
PAGE 2 OF 86 JUNE 2012

How do you make a submission?
You can provide your comments as an individual or you may wish to contribute to a joint
submission through your employer or union organisation, professional association, safety group
or community forum. It is encouraged that wherever possible, you should include evidence and
examples to support your views on the draft model code.
A Public Comment Submission Cover Sheet and the Public Comment Response Form are
provided for making written submissions. These are available on the Safe Work Australia
website at www.safeworkaustralia.gov.au.
It is preferred that submissions are typed and submitted electronically to the following email
address: [email protected]. If you are unable to email your submission, you can
post it to:
Safe Work Australia
Attn: Codes Public Comment
PO Box 641
Canberra ACT 2601
When a submission is received by Safe Work Australia via email, an automatic response will be
sent to confirm receipt. We do not send individual responses to submissions received by mail.
All submissions will be made accessible to the public on the Safe Work Australia website,
unless marked IN CONFIDENCE.
The closing date for making a submission is Friday 24 August 5:00 pm AEST.
What happens after the public comment period closes?
Safe Work Australia will analyse all written submissions that are received during the public
comment period. Safe Work Australia will review and as necessary revise the model Codes of
Practice.
The revised model Codes of Practice will then be considered by the Ministerial Council for
adoption as part of the harmonised WHS laws.

TABLE OF CONTENTS
FOREWORD ....................................................................................................................... 6
SCOPE AND APPLICATION .............................................................................................. 6
1. INTRODUCTION .......................................................................................................... 7
1.1 What is a crane? ............................................................................................... 7

1.2 Who has health and safety duties in relation to cranes? .................................... 7
1.3 What is involved in managing risks associated with cranes? ............................. 8
2. MANAGING RISKS WITH CRANES IN THE WORKPLACE ....................................... 9
2.1 Identifying hazards ............................................................................................ 9

2.2 Assessing the risks .......................................................................................... 10
2.3 Controlling risks ............................................................................................... 10
2.4 Maintaining and reviewing risk control measures............................................. 11
3. BEFORE USING CRANES IN THE WORKPLACE .................................................... 13
3.1 Planning the work ............................................................................................ 13

3.2 Selecting a crane ............................................................................................. 14
3.3 Hiring cranes ................................................................................................... 14
3.4 Registering cranes........................................................................................... 15
3.5 Training, information, instruction and supervision ............................................ 17
3.6 Installation and commissioning of cranes ........................................................ 18
3.7 Public safety and site security ......................................................................... 19
3.8 Emergency Plan .............................................................................................. 19
4. USING CRANES IN THE WORKPLACE.................................................................... 21
4.1 Crane documentation and markings ................................................................ 21

4.2 Crane operating personnel .............................................................................. 21
4.3 Licences .......................................................................................................... 22
4.4 Setting up the crane ........................................................................................ 22
4.5 Crane stability.................................................................................................. 25
4.6 Documented lifting procedures ........................................................................ 26
4.7 Minimising risk when lifting loads ..................................................................... 27
4.8 Lifting materials ............................................................................................... 29
4.9 Lifting people ................................................................................................... 30
4.10 Communication ............................................................................................... 31
4.11 Minimising the risk of falling from a height ....................................................... 32
4.12 Operator position ............................................................................................. 32
4.13 Noise ............................................................................................................... 33
5. INSPECTION, MAINTENANCE, REPAIR AND DISMANTLING ................................ 34
5.1 Inspecting and testing cranes .......................................................................... 34

5.2 Maintenance, repair and cleaning of plant ....................................................... 38
5.3 Unattended cranes, parking and storage ......................................................... 39
5.4 Decommissioning and dismantling .................................................................. 39

5.5 Record keeping ............................................................................................... 40
6. CONTROLLING RISKS IN SPECIFIC CRANE OPERATIONS .................................. 41
6.1 Mobile Cranes ................................................................................................. 41

6.2 Vessel-mounted cranes ................................................................................... 42
6.3 Special uses of mobile cranes ......................................................................... 43
6.4 Multiple crane lifts ............................................................................................ 44
6.5 Single crane multiple winch lifts ....................................................................... 46
6.6 Use of other mobile plant as a mobile crane .................................................... 47
6.7 Tower cranes................................................................................................... 47
6.8 Vehicle-loading cranes .................................................................................... 47
6.9 Bridge and gantry cranes................................................................................. 49
APPENDIX A: DEFINITIONS ............................................................................................ 51
APPENDIX B: TOWER CRANES ..................................................................................... 55
APPENDIX C: REGISTRABLE CRANES AND HIGH RISK WORK LICENCES .............. 72
APPENDIX D: CRANE STABILITY................................................................................... 74
APPENDIX E: LIMITING AND INDICATING DEVICES .................................................... 81
APPENDIX F: USING OTHER PLANT AS A MOBILE CRANE ........................................ 84

FOREWORD
This Code of Practice on managing risks associated with cranes is an approved code of
practice under section 274 the Work Health and Safety Act (the WHS Act).
An approved code of practice is a practical guide to achieving the standards of health, safety
and welfare required under the WHS Act and the Work Health and Safety Regulations (the
WHS Regulations).
A code of practice applies to anyone who has a duty of care in the circumstances described in
the code. In most cases, following an approved code of practice would achieve compliance with
the health and safety duties in the WHS Act, in relation to the subject matter of the code. Like
regulations, codes of practice deal with particular issues and do not cover all hazards or risks
that may arise. The health and safety duties require duty holders to consider all risks associated
with work, not only those for which regulations and codes of practice exist.
Codes of practice are admissible in court proceedings under the WHS Act and Regulations.
Courts may regard a code of practice as evidence of what is known about a hazard, risk or
control and may rely on the code in determining what is reasonably practicable in the
circumstances to which the code relates.
Compliance with the WHS Act and Regulations may be achieved by following another method,
such as a technical or an industry standard, if it provides an equivalent or higher standard of
work health and safety than the code.
An inspector may refer to an approved code of practice when issuing an improvement or
prohibition notice.
This Code of Practice has been developed by Safe Work Australia as a model code of practice
under the Council of Australian Governments Inter-Governmental Agreement for Regulatory
and Operational Reform in Occupational Health and Safety for adoption by the Commonwealth,
state and territory governments.
A draft of this Code of Practice was released for public consultation on 8 June 2012 and was
endorsed by the Select Council on Workplace Relations on [to be completed].
SCOPE AND APPLICATION
This Code provides practical guidance to persons conducting a business or undertaking who
have management or control of cranes in the workplace, as well as to persons who install,
commission and maintain cranes. It provides practical guidance on how to manage health and
safety risks associated with cranes in the workplace, from installation, commissioning and use
through to decommissioning and dismantling, and includes information about specific control
measures required under the WHS Regulations for cranes.
This Code should be read in conjunction with the Codes of Practice for Managing Risks of Plant
in the Workplace and Safe Design, Manufacture, Import and Supply of Plant.
How to use this Code of Practice

In providing guidance, the word should is used in this Code to indicate a recommended course
of action, while may is used to indicate an optional course of action.
This Code also includes various references to provisions of the WHS Act and Regulations which
set out the legal requirements. These references are not exhaustive. The words must,
requires or mandatory indicate that a legal requirement exists and must be complied with.

1. INTRODUCTION
1.1 What is a crane?

A crane is an item of plant intended for raising or lowering a load and moving it horizontally
including the supporting structure of the crane and its foundations.
The designs and items of some types of cranes, such as mobile cranes and tower cranes, must
be registered under the WHS Regulations.
Other key terms used in this Code are defined in Appendix A.
1.2 Who has health and safety duties in relation to cranes?

A person conducting a business or undertaking has the primary duty under the WHS Act to
ensure, so far as is reasonably practicable, that workers and other persons are not exposed to
health and safety risks arising from the business or undertaking. This duty includes ensuring, so
far as is reasonably practicable:
the provision and maintenance of safe plant (such as cranes)
the safe use, handling, storage and transport of plant.
The WHS Regulations include specific duties for a person conducting a business or undertaking
with management or control of plant, as well as requirements for plant that lifts or suspends
loads.
If you own a crane, you will be the person with management or control of that crane. If you hire
or lease a crane, you have management or control of that crane for the period that you have
hired it for and will have responsibility for ensuring health and safety together with the person
you have hired or leased it from.
Designers, manufacturers, suppliers, importers and installers of plant must also ensure, so
far as is reasonably practicable, that the plant they design, manufacture, import, supply or install
is without risks to health and safety.
Designers, manufacturers, importers and suppliers also have duties to provide information
about the plant to enable other duty holders to fulfil the responsibilities they have in managing
the risks associated with it. Information must be passed on from the designer through to the
manufacturer and supplier to the end user.
Further guidance is available in the Code of Practice: Safe design, Manufacture, Import and
Supply of Plant.
Officers, for example company directors, have a duty to exercise due diligence to ensure that
the business or undertaking complies with the WHS Act and Regulations. This includes taking
reasonable steps to ensure that the business or undertaking has and uses appropriate
resources and processes to eliminate or minimise risks that arise from plant used in the
workplace.
Workers have a duty to take reasonable care for their own health and safety and must not
adversely affect the health and safety of other persons. Workers must comply with any
reasonable instruction and cooperate with any reasonable policy or procedure relating to health
and safety at the workplace. Workers who operate certain types of cranes must have a relevant
high risk work licence.

1.3 What is involved in managing risks associated with cranes?
R. 203: A person with management or control of plant at a workplace must manage risks to
health and safety associated with the plant.
R. 34-38: In order to manage risk under the WHS Regulations, a duty holder must:
identify reasonably foreseeable hazards that could give rise to the risk
eliminate the risk so far as is reasonably practicable
if it is not reasonably practicable to eliminate the risk, minimise the risk so far as is
reasonably practicable by implementing control measures in accordance with the hierarchy
of control
maintain the implemented control measure so that it remains effective, and
review, and if necessary revise, risk control measures so as to maintain, so far as is
reasonably practicable, a work environment that is without risks to health and safety.
Chapter 2 of this Code provides guidance on how to manage the risks associated with cranes in
the workplace by following a systematic process that involves:
identifying hazards
if necessary, assessing the risks associated with these hazards
implementing and maintaining risk control measures, and
reviewing risk control measures.
Guidance on managing the risks of plant is available in the Code of Practice: Managing Risks of
Plant in the Workplace.
Consulting workers
Consultation involves sharing information, giving workers a reasonable opportunity to express
views and taking those views into account before making decisions on health and safety
matters.
S. 47: A person conducting a business or undertaking must consult, so far as is reasonably
practicable, with workers who carry out work for you who are (or are likely to be) directly
affected by a work health and safety matter.
S. 48: If the workers are represented by a health and safety representative, the consultation
must involve that representative.
Consultation with workers and their health and safety representatives is required at each step of
the risk management process. By drawing on the experience, knowledge and ideas of your
workers you are more likely to identify all hazards and develop effective risk controls.
It is important to consult your workers as early as possible when planning to introduce new plant
or make any changes that may affect their health and safety.
Consultation, cooperation and coordination of activities with other duty holders
S. 46: A person conducting a business or undertaking must consult, cooperate and coordinate
activities with all other persons who have a work health or safety duty in relation to the same
matter, so far as is reasonably practicable.
There may be other businesses who share the workplace where the crane is used or who are
involved in the supply, installation and maintenance of cranes. They will each have health and
safety duties to the extent of their ability to influence and control various aspects of crane
safety. Therefore, it is important that these duty holders consult each other on the risks
associated with the use of the crane and work together in a cooperative and coordinated way to
control the risks, for example, controlling traffic movements in or near the work area.
Further guidance on consultation requirements is available in the Code of Practice: Work Health
and Safety Consultation, Cooperation and Coordination.

2. MANAGING RISKS WITH CRANES IN THE WORKPLACE
There are a range of risks associated with crane operation and use. A risk management
process that identifies the hazards and controls the risks will help maintain the crane so that it is
safe to use.
2.1 Identifying hazards

Identifying hazards involves finding all of the things and situations that could potentially cause
harm to people. Hazards associated with cranes generally arise from:
the crane itself - for example, hazards associated with the cranes structural condition,
electrical and hydraulic systems, mechanical power sources, moving parts, load-carrying
capacity and operator protection
how and where the crane is used for example, there may be hazards associated with
using a mobile crane as a result of the terrain it is to cross and operate on (for example,
the slope or evenness of the ground), the kind of loads it will lift, and the size of the area
in which it is to be used.
The key hazards associated with cranes involve:
structural failure - any crane component, such as the boom, jib, hydraulic rams or wire
rope could suffer structural fail without warning. For example, a mobile crane may suffer
structural failure if the crane has been overloaded in the structural area of its load chart.
crane overturning for example, this could occur when a crane is overloaded in the
stability area of its load chart and this may be influenced by:
o poor ground conditions such as unstable ground
o failure to use or fully extend outriggers or stabilisers
o failure to level the crane or operating the crane beyond its gradient limits
o insufficient counterweights are used for the selected load chart
o load limiting devices not functioning
o rapid slewing
o high wind conditions.
crane collapse for example, a tower crane may collapse if it becomes unstable
through overloading and this may be influenced by:
o the incorrect use of counterweights
o crane tower bolts being incorrectly torqued
o the incorrect installation of crane ties
o poor design of the tower crane base.
contact or collision with persons, other plant and structures - where sufficient
clearance is not maintained between a mobile crane and pedestrian traffic routes or
other plant and structures, such as other cranes, concrete pumping booms, buildings
and overhead electric lines.
falling objects for example, objects falling as a result of erection and dismantling
activities and the way loads are secured during lifting operations may present a risk of
injury to workers and members of the public.
persons falling from height - for example, when undertaking activities associated with
erecting and dismantling of cranes.
When identifying hazards you should think about all the activities that may be carried out during
the life of the crane at your workplace, such as: installation, commissioning, operation,
inspection, maintenance, repair, transport, storage and dismantling.
How to identify hazards
Information gathered from a range of sources can help identify hazards. This may include the
following:

discussions with crane designers, manufacturers, suppliers, importers, maintenance
technicians or engineers and operators
a visual inspection of the crane and any associated environmental and operational
conditions in which the crane is intended to be installed, erected and used
the ergonomic and safety needs of crane operators
inspection, testing and maintenance information
analysis of injury and near miss data.
If you have hired or leased a crane, you should also consult the person who owns the crane
about potential hazards because you both have responsibility for ensuring that the crane is
without risk to health and safety.
2.2 Assessing the risks

A risk assessment involves considering what could happen if someone is exposed to a hazard
combined with the likelihood of it happening. A risk assessment can help you determine:
how severe a risk is
whether existing control measures are effective
what action you should take to control the risk
how urgently the action needs to be taken.
A risk assessment is unnecessary if you already know the risk and how to control it.
To assess the risk associated with the hazards you have identified, you should consider the
following:
What is the potential impact of the hazard?
How severe could an injury or illness be? For example, lacerations, serious or fatal
crushing injury, electric shock
What is the worst possible harm that an incident could cause? For example, could an
incident cause a fatality or injury to workers or members of the public?
How likely is the hazard to cause harm?
Is it highly likely or unlikely to happen?
How frequently are workers and the public exposed to the hazard?
Factors to consider include:
the condition of the crane, for example, its age, maintenance history and how frequently
it is used
the suitability and stability of the crane
the location of the crane, for example, its impact on the design and layout of the
workplace, environmental conditions, access and egress
abnormal situations, for example, misuse or fluctuation in operating conditions.
2.3 Controlling risks

The ways of controlling risks associated with plant are ranked from the highest level of
protection and reliability to the lowest. This ranking is known as the hierarchy of risk control. The
WHS Regulations require duty holders to work through this hierarchy to choose the control that
most effectively eliminates or, where that is not reasonably practicable, minimises the risk in the
circumstances.
The hierarchy of control measures
Elimination the most effective control measure is to remove the hazard or hazardous work
practice associated with the plant. For example, undertake work at ground level to eliminate the
use of cranes and the need to work at height, or plan the work so that only one lift is required to
eliminate multiple crane lifts.

If elimination is not reasonably practicable, you must minimise the risk by:
Substitution substitute the plant (or hazardous parts of it) with plant that is safer. For example,
replace an operating cabin that has a restricted field of vision with one that has a clear field of
vision.
Isolation separate the hazardous plant from people, either by distance or physical barrier. For
example, use concrete barriers to create an exclusion zone to separate mobile plant from crane
operations and workers.
Engineering controls include modifications to plant, for example, enclosing the operator with a
falling objects protective structure (FOPS) and a roll over protective structure (ROPS) to
minimise the risk of being struck by a falling object or being crushed if the crane overturns.
Administrative controls if risk remains, it must be minimised, so far as is reasonably
practicable, by implementing administrative controls. For example, crane cleaning or
maintenance procedures could:
require that all controllers are placed in the "off" position and the main switches are open
and locked, or
controls are locked out and tagged to prevent accidental start-up.
Personal protective equipment (PPE) any remaining risk must be minimised with suitable
PPE, such as providing workers gloves, hard hats, and hearing or eye protection.
Administrative control measures and PPE rely on human behaviour and supervision, and used
on their own, tend to be least effective in minimising risks.
Combining control measures
In many cases, a combination of control measures will provide the best solution. . For example,
control measures to reduce the risk of persons working in the same area from being struck a
crane or its load could include a combination of the following:
separating workers in a work area from the crane operation through physical barriers
(isolation)
installing motion limiting devices to prevent the crane or part of the crane moving outside
of its designed range of motion (engineering)
developing and implementing a traffic management plan for any traffic control required
(administrative)
requiring all workers to wear high visibility reflective clothing or vests (PPE).
2.4 Maintaining and reviewing risk control measures

R. 37: Control measures must be maintained so that they continue to protect workers and other
people from the hazards associated with plant. The control measures must be:
fit for purpose
suitable for the nature and duration of the work
installed, set up and used correctly.
R. 38: A person conducting a business or undertaking must review and as necessary revise
control measures:
when the control measure is not effective in controlling the risk
before a change at the workplace that is likely to give rise to a new or different health and
safety risk that the control measure may not effectively control
if a new hazard or risk is identified
if the results of consultation indicate that a review is necessary
if a health and safety representative requests a review.
The control measures that are implemented must be reviewed and, if necessary, revised to
make sure they work as planned and that no new hazards have been introduced by the control

measures. Controls can be checked by using the same methods as in the initial hazard
identification. Common methods include workplace inspection, consultation, testing and
analysing records and data.
When deciding how frequently to carry out a review, you should consider the level of risk (high
risk plant may need more frequent review) and the type of plant involved (there may be
particular stages in the life of the plant where a more frequent review is needed).

3. BEFORE USING CRANES IN THE WORKPLACE
3.1 Planning the work

R. 219: The person with management or control of plant at a workplace must ensure, so far as
is reasonably practicable, that the plant used is specifically designed to lift or suspend the load.
If it is not reasonably practicable to use plant that is specifically designed to lift or suspend the
load, the person must ensure that:
(a) the plant does not cause a greater risk to health and safety than if specifically designed
plant were used; and
(b) if the plant is lifting or suspending persons, the use of the plant complies with
regulation 220.
Planning is the first step in ensuring that lifting of a load is done safely. Planning includes:
development of an initial scope of work
selection and acquisition of the crane(s)
planning, programming, scheduling and organising the work
managing the work.
Planning for crane operations should start as early as possible and involve consultation,
cooperation and coordination with all persons engaged in the work. These persons may include
the principal contractor and/or crane hirer, crane manufacturer and/or supplier, installer,
electricity authority, designer (for example an engineer), contractors, crane operator and crane
crew.
Effective planning will help identify ways to protect persons who are:
installing, erecting, climbing and dismantling cranes
directly involved in the lifting operation, such as crane the operator, dogger and/or rigger
performing other work activities at the workplace
in an area adjacent to a crane, including a public area.
Some of the issues to be considered when planning for general crane operations include:
determining scope of work and the appropriate crane for the work to be undertaken
ensuring that the ground conditions are adequate to support the weight of the crane and
loads while conducting the planned lifts
identifying the most appropriate location to site the crane to undertake the planned lifts
and in relation to other buildings, structures and plant at the workplace
ensuring there is adequate workplace access and egress for the crane, equipment,
people and other mobile plant/vehicles
liaising with electricity supply authorities regarding the control measures for working near
overhead electric lines
ensuring that the appropriate number of persons are available to support safe crane
operations.
Additional issues to consider when planning tower crane operations include:
determining crane requirements, including loading bays and site access, at the project
design stage
minimising the number of cranes on site to reduce the likelihood of collision between
cranes and/or other plant
ensuring that each tower crane can be installed at an acceptable distance away from
any other tower crane and concrete placement booms, and
ensuring there is adequate clearance distances maintained (for example, between the
crane and structure being constructed or plant on the structure)

3.2 Selecting a crane
It is important to select the type and number of cranes to suit the particular needs of a
workplace and the work to be undertaken. Hazards can be introduced if crane characteristics do
not match the work requirements and work environment.
When selecting a crane, the size and characteristics of the crane should be assessed including:
the workplace conditions, including the ground on which the crane is to be set up, wind
conditions, access roads and ramps it must travel on, space for erection, and any
obstacles that may impede access or operation
the weights and dimensions of loads to be lifted and the locations of the loads relative to
the crane
the range of lift heights and radii from the crane and the weight of the loads to be
handled at these points
the number and frequency of lifts to be made
the length of time that the crane will be required at the workplace
the type of lifting to be done (for example, precise placement of loads)
the type of carrier requiredthis depends on ground conditions and machine capacity in
its various operating quadrants
whether loads are to be walked or carried
whether loads may need to be suspended for lengthy periods of time.
If you purchase a crane that requires design registration, the supplier must provide you with the
plant design registration number.
Second-hand cranes
R. 199-200: A supplier of second-hand plant must ensure, so far as is reasonably practicable,
that any faults that may give rise to health and safety risks are identified. The supplier must
provide information in writing about the condition of the plant and any identified faults or, if the
plant is supplied only for spare parts or scrap, that it is not to be used as plant.
The inspection and maintenance history of second-hand cranes should be requested prior to
purchase, in addition to plant design and item registration details (where required). Where the
crane has been in service prior to purchase and information on its condition and safe use is not
available, a competent person (for example, a qualified mechanical engineer) should be
engaged by the supplier to assess the crane and develop this information.
Where a second-hand crane has been imported from overseas, the importer or supplier must
obtain design and item registration, where required, prior to use.
3.3 Hiring cranes

When you hire a crane you and the person you have hired it from will both have duties for
health and safety. This is because during the time that the crane is in your possession or
operating at your workplace you will have some control over the way the crane is used.
Any person hiring or leasing crane to others will have duties as a supplier of cranes and as a
person with management or control of cranes in the workplace. This means that they must
ensure, so far as is reasonably practicable, that the crane is safe to use and properly
maintained. They must also provide specific information with the crane including on how to
operate it safely.
Before you hire the crane you should ensure that the crane is suitable for its intended use. If
you do not have the knowledge or expertise regarding crane specifications, limitations and
operational requirements, you should consult the crane supplier and provide all relevant
information regarding the nature of the work, the workplace and the type of lift to enable the

supplier to provide the appropriate crane. You should also check that the crane has been
inspected and maintained by the owner according to the manufacturers specifications. This
may involve checking the log book or maintenance manual. You should also ensure that the
hirer provides you with the manufacturers information about the purpose of the crane and its
proper use.
In most cases the supplier will be responsible for inspecting and maintaining the crane.
However, if the crane is to be hired for an extended period of time, you and the supplier may
develop arrangements to ensure that the crane is adequately inspected and maintained
throughout the lease. This may involve the supplier coming to your workplace to maintain the
crane, or you maintaining the crane while it is at your workplace.
The arrangements you make will depend on your ability to inspect and maintain the crane in
accordance with the manufacturers specifications. If you choose to maintain the crane yourself
during the lease, you should provide all information and records about the maintenance to the
supplier at the end of the lease.
3.4 Registering cranes

Certain plant designs and items of plant must be registered under Schedule 5 of the WHS
Regulations before they are used in the workplace (referred to as registrable plant). Cranes
that are registrable plant must be design registered before they are supplied and, where
necessary, item registered before they are used.
Design Item
Crane
Registration Registration
Tower crane
Self-erecting tower crane
Mobile crane with a rated capacity of greater than 10

tonnes
Gantry cranes with a safe working load greater than
-
5 tonnes
Bridge cranes safe working load greater than 10
-
tonnes
Hoists with a platform movement exceeding 2.4
-
metres, designed to lift people
Vehicle hoists -
Further information on registering plant is available in the:

Code of Practice: Managing Risks of Plant in the Workplace, and
Code of Practice: Safe Design, manufacture, Import and Supply of Plant.
Design Registration
Design registration is the registering of a completed design, from which any number of
individual items can be manufactured. The person applying for design registration may be either
the original designer or the person with management or control of the crane.
A crane design must be registered if the crane requires design registration and
the design has not already been registered, or
you significantly change the crane design by modifying the crane.

When a design is registered, the WHS regulator must issue a crane design registration number
and this number must be provided by the supplier to the person with management or control of
the crane at a workplace.
The person with management or control of plant must keep the design registration number in a
readily accessible location in the vicinity of the crane at all times.
Changes to design registration
R. 244: If the design of an item of plant specified in Part 1 of Schedule 5 that is registered under
this Part is altered, the altered design must be registered.
R. 282: A registration holder must give the regulator written notice of any change to:
the registration holder's name; or
any of the information referred to in the design registration application or additional
information requested by the WHS regulator
within 14 days after the registration holder becomes aware of the change.
If a registered crane design is altered or modified so as to require any new risk control
measures or if there is any change to any information provided at the time of design registration
(or in relation to the registration itself), the WHS regulator must be notified in writing within 14
days.
Where an alteration has been made to the design of a crane the person making the design
change is a designer and has designer duties. For crane design alteration it is likely that the
designer will need to perform engineering calculations on the crane design to determine that it
complies with relevant technical standards.
Item registration
Plant item registration applies to a specific item of plant and each item requires registration. It is
the responsibility of the person with management or control of plant to ensure that all registrable
plant items are registered.
In order to have a crane item registered, it must be inspected by a competent person and a
statement provided to ensure that it is safe to operate.
A person is competent to inspect a crane for item registration purposes if the person:
educational or vocational qualifications in an engineering discipline relevant to the plant
to be inspected, or
knowledge of the technical standards relevant to the crane to be inspected.
Once the crane is registered
The WHS regulator will issue a registration document including an item registration number.
The registration document must be kept and made available for any inspection required under
the WHS Act.
The item registration number must be permanently marked on the crane in a location that will be
readily accessible. It will generally be a simple task to mark large cranes with the item
registration number by either stamping or etching the number onto a structural member or by
fixing the number in place on a plate in a position that will not lead to damage or removal over
time.
On some items, such as a tower crane that may comprise many parts assembled in variable a
configuration to suit a particular site, it may not be feasible to mark each component of the
plant. In such cases the item registration number should be marked on those components that
are readily accessible and able to be seen when the crane is fully assembled.

Item registration renewal
Plant item registration must be renewed every five years. An application for registration renewal
requires a declaration that the crane has been maintained, inspected and tested in accordance
with the WHS Regulations.
Changes to item registration
R. 282: A registration holder must give the regulator written notice of any change to:
the registration holder's name; or
any of the information referred to in the item registration application or additional
information requested by the WHS regulator
within 14 days after the registration holder becomes aware of the change.
You must inform the WHS regulator if:
the crane is altered to the extent that it requires new risk control measures
the crane is usually at a fixed location but has been moved or relocated, or
the registration holder no longer has management or control of the item of crane.
3.5 Training, information, instruction and supervision

S. 19: A person conducting a business or undertaking must provide relevant information,
instruction, training and supervision necessary to protect all persons from risks to their health
and safety arising from the work carried out.
R. 39: A person conducting a business or undertaking must ensure that information, training
and instruction provided to a worker is suitable and adequate having regard to:
the nature of the work carried out by the worker
the nature of the risks associated with the work at the time of the information, training and
instruction, and
the control measures implemented.
The training provided must be readily understandable by any person to whom it is provided.
Information, training and instruction for crane operations should include:
the safe work procedures to be used in the setting up and safe operation of crane
activities, such as traffic rules and clearances from overhead electric lines
knowledge of the crane manufacturers operation and service manuals
the method for inspection and maintenance of cranes
the correct use, care and storage of tools and equipment, including personal protective
equipment
emergency procedures.
Crane operators should be closely supervised until they are competent in operating the crane.
Where necessary, the person operating the crane and persons working with a crane (for
example, a dogger or rigger) must hold an appropriate high risk work (HRW) licence.
Management systems should be in place to:
ensure only those workers who hold an appropriate high risk work licence and/or have
received the required training and instruction and are deemed competent are authorised
to carry out the work
sufficiently monitor the work to ensure that agreed safe work procedures are being
adhered to, including the use of personal protective equipment.
The necessary safety information must also be provided to persons who are involved in
installing, commissioning, testing, maintaining or repairing plant, as well as decommissioning,

dismantling or disposing of plant. This should include information on the types of hazards and
risks the plant may pose to the person when they are involved in these activities.
Familiarisation training
Cranes can be fundamentally different in their design, mode of operation, control layout and
configuration. For example, there are three different types of tower crane: luffing, hammerhead
and self-erecting tower cranes.
Familiarisation training provides crane operators with an opportunity to be familiar with the
design, layout, operating functions and maintenance/inspection requirements of a specific
crane. This training should be provided to crane operators prior to commencing work on a crane
for the first time. This process may involve a representative from the crane supplier or
manufacturer, particularly when the crane is new. The representative should have detailed
knowledge of the operational and safety features of the crane and should also be endorsed by
the crane supplier or manufacturer as being competent to deliver any familiarisation training.
Refresher training
Regular refresher training should be provided to persons who work as part of a crane crew (for
example, crane operators, doggers and riggers). Refresher training will enable the crane crew
to maintain the competencies originally achieved in the relevant licence class for performing
high risk work and the familiarisation training relevant to the cranes they are working with.
Refresher training should include:
the application of new technology, particularly for those persons who obtained their
licence class while working on more basic cranes
health and safety hazards, risks and controls
safe crane operation, maintenance and inspection
any relevant changes to workplace health and safety legislation, manufacturers
instructions and technical standards that may have an impact on safe crane operation.
Refresher training may include:
conducting a training needs analysis to identify the particular training needs of individual
workers
providing technical and theoretical information, where required
providing practical demonstration and supervision.
3.6 Installation and commissioning of cranes

R. 201: A person that installs, constructs or commissions plant must ensure that the plant is
installed, constructed or commissioned having regard to:
the information provided by the designer, manufacturer, importer or supplier of the plant
under the Act and these Regulations, or
the instructions provided by a competent person to the extent that those instructions relate
to health and safety.
R. 204: A person with management or control of plant at a workplace must:
not commission the plant unless the person has established that the plant is, so far as is
reasonably practicable, without risks to the health and safety of any person
ensure that a person who installs, assembles, constructs or commissions the plant is a
competent person and is provided with the available information for eliminating or
minimising risks to health or safety, and
ensure that the processes for the installation, construction, and commissioning of plant
include inspections that ensure, so far as is reasonably practicable, that risks associated
with these activities are monitored.

Installing and commissioning cranes involves performing the necessary adjustments, tests and
inspections to ensure the crane is in full working order and meets the specified requirements
before it is used. It also involves ensuring that:
the crane is installed and/or commissioned in accordance with the crane designers or
manufacturers instructions and any specified technical standards
the proposed method for installing or commissioning the crane will not adversely affect
other plant and structures in the vicinity
installing and commissioning activities are supervised by a competent person
only parts and components that meet the specifications of either the crane manufacturer
or a competent person are used
the components are assembled in the correct sequence using appropriate tools and
equipment (including special tools, jigs and appliances)
the crane is stable during installing and commissioning
adequate fall risk controls are implemented where workers are working at a height
access to and egress from the crane complies with the relevant technical requirements
environmental factors, such as ground load bearing capacity, wet or windy conditions
are considered
all relevant electrical installations associated with the crane comply with AS/NZS 3000:
Electrical installations.
Falling objects
Installing and commissioning activities may include a risk of persons being struck by falling
objects. Control measures based on a risk assessment should be implemented to minimise the
risk. For example:
erect and maintain effective barricades at an appropriate distance around the work area
to prevent access - only persons who are directly involved in crane installation and
commissioning activities are to be allowed inside this area
erect and maintain protective hoardings to protect persons in the vicinity of the work, or
schedule the crane installation and commissioning to occur when the movement of other
persons and mobile plant at the workplace is at a minimum.
3.7 Public safety and site security

Adequate public safety must be maintained in areas adjoining the workplace (for example, on
roads, walkways, water courses). Control measures to protect the public include street closures,
hoardings, scaffolding and other types of overhead protection, used either singly or in
combination.
R. 298: A person with management or control of a workplace at which construction work is
carried out must ensure, so far as is reasonably practicable, that the workplace is secured from
unauthorised access.
Further guidance on securing a construction workplace is available in the Code of Practice:
Construction Work.
3.8 Emergency Plan

R. 43: A person conducting a business or undertaking must ensure that an emergency plan is
prepared for the workplace that provides procedures to respond effectively in an emergency.
Check that the workplace where the crane will operate has an emergency plan to provide an
effective response in various types of emergencies, including how to evacuate people from the
vicinity of the crane in a controlled manner. Contact numbers for emergency services should be
prominently displayed.

A reliable and effective means of communication should be established between all workers in
the vicinity of the crane to permit and ensure effective evacuation of danger areas.
Rescue equipment for the prompt removal of an injured worker, including retrieval of the
operator, as well as a communication system to contact any necessary ambulance service,
should be available and readily accessible.
Emergency procedures should be communicated to all workers and may include:
a warning system
safe and rapid evacuation procedures, including for injured persons
having trained personnel to respond to and oversee the evacuation of injured persons
appropriate medical treatment and evacuation of injured persons
shutting down of the crane
provision of fire fighting and rescue equipment at appropriate locations
display of evacuation procedures in appropriate location(s).

4. USING CRANES IN THE WORKPLACE
4.1 Crane documentation and markings

Load charts
Each crane has a specific load chart that sets out how its lift capacity varies when considering
how the crane is set up, the weight of the load, boom extension and boom angle. Using the load
chart correctly is critical to ensure safe crane operation.
Where the crane has one main load chart, this should be fixed in the operators cabin in a
clearly visible location. Where the crane has numerous load charts (for example, for different
boom and fly jib configurations) the charts must be easily accessible for the operator to verify
that the crane is not overloaded and may be kept electronically or in hard copy.
The lifting capacity of a crane is limited by:
structural strength when the working radius is small
stability when the working radius is greater.
If a crane is overloaded in the structural area of the load chart a structural or mechanical
component of the crane may fail. However, if the crane is overloaded in the stability area of the
load chart the crane may overturn.
The lifting capacities specified on a load chart must never be exceeded except during testing of
the crane by a competent person under controlled conditions.
On some mobile cranes there may be numerous load charts for differing boom and
counterweight configurations. The load charts may be complex and include numerous
conditions that must be complied with to ensure the crane can safely lift a load. Two important
factors that are often overlooked when reading load charts are:
The need to subtract the mass of the hook block and lifting slings from the capacity of
the crane at the particular radius, unless otherwise noted on the load chart. For example,
if the load chart states that the crane can lift 20 tonnes at a given radius but the hook
and lifting gear have a combined mass of one tonne the load to be lifted cannot be
greater than 19 tonnes. This issue becomes critical for heavier hook blocks and lifting
gear (for example, spreader beams).
The need to subtract the mass of the fly jib from the capacity of the main hook when
lifting from the main hook on the main boom with a fly jib attached to the boom head
(unless this is allowed for and noted on the load chart). Capacities of the main boom are
generally based on the fly jib being removed. If this issue is ignored, the likelihood of the
crane overturning can be very high.
Crane markings
A mobile crane and its lifting components should be marked permanently and legibly in English.
All operator controls must be suitably marked to indicate their function and operation. The
cranes computer should be compatible with these requirements and indicate the control
function, options and settings.
4.2 Crane operating personnel

A risk assessment will assist in determining the number and competency of persons required in
the crane crew to ensure the safe operation of the crane at a workplace. The work
arrangements must eliminate or minimise the risk of collision between the crane and other plant,
and loads contacting other structures, overhead electric lines or persons. A risk assessment
should consider the plant to be used and the size and complexity of the lifts to be performed
when determining a crane crew, including crane operators and persons to sling loads.

4.3 Licences
High risk work licences
The high risk work licences required to perform work with cranes are set out in Schedule 3 of
the WHS Regulations. These include licences for crane operators, doggers and riggers.
Where the person responsible for slinging a load is required to exercise judgement in relation to
the suitability and condition of lifting gear and the method of attaching the sling (including sling
accessories) to the load or crane, then this person must hold a dogger or rigger high risk work
licence or be an adequately supervised trainee. A crane operator may only supervise a trainee
in performing the work of a dogger if the crane operator also holds a doggers licence.
A matrix showing the types of plant that require registration and/or an operator with a high risk
work licence is included at Appendix C.
A person who carries out work with a crane is not required to be licensed as a crane operator if
the work is carried out:
in the course of training towards certification to be licensed and the person is under the
supervision of a person licensed to carry out the high risk work
is solely for the purpose of manufacture, testing, trialling, installation, commissioning,
maintenance, servicing, repair, alteration or disposal of the plant or moving the plant in
the workplace (see also below) and the plant is operated or used without a load (except
when standard weights with predetermined fixing points are used for calibration)
the work is limited to setting up or dismantling the crane, and the person carrying out the
work holds a licence in relation to rigging, which qualifies the person to carry out the
work.
Moving plant in the workplace does not include loading or unloading the plant from a vehicle or
equipment used to move the plant.
Drivers licence requirements
Operators of cranes are required to hold the appropriate class of drivers licence before driving a
mobile crane on a road. This means that a person who has been granted a licence class to
operate a mobile crane must also hold the appropriate class of drivers licence to drive that
mobile crane on a road.
4.4 Setting up the crane

Siting the crane
The siting of cranes should be considered in the planning phase and occur after careful
consideration of the relevant factors, including:
the crane overturning or collapsing due to:
o the failure of the foundations or structure (crane standing) supporting the crane
o failure of the crane to withstand the forces likely to be imposed on it
collision between the crane with other plant and structures at the workplace.
Mobile cranes
R. 214: The person with management or control of powered mobile plant at a workplace must
manage risks to health and safety associated with the plant overturning.
A mobile crane can be set up in a range of locations and environmental conditions. Some
mobile cranes (pick and carry) can also carry a load while moving (mobiling). Crane design,
ground conditions and loads need to be considered when siting and setting up a mobile crane
(see Appendix D).

Tower cranes
When siting a tower crane, consider the working radius of the crane in relation to:
other permanent or temporary plant and structures
common access areas for workers and other persons at the workplace
public access areas, such as footpaths, roadways and railways.
The size and design of tower crane bases must take into account factors such as tower height,
wind speed, terrain type, ground type and bearing capacity, boom length and crane lifting
capacity.
Crane standing
The design of the crane standing must conform to the crane manufacturers instructions and be
capable of withstanding the forces likely to be imposed on it by the crane while in-service, out-
of-service, and during erecting and dismantling. These forces include:
dead weight of the crane
dead weight of the load and any lifting attachments
dynamic forces caused by movements of the crane
wind loadings
other loads as identified by the designer of the crane standing.
When a crane is to be supported on, or tied to, a permanent or temporary structure, the design
of the structure must be capable of withstanding the forces designed to be imposed on it by the
crane ties. Adequate precautions should also be taken to ensure the stability of the crane when
the crane will be sited in the vicinity of underground services, excavations or embankments.
Collision between the crane and other plant and structures
manage risks to health and safety associated with the plant colliding with any person or thing.
R. 215 (4): The person must ensure that the plant does not collide with pedestrians or other
powered mobile plant.
The siting of a crane should consider hazards such as:
overhead electric lines and other services
nearby structures
other cranes or high obstructions, including those on adjacent workplaces (for example,
concrete placement booms)
other mobile equipment moving within the crane working area
the vicinity of airports and aircraft flight paths for high cranes.
Cranes should be positioned to maintain sufficient clearance between the crane and its load
and other plan, structures and workers. A collision between the crane or its load and other plant
or structures may:
damage crane components, such as the boom, may seriously weaken the component
leading to structural collapse of the crane and/or loss of load
result in overturning cranes or other plant
result in dropped loads
damage the structure or other plant making it unsafe
result in injury to persons in the vicinity of the crane, including workers and members of
the public.
A risk of injury from collision may exist for example where:
a concrete placement boom is working within the tower cranes operating radius, or
tower cranes located on adjacent sites are operating in the same air space.

When cranes operate in adjacent areas, they may share the same airspace. The persons in
control of each work area should consult and develop safe systems of work to ensure sufficient
clearances are maintained between the cranes. Each work area should nominate a person who
has a responsibility to implement the safe system of work to minimise the risk of collision.
This issue is particularly important where mobile cranes are set up on public roads. In this
situation, the traffic control procedures of the road controlling authority must be complied with.
Where cranes are set up in or near flight paths the local airport operator must be contacted to
ensure the requirements of the Civil Aviation Safety Authority (CASA) are met. Where
necessary, aircraft warning lights will need to be fitted to the highest part of the crane.
Tower cranes
A documented procedure, such as a safe work method statement, should be prepared to
minimise the risk of injury from a collision. This procedure should address the following issues:
siting cranes to minimise the need for other plant to operate within the cranes operating
radius
siting cranes and other plant that have counterweights so that the counterweights cannot
collide with other counterweights, plant, structures of persons during slewing operations
the method of communication between the crane crew and other plant operators
scheduling of work to minimise the time the crane and other items of plant are required
to work in the same area, or at the same height
the tower cranes climbing procedure to ensure the crane remains as far above any
structure or plant (for example, jump forms) as practicable
the frequency of regular meetings to monitor and review the effectiveness of control
measures and who should attend such meetings.
Where tower cranes share the same air space but are sited on adjacent workplaces, the
principal contractor from each workplace should consult and cooperate the other to implement
safe systems of work (for example, within the WHS management plans) to ensure sufficient
clearances are maintained between cranes, minimising the risk of collision. The system of work
should identify persons from each workplace who have this responsibility, scheduling
requirements for crane operations, and a clear method of communication between the
workplaces.
Overhead electric lines
R. 166: A person conducting a business or undertaking must ensure, so far as is reasonably
practicable, that no person, plant or thing at the workplace comes within an unsafe distance of
an overhead electric line.
If this is not reasonably practicable, the person must ensure that a risk assessment is
conducted in relation to the proposed work and control measures implemented are consistent
with the risk assessment and, if an electricity supply authority is responsible for the electric line,
any requirements of the authority.
Siting of the crane must prevent contact with overhead electric lines. Contact with electric lines
while operating a crane can pose a risk of electrocution and crane failure. It can be extremely
difficult for crane operators to see electric lines and to judge distances from them.
Careful planning and preparation is essential to ensure that work is done safely when operating
a crane in the vicinity of overhead electric lines. Consideration should be given to:
identifying the nature of the work, the height and voltage of electric lines and the
proximity of the crane to overhead electric lines
consulting the electricity supply authority about the work and complying with any
conditions imposed by them

eliminating the risk by arranging for the electricity supply authority to isolate the
electricity supply for the duration of the work
establishing and implementing approach distances to energised electrical conductors
and no-go zones in the work area
providing an effective communication system between workers at the site
ensuring a safety observer is used whenever mobile plant is in motion and is likely to
come closer than the approach distances
ensuring the operator has the appropriate training and competency to undertake the
work
emergency rescue procedures.
Approach distances to energised electrical conductors are set out in the Code of Practice:
Working in the Vicinity of Overhead and Underground Electrical Lines. This Code also provides
information about the type of controls that should be in place when work is undertaken within
unsafe distances.
4.5 Crane stability

Failure to maintain stability is one of the key factors associated with serious crane incidents.
Things to consider are:
crane operation parameters that result in an overturning moment greater than the
stabilising moment of the crane - the crane counterweight generally provides the primary
stabilising moment
the ground conditions and means of supporting the outrigger pads or the crane tyres
the slope of the ground - both side slope and slope in direction of crane travel
wind conditions - this will vary depending on the size and shape of the suspended load
and crane boom
the manner in which loads are to be lifted or moved (for example, when mobiling a
load a sudden stop may cause the load to swing, destabilising the crane).
Wind conditions
Strong winds impose additional loads on a crane and affect the cranes stability. For example, a
maximum permissible wind speed of 10 m/second (36 km/hour) is specified for mobile crane
operation by some crane manufacturers. Crane configurations designed for wind speeds other
than 10 m/second should have the design wind speed marked on the rated capacity chart.
Where wind speeds exceed the maximum figure stated by the crane manufacturer for a specific
mobile crane, crane operations should cease and the crane stowed. Crane operators should
recognise that dependent on the boom length and luffing angle, the wind speed may be greater
at the height of the load compared to the wind speed at the height of the cranes cabin. Also, the
effect of wind gusts will have a different effect on the crane than a constant wind. Given these
variables, crane operators must base their decision to make a lift based on the information
provided by the crane manufacturer, advice provided by competent persons, such as an
engineer or rigger, and their experience as a crane operator. If the operator believes it is unsafe
to lift the load, it should not be lifted until written authorisation is provided by a competent
person, confirming that the load is safe to lift and how it is to be lifted.
For example, mobile cranes must be operated within their engineered design capacity. To
ensure the stability of a mobile crane in windy conditions, the following factors should be
addressed:
The crane manufacturers instructions should state the maximum wind speed that the
crane may be operated in irrespective of the size of the load.

Although a crane manufacturer may specify a maximum wind speed, a lower wind speed
may need to be applied, for example, where the load and boom have large surface
areas.
Where the crane is lifting close to its rated capacity, wind speed is a critical factor as the
safety margin is lower and wind can more easily impact on the cranes stability.
Where the lift is a non-standard lift, with a suspended load or large surface area to be
undertaken in windy conditions, a competent person should provide written advice on
safe lifting conditions (for example, a lower maximum wind speed than that identified by
the manufacturer may need to be applied).
A wind gauge attached to a mobile crane or another reliable method of measuring wind
speed (for example, handheld wind gauge) is recommended. Where wind gauges are
attached to the crane, they should be mounted at the top of the main boom, and
calibrated at predetermined intervals, to ensure they provide accurate readings.
Guidance should be obtained from the crane manufacturer or supplier.
Further information on crane stability is included at Appendix D.
4.6 Documented lifting procedures

Documented lifting procedures can greatly assist with safe crane operation as they help to
define responsibilities and approach the crane lift in a logical, systematic way. For example,
comprehensive documented lifting procedures should be developed in the following situations:
tilt-up and precast concrete lifts
multiple crane lifts, where more than one crane is used to lift a load at any one time
lifting of workboxes with persons in the boxes
installation of bridge beams during bridge installation work
working near live overhead electric lines
lifting large pressure vessels or tanks
the use of mobile cranes on barges
erection of tower cranes
erection of wind turbines
heavy lifts (for example, where the load is 50 tonnes or more).
Documented lifting procedures for the lift types mentioned above should include the following:
specification of the loads to be lifted
specified load working radius range to be used for the cranes
where spotter duties are required (for example, for preventing collision or contact with
electric lines), what the duty is and who is responsible for performing the duty and
communications systems to be used
position of the load to be lifted and the final position to which it is to be lifted, where
practicable (for example, a diagram that shows a plan view of the site may assist)
maximum wind speed for the crane and any lower wind speeds for specified loads, for
example, where the load has a large surface area
verification that the crane standing will support the maximum ground bearing pressure to
be imposed by the crane during operations - this is particularly important when
performing heavy lifts
allowance for any factors that may require de-rating of the crane (for example, for
multiple crane lifts, additional radius caused by tilting of tilt-up panels)
rigging requirements of the job.
Construction work
The erecting and dismantling of a tower crane is construction work and therefore Chapter 6 of
the WHS Regulations will apply.

The WHS Regulations define a number of construction activities as high risk construction work.
Some examples of high risk construction work that may be related to or involve the use of
cranes includes construction work that:
involves a risk of a person falling more than 2 metres
is carried out on a telecommunication tower
is carried out on or near energised electrical installations or services
involves tilt-up or precast concrete
is carried out in an area at a workplace in which there is any movement of powered
mobile plant.
Safe work method statements (SWMS) must be prepared for high risk construction work.
SWMS may include or be accompanied by a specific documented lifting procedure for a crane
lift.
Further guidance on construction work and SWMS is available in the Code of Practice:
Construction Work.
4.7 Minimising risk when lifting loads

Lifting loads may present a risk to the health and safety of persons in the vicinity of a crane due
to:
damaged or inadequate lifting gear
unexpected crane movement while mobiling and/or or slewing
crane overload or instability, and
poorly secured and dropped loads (falling objects).
R. 219: The person with management or control of a crane at a workplace must ensure, so far
as is reasonably practicable, that:
the lifting and suspending of loads is carried out with lifting attachments that are suitable for
the load being lifted or suspended, and within the safe working limits of the plant
no loads are suspended or travel over a person unless the plant is specifically designed for
that purpose, and
loads are lifted or suspended in a way that ensures that the load remains under control
during the activity.
Limiting and indicating devices
Limiting devices are a higher order engineering control that prevent a specific crane motion
before the crane moves out of its limits into an unsafe situation.
Indicating devices are a lower order engineering control that rely on a persons intervention.
Indicating devices visually or audibly warn the crane operator that the crane may be
approaching its set limits or an unsafe situation.
These devices may be used individually, or together, for specific crane motions and are
intended as an aid to crane operators. The devices should not be relied upon to replace the use
of the cranes load chart and operating instructions under any circumstances. Sole reliance on
these devices in place of good operating practices may cause an accident.
There are a number of devices that can be used including rated capacity limiters. Further
guidance on limiting and indicating devices is provided in Appendix E.
Lifting gear
Lifting gear should be checked before and after use, as well as being regularly inspected for
suitability of ongoing use. Checks should include that:

the lifting gear is tagged and all relevant information listed (for example, relevant
information for a chain sling includes grade of chain, rated capacity, manufacturer, chain
size and any relevant Australian Standard marking)
lifting hooks are provided with operable safety latches
shackles used as terminal fittings are prevented from unscrewing (for example, mousing
or similar)
lifting eyes and inserts are compatible
lifting slings are not damaged (for example, excessive wear, damaged strands, cracks,
deformation or severe corrosion)
the sling is appropriate for loads being lifted, including adequate capacity and protection
from sharp edges.
All lifting gear, including slings, hooks and material boxes, should be periodically inspected for
damage and wear by a competent person and inspection records kept. The period between
inspections will depend on the severity of use, but should generally not exceed 12 months. The
period between inspections of synthetic slings and fibre rope slings should not exceed 3
months.
Where synthetic slings are used, protective sleeves and corner pieces should be used for all
loads. Although the edges of the load may not appear to be sharp, the sling may become
damaged when it is placed under tension.
All lifting gear should be tagged to identify the date of the lifting gears last inspection.
Documented maintenance records for the lifting gear should be available at the workplace.
Unexpected crane movement
Unexpected crane movement while mobiling and/or slewing can cause the load to swing
unexpectedly. Cranes should only be sited and operated on stable surfaces, with adequate
bearing pressure and without significant holes or indentations that may cause unexpected
movement of the crane and the load due to instability.
Crane overload
A crane must not be subjected to overloading. The crane operator and/or dogger should:
verify if the marked load mass is correct and ensure that loads in excess of the cranes
rated capacity are not lifted
control crane movement, including mobiling, to prevent excessive load swing that may
overload the crane.
Before starting to hoist a load, the crane operator or dogger should make sure that the hoist
rope hangs vertically over the load. Care should be taken to ensure that swinging of the load is
avoided when the lift is taken. The crane operator should always have the load under control
when lowering loads, or when the load is suspended.
Except in an emergency, the crane operator should not leave the crane cabin or controls while a
load is suspended from the crane.
Falling objects
Where possible, handling loads over public access areas, such as footpaths, roads, highways,
railways, waterways and buildings, should be avoided. If lifting over these areas cannot be
avoided, appropriate control measures (for example, exclusion zones or suitably designed
gantries) must be in place to control the risk of being hit by falling objects during the lifting
operation.

Exclusion zones
Exclusion zones should be established around cranes and adjoining areas to prevent persons
from entering the area and being injured by falling materials. The size of the exclusion zone
should be based on a written risk assessment.
Where the exclusion zone requires closure of a public footpath or roadway, approval must be
obtained from the relevant authority, and persons should be safely directed to an alternative
footpath. Lane closures and other operations that require the erection of barricades and signs
should comply with the requirements of the local road traffic authority, local government
authorities and any relevant building or local acts.
4.8 Lifting materials

Crane-lifted loads should be slung and secured so that the load (or any part of it) cannot fall.
Loads must not be lifted over a person unless the crane is equipped with secondary back-up
systems that prevent the load from falling if the primary lifting device fails. Loads must be
controlled during while being lifted/suspended by, for example, using tag lines or similar control
devices.
Material boxes
The tare mass and safe working load should be clearly marked on all material boxes.
Material boxes should be appropriate for the material being lifted and be engineer-
designed and certified.
Four chains (one in each corner) should be attached to material boxes during lifting.
Specifically designed material boxes should be used to lift smaller components. Boxes
should have enclosed sides or robust mesh, with openings less than the minimum size
of materials being lifted.
Material boxes should be inspected and maintained and inspection records kept.
Loads within material boxes should be secured against movement.
Materials should not be stacked higher than the side of the material box unless they are
adequately secured, but at no time should the material box become top heavy.
General lifting
Formwork frames should be either tied together or lifting slings should be wrapped
around the load.
Loads of joists or bearers should be strapped together before lifting.
Timber sheeting should be strapped together and lifted in a flat position.
Sheets of plasterboard may be lifted in a specifically designed material box. If a material
box is not used, then the lifting system should:
o be certified by an engineer
o specify the minimum and maximum number of sheets
o specify the number and locations of lifting slings
o specify the capacity of lifting slings.
Tag lines should be used as required to control loads.
All loads should be supported where possible with dunnage, with the load uniformly
distributed over the supporting surface.
Basket hitches should not be used wherever persons may be located near a lifted load,
unless the sling is positively restrained from sliding along the load.

4.9 Lifting people
R. 220: Where people are lifted using plant that is not specifically designed to lift or suspend a
person, the person with management or control of the plant at a workplace must ensure that:
(a) the persons are lifted or suspended in a work box that is securely attached to the plant; and
(b) the persons in the work box remain substantially within the work box while they are being
lifted or suspended; and
(c) if there is a risk of a person falling from a height, a safety harness is provided and worn by
the person in order to prevent, so far as is reasonably practicable, injury to the person as a
result of the fall; and
(d) means are provided by which the persons being lifted or suspended can safely exit from the
plant in the event of a failure in its normal operation.
Work boxes
If it is not practicable to use plant that is specifically designed to lift persons, then a crane-lifted
workbox may be used to enable workers to perform minor work of short duration in an elevated
work area. Generally, crane-lifted work boxes do not provide a level of safety equivalent to
properly erected scaffolding, elevating work platforms and other specifically designed access
systems. However, the use of crane-lifted work boxes is considered to provide a higher level of
safety than fall-arrest systems when used as the primary control measure.
Work boxes must be design registered as required by Schedule 5 of the WHS Regulations.
First aid boxes should be clearly identified as first aid boxes and only used for the retrieval of
injured persons.
When using a crane-lifted work box or a first aid box, the crane should meet the following
criteria:
have at least two brakes, independent of each other where failure of a brake or any
single component in the brake drive train will not result in loss of control of the load, or
a brake acting directly on the hoist drum and a hoisting mechanism or other brake
capable of holding the load when not under power
a minimum rated capacity of at least twice the total load of the workbox and its contents,
at the maximum radius for the task to be performed and not less than a 1000 kg
be fitted with an upper hoist limit (anti-two block) that stops operation of the hoist, luff
and telescope functions of the crane, or be designed so that two-blocking cannot
damage any part of the crane or lifting gear
levers and foot pedals are to be fitted with a constant pressure system that stops the
cranes motions when the operator removes pressure from the controls
if fitted with a free fall facility, the free fall function is to be locked out with a keyed lock
out.
Cranes used to lift a work or first-aid box must be adequately maintained and monitored. Where
a crane has a single brake acting directly on the drum, the braking efficiency of the hoisting
drive train should be tested by hoisting and holding a load:
equivalent to the line pull of the hoist winch, or
not less than twice the maximum hoisted load.
In either case the crane should hoist and hold a load that is not less than 200% of the maximum
hoisted load. With the load stationary, all power and hydraulic/pneumatic power should be
released and the brake backed-off or isolated to the extent it no longer applies a restraining
force. The load is then monitored for movement or creep. The drive train is considered to be a
satisfactory braking system if no movement or creep is detected over a 5 minute testing period.
If the crane is to be used to lift other loads, the above test should be repeated prior to re-lifting
the workbox.

During operation of the crane with a workbox, the line pull of the hoist winch shall not exceed
that used in the above test.
Crane-lifted work boxes and first aid boxes should:
have the safe working load and tare mass and design registration number marked on the
workbox or first aid box
have fall-arrest anchorage points
be correctly tagged lifting slings are to be supplied with the work box or first aid box and
attached to the lifting points by means of hammerlocks or moused shackles
have a safety factor for each suspension sling of at least eight for chains and 10 for wire
rope
if the work box is provided with a door, this should be inward opening only, self-closing
and provided with a latch to prevent accidental opening (first aid boxes may be provided
with outward opening doors)
have sides not less than one metre high.
Safety of persons in crane-lifted workboxes
The following must occur to ensure the safety of persons in a crane-lifted workbox:
all persons in the workbox must wear full body fall-arrest harnesses at all times.
Harnesses must be attached to fall-arrest anchorage points in the workbox or to the
main sling ring above the workers heads
at least one person in the workbox holding a doggers licence must ensure correct
directions are communicated to and from the crane operator, and
emergency retrieval arrangements are implemented prior to the lift to ensure workers
can safely exit the work box in the event of a failure in the cranes normal operation.
4.10 Communication
A reliable method of signalling between the crane operator and dogger (or rigger) is essential
for safe crane operation. Failure to implement a reliable method of communication may lead to
unsafe crane operations and contribute to injury to persons from:
dropped loads
collision with other plant and structures.
Only one dogger should give visual and audible signals at any time. When more than one
dogger is involved in a lift, each dogger should understand when responsibility for their part of
the lifting operation should be handed over to another dogger.
An effective means of communication is particularly important where:
the crane operator cannot see the load
the crane operator cannot see the loads landing area
the crane operator cannot see the path of travel of the load or the crane
the crane operator is not in a position to make an accurate judgement of distance, and
it is possible for the crane to come into contact with overhead electric lines.
Persons using radio equipment should be familiar with the manufacturers operating
instructions. A dedicated radio frequency should be selected for the duration of the crane
operations to prevent interference with other radio equipment being used in the vicinity of the
crane. Work should stop immediately if there is a loss of radio communication.
The safe use of radio communication usually involves:
the crane operator and dogger performing an operating safety check to ensure the
radios are operational, dry, performing satisfactorily and a fully charged battery and
spare are available

ensuring operators are familiar with the specific procedures for using radio
communication for that workplace
adopting a constant talk method between radio users so that all involved persons are
aware of the progress of the lifting operations at all times
ensuring the crane operator takes radio instructions from one person only, unless
special circumstances exist that require specific arrangements to be in place for the use
of more than two radios.
Where radio communication cannot be used, other forms of communication, such as hand
signals and bell, buzzer and whistle signals should be used. Mobile phones should not be used
for directing mobile crane operations.
4.11 Minimising the risk of falling from a height

Persons undertaking the installation, erection and dismantling of some types of cranes will be
exposed to the risk of falling when working at a height.
Undertaking a construction activity where a person could fall more than two metres is high risk
construction work and requires the preparation of a safe work method statement before the
work commences.
Risk control measures must be implemented to protect workers from the risk of falls from height.
Control measures can include:
temporary work platforms such as an elevating work platform
travel restraint systems
fall-arrest harness systems
edge protection systems.
Further guidance on controlling the risk of falls is available in the Code of Practice: Managing
the Risk of Falls in the Workplace.
4.12 Operator position

Protective devices
manage risks to health and safety associated with things falling on the operator of the plant.
R. 215 (2): The person must ensure, so far as is reasonably practicable, that a suitable
combination of operator protective devices for the plant is provided, maintained and used.
Suitable operator protective devices must be provided for powered mobile plant, including
cranes. Typically these could include falling object protective structures (FOPS) and operator
restraints. For example, if a person travels in a mobile crane operators cabin while the crane is
driven by another person, a seat belt is required.
Safe means of access
Cranes should be fitted with safe means of access that allow the crane operator to safely
access the crane cabin and other frequently accessed areas of the crane. Safe access includes
the provision of ladders, footholds, steps and grabs rails.
Access provisions provided by the crane manufacturer should not be removed or modified
unless a competent person specifies otherwise.
Seating
The design of crane seating should take account of the extensive periods of time the crane
operator may spend in the seat. The seating should be comfortable, have adequate back
support and be adjustable so that the crane controls can be easily accessed by the operator.

Windows and windscreens
Clear vision must be provided in the operator's cabin at all times. Windows and windscreens
need to be easily accessible for regular cleaning.
Working in heat
Heat stress may occur in hot work environments when heat is absorbed faster than the body
can release it. One way to reduce heat stress on crane operators is to minimise the heat in the
crane cabin. Temperature control units supplied with the crane should be maintained and kept
in a serviceable condition according to the crane manufacturers instructions.
Further information on managing hot environments is available in the Code of Practice:
Managing the Work Environment and Facilities.
4.13 Noise
Activities, such as the erection or dismantling of tower cranes, and in particular, the use of an
impact wrench, create noise which can damage hearing immediately. This type of noise is
particularly damaging to hearing because of its high impulsive noise levels. Other loud noise, for
example that is created by the operation of a cranes diesel engine without sound proofing, will
gradually damage a persons hearing after repeated exposures.
Engineering controls, such as enclosing the engine in a sound proof cabinet, should be applied
to manage exposure to the noise created by the operation of a tower cranes diesel engine.
Further guidance about managing risks associated with noise is available in the Code of
Practice: Managing Noise and Preventing Hearing Loss at Work.

5. INSPECTION, MAINTENANCE, REPAIR AND DISMANTLING
5.1 Inspecting and testing cranes

Failure to carry out appropriate planned inspections, tests and preventative maintenance
programs in accordance with the manufacturers instruction or those of a competent person may
lead to structural or mechanical failure, collapse, decreased safety and efficiency in the
operation of cranes.
Inspection and appropriate testing should be carried out frequently to ensure parts of the crane
subject to deterioration through corrosion, damage, wear or abrasion are replaced before they
become unserviceable.
Inspecting and testing of cranes must include the:
major inspection required for registrable mobile and tower cranes
regular inspection and testing required for all plant, and
inspection and testing for plant re-registration purposes.
Inspecting and testing should generally include:
annual inspections
commissioning inspection and tests
routine inspections and maintenance, and
pre-operational inspections.
The inspection and testing regime for tower cranes should also include pre-erection inspection
and testing.
R. 266: An application for the registration of an item of plant must include a statement that the
item of plant has been inspected by a competent person and assessed by that person as being
safe to operate.
Inspection records should include the appropriate competent person statement that the item of
plant has been inspected and is safe to operate. As item registration must be renewed every
five years, major inspection and/or relevant annual inspections will enable appropriate
statements to be prepared for re-registration purposes.
Inspection records should include the following information:
What was looked at (for example, specification of components or areas of the plant
inspected).
What is looked for (for example, checks were conducted for signs of wear, damage,
cracking, corrosion).
What were the pass/fail criteria (for example, specifying rejection criteria in accordance
with requirements of a published technical standard).
How was it looked for (for example, the techniques used, such as visual inspection for
damaged parts, taking of measurements of components and comparing those to
specifications, non-destructive examination & testing).
What was found (for example, specifying the results of the examinations, this may
include photographs or measurements recorded).
What recommendations were made (for example, a competent persons may specify
components are to be replaced, or repaired prior to continued use, or after a nominated
operational period).
What actions were undertaken based on the recommendations made (for example,
recording that recommendations were acted upon, and the date that any tasks were
completed).

Major inspection
R. 235: The person with management or control of a registered mobile crane or tower crane at
a workplace must ensure that:
the maintenance, inspection and, if necessary, testing of the crane is carried out by a
competent person who:
a) has the skills, qualifications, competence and experience to inspect the plant and is
registered under a law that provides for the registration of professional engineers, or
b) is determined by the WHS regulator to be a competent person.
the crane is inspected:
a) at the end of the design life recommended by the manufacturer for the crane, or
b) if there are no manufacturer's recommendations, in accordance with the
recommendations of a competent person, or
c) if it is not reasonably practicable to comply with (a) or (b), every 10 years from the date
that the crane was first commissioned or first registered, whichever occurred first.
A major inspection must be completed for registered mobile and tower cranes. Similarly, bridge
and gantry cranes should have a regular major inspection completed and the results recorded
so that they continue to be safe to operate.
A person with the relevant the skills, qualifications, competence and experience to inspect the
crane (must be a registered professional engineer in Queensland) must oversee and certify the
major inspection. A person who is determined by the WHS regulator to be competent may also
carry out the inspection.
Inspecting a crane
An engineer who has been engaged to oversee a major inspection of a crane should have
suitable knowledge and experience in undertaking major inspections of cranes. This person
should be able to make judgements about the maximum allowable amount of wear and
deformation in mechanical and structural components, and the associated quantifiable pass/fail
criteria. The person should also be able to demonstrate experience in the inspection of the
specific crane type.
In forming their opinion, the person may use the advice of other competent persons involved in
the crane inspection who are not engineers. These decisions should be based on information
contained in the crane manufacturer's instructions, relevant technical standards, sound
engineering principles or a combination of all these.
These other competent persons may, for example, dismantle and inspect specific items for wear
or undertake non-destructive testing and provide a report to the engineer. This work can also be
referred to as part of the maintenance and testing requirements of the major inspection.
A person who inspects, maintains or tests a specific part of a crane for the engineer as part of a
major inspection should have suitable experience and knowledge and be competent in the
inspection of that part of the crane. For example:
A competent person inspecting welding on a crane should have suitable knowledge and
experience in the inspection and testing of welds. This should include knowledge of non-
destructive testing methods and technical standards.
A competent person inspecting hydraulic systems and circuitry on the crane should have
suitable knowledge and experience in the inspection and testing of hydraulic systems.
A competent person inspecting electrical systems on the crane should have suitable
knowledge and experience in electrical systems, including the ability to read circuit

diagrams and understand relevant technical standards. This person must be a qualified
and licensed/registered electrician where the voltage of the electrical system is greater
than 50 volts alternating current or 115 volts direct current.
A competent person carrying out non-destructive (NDT) testing on crane components
should have suitable knowledge and experience in NDT methods, for example, an NDT
specialist accredited by the National Association of Testing Authorities (NATA).
In these instances, the competent person would make a statement that the particular part of the
crane (for example, the welding, hydraulic system or electrical system) has been inspected in
accordance with the relevant technical standard and/or engineering principles and meets (or
not) the manufacturers or a competent persons specifications..
Inspection parameters
A major inspection is more comprehensive than the annual inspection due to the extent of
operation that a crane will be exposed to over time. Even if the crane has not been exposed to
regular operation during the operating period, the crane may have deteriorated due to the way it
has been stored or the environment it has been operated in (for example, dirty or corrosive
environments).
Where the crane manufacturer specifies instructions for the major inspection, these instructions
are to be followed. Where this information is not available or not longer meets accepted
technical standards, a competent person should specify the requirements that provide an
equivalent level of safety to the minimum requirements established by relevant technical
standards. The extent of inspection performed during the major inspection will largely depend
on this information.
However, a number of key items should form part of the major inspection.
Inspecting a mobile crane
For mobile cranes the items to be inspected include:
drive train and suspension components
slew ring
slew ring bolts
hook rollers
drive systems (including hydraulic motors, gearboxes and drive-shafts)
control systems
braking systems
electrical systems
hydraulic systems (all cylinders, including outrigger cylinders)
booms
safety devices, including rated capacity limiters and load indicators
outriggers
steel wire ropes
rope sheaves.
The actual list of items inspected will be considerably larger and will be based on the
requirements of the crane manufacturer and/or the instructions of a competent person. It should
be noted that:
completion of a major inspection does not indicate that the components inspected will
have an additional life of 10 years
it must not be assumed that the items included in the list only require inspection at 10-
yearly intervals. All items will require some type of inspection and maintenance at more
frequent intervals (for example, at annual and other inspection intervals) in accordance
with the crane manufacturers instructions.

Where there is documented evidence that the appropriate inspecting and testing has been
carried out on a certain item (for example slew ring bolts, drive systems and braking systems)
within a reasonable preceding period as determined by a competent person, the item may not
need to be stripped down in the major inspection. However, the competent person must still
inspect the safe operation of the item to certify that it is operating safely and document the
reasons for the decision.
Inspecting a tower crane
A major inspection will involve the examination of the structure and all working components of
the crane. This would usually involve stripping down the crane unless otherwise determined by
the competent person. All covers and cladding must be removed where necessary to enable the
major inspection to be carried out.
A major inspection of a tower crane requires particular attention to be given to the following:
structural, mechanical, electrical, instrumentation, control and operational systems
non-destructive testing examination to an appropriate standard
controls and emergency stop
braking systems
manufacturers safety upgrades
adequacy of safety instructions and manuals
the capacity and viability of upgrading the crane to the requirements of the latest
relevant technical standard.
The items to be inspected for tower cranes, where appropriate, include:
slew ring
hydraulic motors
hydraulic pumps
valve blocks (bodies)
hoist and luff drums
braking systems
rope sheaves
hydraulic luffing cylinder
gear boxes and drive shafts
boom
A-frame
pins with moving parts (for example, boom heel pins, ram pins)
static pins
steel wire ropes
electrical systems
control systems
electric motors
hook trolley (non-luffing cranes)
hook assembly.
The full list of items to be inspected must be determined by the competent person.
Further guidance on tower crane inspections is provided in Appendix B.
Annual inspection
An annual inspection should include all items specified by the crane manufacturer for annual
inspection, as well as all items included in the routine inspection and maintenance programs.
Annual inspections should include:
the effective functioning and calibration of all limiting and indicating devices

detailed visual inspection and tolerance checking of all structural and wear components
checking of tolerances for wear limit
a detailed check for corrosion
a detailed examination of critical areas for evidence of cracking
for tower cranes, all relevant items in the pre-erection inspection and tests that can be
safely completed while the crane is erected.
Routine inspection and maintenance
Routine inspection and maintenance should be carried out in accordance with the crane
manufacturers instructions. These inspections may include a program of weekly, monthly and
quarterly inspections, and should include:
all functions and their controls for speed, smoothness of operation and limits of motion
all emergency and safety switches and interlocks, including limiting and indicating
devices
lubrication of all moving parts
inspection of filter elements and fluid levels
visual inspection and measurements as necessary of structural members and other
critical components such as brakes, gears, fasteners, pins, shafts, wire ropes, sheaves,
locking devices and electrical contactors
signage, including warning signs and control markings
wear on wheels
additional items nominated in the crane manufacturers instructions.
All replacement parts should be identical or equivalent to the original parts or components. A
written report should be prepared on completion of the inspection.
Pre-operational inspection
The crane operator should carry out a visual inspection and functional tests before the
commencement of each work shift, including inspecting and testing the following:
all relevant items indicated in the operations manual
operating and emergency controls
brakes
safety switches and interlocks, including limiting and indicating devices
visual inspection of the structure
wire ropes to ensure they are on the drum and correctly reeved on the sheave.
The results of the inspection should be entered into a logbook and kept with the crane.
All personal protective equipment should also be inspected to ensure it is functioning correctly.
Where issues are identified these should be recorded, reported and rectified before the crane is
used.
5.2 Maintenance, repair and cleaning of plant

Cranes should be maintained, serviced and cleaned according to the manufacturers
instructions, competent person specifications or, in the absence of such specifications, in
accordance with relevant technical standards and engineering principles
All worn or damaged parts of a crane that constitute a hazard or impair the operation of the
crane should be repaired or replaced. In particular:
repairs are carried out in accordance with manufacturers or a competent persons
instructions so as to retain the crane within its original design limits
replacement parts and components should be identical or equivalent to the original
equipment parts and components

When a crane has been damaged to the extent that its function or condition is impaired,
resulting in increased risk to health or safety, it should be immediately taken out of service. A
competent person should assess:
the nature of the damage
whether the crane is able to be repaired, and if so, what repairs must be carried out.
The WHS Regulations require that the operator controls either prevent the person undertaking
maintenance or cleaning to operate the plant or if the plant must be operated during
maintenance or cleaning that there are appropriate risk controls in place to enable this to occur
without risk to health and safety.
5.3 Unattended cranes, parking and storage

Leaving a crane parked and unattended may encourage unauthorised use of the crane by
person who are not competent crane operators. Cranes may also present a risk to health and
safety if measures are not taken to prevent them moving of their own accord (for example,
rolling down a sloping surface).
A crane should not be left unattended unless:
all loads are removed from the hook or lifting device
the hook has been secured or raised to a position where is clear of other operations
all powered motions have been disabled
the keys removed or the starting device locked out.
Where there is no risk of a tower crane boom contacting other structures, the crane should be
left to weathervane when unattended in accordance with the crane manufacturers instructions.
Where it is necessary to restrict the movement of the boom of a tower crane, the method of
tethering that is, securing the boom to prevent slewing) must be in accordance with the crane
manufacturers instructions or determined by an engineer.
When leaving a mobile crane unattended for a longer period of time, ensure the cranes boom is
folded up and retracted as far as possible.
If a crane is to be stored it should be prepared as above and:
the manufacturer storage instructions followed
any remote control equipment isolated
the power supply and controls isolated and locked off
storm anchors applied (if fitted)
doors and windows locked to prevent unauthorised access.
5.4 Decommissioning and dismantling

R. 204: A person with management or control of plant at a workplace must:
not decommission or dismantle the plant unless the decommissioning or dismantling can be
carried out, so far as is reasonably practicable, without risks to the health and safety of any
person
ensure that a person who decommissions or dismantles the plant is a competent person and
is provided with the available information for eliminating or minimising risks to health or
safety
the processes for the installation, construction, commissioning, decommissioning and
dismantling of plant include inspections that ensure, so far as is reasonably practicable, that
risks associated with these activities are monitored.
The crane should be decommissioned and dismantled in accordance with the manufacturers
instructions and/or those prepared by a competent person.

5.5 Record keeping
R. 237: The person with management or control of the plant at a workplace must keep a record
of all tests, inspections, maintenance, commissioning, decommissioning, dismantling and
alterations of the plant for the period that the plant is used or until the person relinquishes
control of the plant.
Crane records should include:
the unique plant item registration number, if applicable
plant design registration information, if applicable
final (as-built) and approved design drawings and calculations
relevant methods of test and inspection results and data from commissioning
compliance statements and/or test certificates
manufacturers specifications
results of inspections
results of tests on safety devices
information on maintenance and major repairs carried out
information on major modifications
information on approved uses that deviates from intended operating or design conditions
results of risk assessments
information, instruction, training provided to workers
log books, and
operator competencies.
A modification to the design of a tower crane can occur, for example, if a different base is
designed to install the tower crane at a different site. This alteration must be recorded, including
where a static base on a self erecting tower crane is different to that included in the original
design registration.
Records may be kept in any suitable format and should be transferred with ownership of the
crane. A crane service record, such as a maintenance logbook, of the significant events
concerning the safety and operation of the crane should be kept and readily available. All
entries in the maintenance logbook should:
clearly describe the work undertaken and parts replaced
identify the person or business who completed the work and be dated.
Documentation stating that the crane has been inspected by a competent person, and is in a
safe and satisfactory condition, should be readily available.
The checks, adjustments, replacement of parts, repairs and inspections performed, and all
irregularities or damage concerning the cranes safe use, should be recorded.
Additionally, all complete routine, annual and major inspection reports should be maintained
and made available for examination as required.

6. CONTROLLING RISKS IN SPECIFIC CRANE OPERATIONS
6.1 Mobile Cranes

There are four general types of mobile crane operating in Australia:
hydraulic slewing cranes
lattice boom cranes (including crawler cranes)
hydraulic pick-and-carry (non-slewing) cranes
vehicle-loading cranes.
Road travel
Failure to follow proper precautions before and during road travel may increase the risk of injury
to the crane operator and other persons, such as pedestrians and other drivers. The crane
manufacturers instructions must be followed when preparing a mobile crane for road travel.
Precautions for road travel include:
securing outriggers (both hydraulic and manual) with a locking device specified by the
crane manufacturer, and stowing them in a travelling position to ensure that there is no
lateral movement
storing loose components in appropriate storage areas in accordance with the crane
manufacturers instructions or any other relevant published guidelines for the safe
carriage of loads on road vehicles (for example, the Load Restraint Guide (2nd ed. 2004))
disengaging all drives to hydraulic pumps, booms and outriggers, and putting the
controls in the OFF position
restraining the boom in accordance with the crane manufacturers instructions to ensure
there is no unintended movement of the boom.
Lattice boom cranes
On lattice boom cranes, the top of the extended boom should not be lowered to a point below
the horizontal line that passes through its base pivot pin. If the boom tips below this plane, the
angle of pull of the boom luffing ropes could cause the boom to buckle before the boom begins
to lift.
Lattice boom cranes should not be moved uphill with an unloaded boom in the near vertical
position. They should not be operated:
with the boom at an angle less than that shown on the load chart, or
with the boom hard against the boom backstop to avoid serious damage to the structural
members of the boom - regard the boom backstop as a safety device only.
Hydraulic boom cranes
When extending the boom on hydraulically operated cranes, ensure that the boom sections are
extended or retracted in accordance with the manufacturers recommendations. Boom sections
have failed through being extended contrary to recommendations.
The crane should not be operated with the boom at an angle less than that shown in the load
chart.
Pick-and-carry cranes
When moving a load in the pick-and-carry mode, the dogger should remain in sight of the crane
operator and not walk in the path of the crane. When travelling and manoeuvring with a load,
the crane operator should ensure that:
the slew brake is applied at all times other than when the slew motion is being used
precautions are taken on uneven road surfaces when loaded or unloaded, as an
undulation in the road surface may move the crane into an unstable zone

the slewing brake or lock is applied when travelling with a load
the crane is not moved uphill with an unloaded boom in the near vertical position.
Always travel slowly to prevent excessive swinging of the load. The load should be carried as
close to the ground as possible, and should not lift higher until it is almost in position.
Where possible, avoid travelling the mobile crane across slopes or over potholes, depressions,
soft ground, road chambers or shoulders, rail tracks, dunnage wood or any objects, as these
could destabilise the crane or load.
Sloping ground
Crane roll over can occur when pick-and-carry cranes travel with a load along a side slope.
Working on a slope has the effect of either increasing or decreasing the working radius of the
crane, which may in turn affect the stability of the crane, and cause the crane to overturn either
forwards, backwards or sideways.
Where the centre of gravity of the mobile crane is high above the ground, a minimal ground
slope can be a major factor in causing the crane to overturn. This particularly applies when:
the boom has a high luff angle
the boom is telescoped out
the centre of gravity of the suspended load is high.
A side slope of only two or three degrees can have a drastic effect on the stability of the crane.
Soft ground, pneumatic tyres and suspension movement will also tend to increase the side
angle of the crane and make the risk of overturning greater.
Most manufacturers of mobile cranes with pick-and-carry capability specify the cranes are to be
operated on firm level ground. Manufacturers and suppliers should provide clear documented
information on the maximum side slope a crane can safely travel over while in pick-and-carry
mode. For example, specifying the maximum allowable side gradient will provide more specific
information to the operator compared to the term firm level ground.
It is very difficult for a pick-and-carry crane to consistently operate on side slopes at a workplace
where construction work is being performed. It is recommended that crane manufacturers and
suppliers provide details on the amount of de-rating that must be applied on side slopes if the
crane is designed to travel on gradients of up to five degrees. Where the crane is not rated for
gradients in excess of 1% the manufacturer should state that the crane is not to be travelled on
ground that is not firm and level and where the gradient is in excess of 1%.
Where possible, avoid working or travelling on sloping or uneven ground. Travel on a slope
should be up or down the slope, not across the slope. If working or travelling on a slope is
unavoidable, use the crane within the manufacturers specified capacity for operating on the
relevant degree of slope. Reference should be made to side de-rating capacity charts prior to
carrying out this work.
Ground pressure
Manufacturers and suppliers of pick-and-carry cranes should provide documented information
on the maximum pressure applied by the cranes tyres or tracks to the supporting surface.
6.2 Vessel-mounted cranes

Vessel-mounted cranes include cranes that may be operated on a barge, pontoon or vessel.
The combined mass is to be considered as a vessel-mounted crane. The vessel should be
anchored during crane operation. If this is not possible, then the vessel should be anchored to a
craft alongside it.
When positioning the crane on a barge, pontoon or vessel in either loaded or unloaded
conditions, the following should be considered:

the effect on freeboard (that is, distance between the vessels deck and the water)
the strength of the vessel to support the crane structure
the installation of stops to prevent the crane driving off the vessels side
the degree of capacity de-rating required for the crane
the method of securing the crane when working outside of smooth water limits.
A competent person must determine the list (that is, deck tilt) and freeboard allowable with the
rated capacity and test load conditions of the crane. The competent person must be
experienced in crane design and stability of waterborne vessels. The vessel and crane
combination must be certified as required by the Australian Marine Safety Authority (AMSA),
which is responsible for managing survey and certification arrangements for Australian ships.
As a general guide, the maximum list of the vessel under rated capacity conditions should not
exceed 5o with one half of the freeboard remaining. Confirmation should be obtained from the
crane manufacturer on the de-rating of the crane from land-based ratings when on the barge,
pontoon or vessel. Note that generally, the manufacturers rated capacities for cranes mounted
on vessels are frequently not greater than 70% of the land-based rated capacity.
Where the crane can move along the deck of the vessel, lifting should only take place when the
crane is secured to the deck (for example, by chains of adequate strength).
Testing before use
The crane and vessel combination should be inspected after erection and before the application
of any loads to ensure:
all ties, anchorages and ballast are in place and correctly secured
the crane configuration is in accordance with the crane manufacturers or a competent
persons specifications, and
the crane configuration is free from any defects that would preclude the vessel-mounted
crane from handling the test load safely.
The crane should undergo testing of its stability, functions and brakes. After these tests have
been completed, a competent person must complete a full assessment to ensure the vessel and
crane combination has withstood the test loadings without structural damage and the
mechanisms function free of any defect that will affect the safety of the crane.
6.3 Special uses of mobile cranes

Working on suspended slabs
Mobile cranes are sometimes lifted onto a suspended floor or other elevated parts of a building
for either construction or demolition activities. Suspended floors are not usually designed or
intended to support mobile plant and there may be a risk of the floor or structure collapsing. This
is particularly the case for heavier mobile cranes.
Prior to positioning the crane on the elevated area, written documentation should be obtained
that demonstrates the design floor loading of the building is not being exceeded or details the
additional support required to support the maximum bearing pressure imposed by the crane and
the maximum load. Where the floor requires strengthening (for example, by propping), an
engineer should provide written instructions that detail the dimensions, locations and other
specifications of the strengthening to be used.
If the crane can only be used in particular areas of the building, due to inadequate strength in
other areas, access to such areas should be prevented by the use of signed barricades or other
types of barriers.

Demolition
Not all mobile cranes are sufficiently robust to withstand the stresses of demolition work. The
use of mobile cranes for demolition work should be restricted to cranes designed for arduous
duty, such as convertible dragline excavators. Hydraulic boom cranes should not be used for
demolition ball work, as overstressing of the sliding points can occur.
All cranes used for demolition work should be fitted with a suitable falling object protective
structure (FOPS), to protect the operator from falling objects.
The hoist rope should be prevented from leaving the boom point sheave. This may include
fitting heavy duty rope guards to the sheave to control the slack rope condition that may occur
as the ball falls. Damage is likely where the demolition ball is attached to the hoist rope. Hoist
ropes should not be fixed directly to the demolition ball. A length of chain should be used to join
the hoist rope to the demolition ball. The chain should be at least 16 mm, and at least two
metres in length.
A crane that has been used for demolition ball work must be thoroughly inspected and verified
by a competent person to be in a satisfactory condition before it is used for general lifting. The
results of the inspection must be noted in the cranes service logbook.
Further guidance on demolition is available in the Code of Practice: Demolition Work.
Using cranes for tree lopping
The WHS Regulations allow a crane to be used to place a person in a tree to trim or remove the
tree in specific circumstances, known as the crane access method.
Before a decision is made to use the crane access method a risk assessment must be
conducted to assess that the use of this method does not create a greater risk to the health or
safety of the worker than climbing a tree, or using plant specifically designed to lift a person to
access the tree. If the risk assessment shows that the crane access method can be used the
requirements of Regulation 221 must be followed.
Further guidance on using cranes for tree trimming is available in the Code of Practice: Tree
Trimming and Removal Crane Access Method.
6.4 Multiple crane lifts

R. 219(7): The person with management or control of the plant must ensure, so far as is
reasonably practicable, that no load is lifted simultaneously by more than 1 item of plant unless
the method of lifting ensures that the load placed on each item of plant does not exceed the
design capacity of the plant.
Lifting a load with two or more cranes requires more detailed planning and supervision to
control the risks. This is because the effects of the relative motion between the cranes may
create additional loadings on the cranes, the load and the lifting gear. Therefore, the design
capacity of the crane is not the maximum rated capacity but the de-rated capacity relevant to
the multi-crane lift to be undertaken.
Safety measures for multi-crane lifts
Where possible, avoid hoisting a load with more than one crane. However, where it is
necessary to lift a load using more than one crane, the following steps should be taken:
the person in overall control of the lift should hold a minimum intermediate riggers high
risk work licence
make an accurate assessment of:
o the share of the load which is to be carried by each crane throughout the complete
lift cycle
o how the load sharing is to be proportioned

o how the proportioning is to be maintained during the lift
ensure the instructions to each crane operator and other persons involved are clear and
documented (for example, in a safe work method statement) and rehearse the operation
wherever possible
use cranes of equal capacity and similar characteristics
ensure that cranes are aligned in the same direction
use luffing up in preference to luffing down.
Multi-crane lifts should not be undertaken unless all cranes are fitted with a load indicator. Load
indicators should be fitted to all mobile cranes with a maximum rated capacity of more than
three tonnes.
Calculated share of the load
Where multi-crane lifts are to be carried out, a documented lift plan and procedure should be
prepared by a competent person (for example an engineer) and followed. Typical minimum
capacity de-rating requirements for each crane involved in a multi-crane lift are:
for two cranes de-rate each crane by 20%
for three cranes - de-rate each crane by 33%
for four or more cranes - de-rate each crane by 50%.
The crane de-ratings for multi-crane lifts should not be less than those identified above and in
some circumstances an increase in the de-rating may be required. For example, where multiple
cranes are to be used for the mid-air rotation of a precast concrete panel, the following issues
should be considered and allowed for:
the load on each crane will change during rotation
the radius for one or both cranes will change during the lift
rotation should take place with adequate clearance from the ground for full rotation to
ensure that the panel does not strike the ground, the cranes or any other objects.
Principles for multiple crane lifting
Factors are to be considered when planning for multiple crane lifts include the:
mass of the load
position of the centre of gravity
mass of the lifting gear
safe working capacity of the lifting gear
synchronisation of crane motions.
Mass of the load
Ensure the total mass of the load and its distribution is either known or calculated. Where the
information is taken from a design drawing, ensure allowances are made for manufacturing
tolerances. The accuracy of the design drawing should be confirmed prior to the lift
commencing.
Position of the centre of gravity
Due to the variable effect of manufacturing tolerances and rolling margins, the position of the
centre of gravity may not be accurately known. Accordingly, the proportion of the load being
carried by each crane may be uncertain and adequate allowances should be made. This will
involve reducing the crane capacities further.
Mass of the lifting gear
Ensure the mass of the lifting gear and its distribution are accurately known and included as
part of the calculated load on the cranes. Where heavy or awkwardly shaped loads are handled
and significant lifting gear is required, the de-rating of the cranes capacity may need to be
further increased to allow for the weight of the lifting gear.

Safe working capacity of the lifting gear
Ensure the distribution of the forces within the lifting gear that will occur during the lifting
operation is established. The lifting gear should have a rated capacity in excess of that needed
for its proportioned load. Determine whether special lifting gear is required to suit the maximum
variation in distribution and direction of applied loads and forces which may occur during
multiple lifting.
Synchronisation of crane motions
Minimise the variation in the direction and magnitude of forces acting on the cranes by
synchronising the cranes motions. Where possible, ensure cranes of equal capacity and similar
operating characteristics are used. However, in practice, there will always be some variation
due to differences in response to the activation of the motion controller and the setting and
efficiency of the braking system.
As it is unlikely that the motions of the cranes will be accurately synchronised, ensure that an
assessment of the effect of variation in plumb of the hoist ropes, which may arise from
inequalities of speed, and the means for keeping such inequalities to a minimum, is made. To
allow for these inequalities, the lifting operation should be performed at low speeds with
extreme care to ensure the hoist ropes are kept as close as possible to vertical.
The rated capacity of a crane is calculated on the assumption that the load will be raised and
lowered in a vertical plane. The crane boom has limited strength in the lateral plane.
6.5 Single crane multiple winch lifts

A single crane may be used to lift a load using both the main and auxiliary winches, for
example, when erecting precast concrete panels.
In order to move the concrete panel into its vertical position, the concrete panel may need to be
rotated through using one or two cranes. Even though the concrete panel will be suspended by
two hoist ropes, both ropes will need to support more than 50 per cent of the concrete panel
weight during the rotation. The actual load should be calculated and documented by a
competent person before the element is manufactured.
Where a single crane is to be used for mid-air rotation, the following should be considered:
The crane must be designed and manufactured for simultaneous multiple winch as set
out in the manufacturers instructions.
Some cranes may need to be reconfigured before they can be used in this manner.
The main winch and auxiliary winch drives should be independent.
Rigging should ensure that the maximum design fleet angle is not exceeded (for
example, lifting an element that is placed perpendicular to the boom may place
excessive side load on sheaves).
Rotation should be as near as possible to the plane of the boom.
The load on the main and auxiliary winches is to be monitored separately and
simultaneously to avoid overloading of either line and to ensure that the combined load
of both lines does not exceed the rated capacity of the crane.
The included angle between the main hoist rope and auxiliary hoist rope is not to exceed
10 degrees unless otherwise specified by the manufacturer.
Rotation should take place with adequate clearance from the ground for full rotation to
ensure that the panel does not strike the ground, crane or any other objects.
An engineer should verify the minimum required capacity of the hoist ropes. The auxiliary winch
line passes over the Rooster sheave which is the name given to the sheave mounted on the
short boom extension. Rooster sheaves and the associated rigging on the boom head should
be designed and certified by an engineer.

6.6 Use of other mobile plant as a mobile crane
Other mobile plant may be used as a mobile crane to lift or lower freely suspended loads (that
is, the load is not pinned to the boom or on tynes, but is suspended from the boom by means of
a chain or wire rope sling). Other mobile plant that is sometimes used in this way includes
backhoes, front-end loaders, excavators and telescopic handlers (also known as load-alls and
tool carriers).
Further guidance on using other plant as a mobile crane is provided in Appendix G.
6.7 Tower cranes

There are three general types of tower crane used in Australia:
luffing
hammerhead
self-erecting.
Failure to erect or dismantle tower cranes in accordance with the crane designers or crane
manufacturers instructions may result in injury to persons and property damage from:
crane collapse
falls from heights
falling objects.
The process of erecting or dismantling a tower crane is construction work and if it involves high
risk construction work (for example, work where a person could fall more than two metres) a
safe work method statement must be prepared.
A safe work method statement should consider the following:
the crane designers or crane manufacturers instructions
technical standards relevant to access and egress
the cranes stability
any adverse effects on other plant, structures or work processes at the workplace
the use of special tools, jigs and appliances necessary to minimise the risk of injury
control measures for securing crane components
the interaction of the crane with other plant
environmental factors, such as wet or windy conditions
all relevant electrical installations associated with the crane comply with AS 3000:
Further guidance on the safe erection, use and dismantling of tower cranes is provided in
Appendix B.
6.8 Vehicle-loading cranes

Vehicle-loading cranes are intended to be mounted on a broad range of vehicles including tray
trucks and prime movers. When originally introduced, vehicle-loading cranes were used for
loading the truck on which they were mounted. However, with the introduction of larger capacity
vehicle-loading cranes and proportional control, these types of cranes are frequently used for
traditional crane operations where either:
the load is lifted from the vehicle tray to an elevated area at a workplace (for example,
lifting packs of timber from the vehicle directly to a building floor), or
the load is lifted both to and from locations, remote from the vehicle on which the crane
is mounted.
While vehicle-loading cranes may be used for the applications stated above, the level of safety
provided by the lifting set-up should not be less than when a mobile crane is used.

Unless a vehicle-loading crane has been designed for pick-and-carry operation, it must never
be used in this mode.
Crane and vehicle suitability
Vehicle-loading cranes must only be mounted on vehicle types and models specified by the
crane manufacturer. Installing a crane on an inappropriate vehicle could lead to structural failure
of the crane or vehicle, or make the vehicle/crane combination unstable. Where second-hand
vehicle-loading cranes are imported from overseas, the crane and vehicle combination must be
provided with a compliance plate that has been attached by an authorised person in compliance
with jurisdictional transport requirements.
The method of mounting the crane to the vehicle must be in accordance with the crane
manufacturers specifications and/or the recommendations of a competent person. Any adverse
effects to both the vehicle and crane are to be taken into consideration. Welding the crane to
the vehicle chassis is unacceptable as it can damage the chassis and also lead to fatigue failure
of the connection.
Design of controls on vehicle-loading cranes
Controls on vehicle-loading cranes must be of the constant pressure (deadman) type, and
permanently marked with clearly visible symbols.
The position and layout of controls on vehicle-loading cranes should be designed so that the
risk of the operator being crushed against the vehicle or controls by inadvertent operation of the
crane is eliminated. For new vehicle-loading cranes, administrative controls are not suitable to
prevent injury and engineering controls should be used.
An emergency stopping device should be provided at every control station on the vehicle-
loading crane. The emergency stopping device should:
remove the energy supply to the crane, and bring the crane to a complete stop when
activated
be readily visible and coloured red
be arranged for easy access, and located so that the operator will not be exposed to
other hazards when activating the device
lock in the stop position when activated and require manual reset.
Operational issues for vehicle-loading cranes
The vehicle-loading crane must be operated in accordance with the operators instruction
manual provided by the crane manufacturer and:
operators of vehicle-loading cranes with a maximum load moment capacity of 10 metre-
tonnes or more must hold the appropriate HRW licence class (CV)
operators must be trained in the operation of the particular vehicle-loading crane
if the load is out of the operators view at any stage during the lifting process, the
movement of the load must be directed by a licensed dogger or rigger
the vehicle-loading crane may only be used with all stabilisers extended in accordance
with the crane manufacturers instructions - where multiple positions can be used on
stabiliser legs, the legs must be set up in compliance with the manufacturers load chart
stabilisers must be interlocked to prevent deployment of the crane boom until the
stabilisers have been correctly extended
the stabiliser legs should be clearly marked with zebra striping to improve visibility
the vehicle-loading crane must only be used so that it is level in accordance with the
crane manufacturers specifications (usually not exceeding one degree or less)
timbers or other pads specified by the crane manufacturer are to be provided under the
stabiliser feet

crane hooks must be provided with spring-loaded safety latches and must be adequately
maintained
vehicle-loading cranes are not to be used for lifting persons where provided, spring lock-
outs on the vehicle are to be activated during crane operation
the vehicle-loading crane must only be used with a load suspended vertically from the
hook - the crane is not to be used to drag a load across a supporting surface.
6.9 Bridge and gantry cranes

Bridge and gantry cranes are commonly used in manufacturing environments where there is a
need to regularly move loads from one location to another. The following bridge and gantry
cranes must be design registered:
bridge cranes with a safe working load of greater than 10 tonnes
gantry cranes with a safe working load greater than 5 tonnes, and
any bridge crane or gantry crane that is designed to handle molten metal or hazardous
chemicals listed in Schedule 10 of the WHS Regulations.
Operating a bridge or gantry crane is skilled work and as there can be a wide range of crane
configurations, operators must be trained and competent in their use. Powered operations of
bridge and gantry cranes include:
traversing - the movement of the crab from one end of the bridge to the other
travelling - the movement of the crane along its runway
hoisting - raise and lower are considered to be one powered operation, and
rotation.
Where a bridge or gantry crane is to be configured for a special use, this requirement should be
discussed with the crane manufacturer and/or supplier prior to purchase. For example, if a
multi-hoist mechanism is required and it is intended to simultaneously use both hoists to lift a
common load that exceeds either hoist capacity, load limiting and movement controlling devices
should be installed to prevent either hoist from being overloaded. If these are not installed then
the capacity of each hoist must be adequately de-rated (for example, by 20%).
Safety devices that can assist in controlling risks include:
anti-collision devices - these prevent two or more bridge and gantry cranes operating on
the same runway from colliding with each other and when approaching the end of the
runway
deceleration devices - such as limit switches and two-stage decelerators, slow the bridge
or gantry crane down regardless of what control is being pressed when a travelling crane
is approaching the end of the runway, to prevent end stop collision or over run
load-limiting devices these devices assess the load and prevent lifting should the
rating capacity of the crane be exceeded
anti-fall devices for example, anti-drop plates, can be fitted to bridge and gantry cranes
to prevent falls of plant in the event of travel-wheel failure.
Licences
A high risk work licence is required to operate a bridge crane or gantry crane that is:
controlled from a permanent cabin or control station on the crane; or
remotely controlled where the remote control has more than 3 powered operations.
A high risk work licence is not required to operate a bridge or gantry crane that is remotely
controlled by way of pendant or radio and only has a maximum of three powered operations (for
example, traverse, travel and hoist).
A dogging licence or rigging licence is required by:

any person other than a licensed crane operator if they exercise judgment in the
selection of slings, the weight of the load or its centre of gravity
any person who directs a bridge and gantry crane operator in the movement of the load.

APPENDIX A: DEFINITIONS
Barrier A physical structure which blocks or impedes something.
Barricade Any object or structure that creates a barrier obstacle to control, block passage
or force the flow of traffic in the desired direction
Boom-type A telescoping device, hinged device, or articulated device, or any combination

elevating work of these, used to support a platform on which personnel, equipment and
platform materials may be elevated.
Bridge Crane A crane that:

(a) a consists of a bridge beam or beams, that are mounted to end carriages
at each end; and
(b) is capable of travelling along elevated runways; and
(c) has one or more hoisting mechanisms arranged to traverse across the
bridge.
Competent A person who has acquired through training, qualification or experience the
person knowledge and skills to carry out the task.
A competent person has a more specific meaning in the following
circumstances:
For inspection of plant for registration purposes the person must have:
o educational or vocational qualifications in an engineering discipline
relevant to the plant being inspected, or
o knowledge of the technical standards relevant to the plant being
inspected.
For a major inspection of registered mobile cranes and tower cranes the
person must:
o have the skills, qualifications, competence and experience to inspect the
plant, and be registered under a law that provides for the registration of
professional engineers (in jurisdictions where such a law exists), or
o be determined by the WHS regulator to be a competent person.
Dogging work Means:

(a) the application of slinging techniques, including the selection and
inspection of lifting gear, to safely sling a load; or
(b) the directing of a plant operator in the movement of a load when the load
is out of the operator's view.
Exclusion An area from which persons are excluded during the work.
zone
Electricity A person or body engaged in the distribution of electricity to the public or in the
Supply generation of electricity for supply, directly or indirectly, to the public. An
Authority electricity supply authority may also be known as a network operator.

Fail safe A state or condition where, if any component or function of the plant fails, a
system exists to prevent any increase in the risks. For example, if the primary
hoist brake fails on a crane lifting a person in a workbox, the secondary hoist
brake will prevent uncontrolled dropping of the workbox. However, once the
secondary brake is engaged, a lower level of safety has been reached. The
situation must be made safe and the fault rectified so that the fail safe capability
is re-established.
The reliability or safety integrity of the fail safe system should be commensurate
with the determined level of risk (for example, Category 1 to Category 4 applied
in AS 4024: Safety of Machinery).
Gantry crane A crane that:

(a) consists of a bridge beam supported at each end by legs mounted on end
carriages; and
(b) is capable of travelling on supporting surfaces or deck levels, whether fixed
or not; and
(c) has a crab with one or more hoisting units arranged to travel across the
bridge.
Hoist An appliance intended for raising or lowering a load or people, and includes an
elevating work platform, a mast climbing work platform, personnel and
materials hoist, scaffolding hoist and serial hoist but does not include a lift or
building maintenance equipment.
Load chart A notice fitted on a crane or hoist specifying the rated capacities as supplied by
the manufacturer.
Mobile crane A crane capable of travelling over a supporting surface without the need for
fixed runways and relying only on gravity for stability.
Non-slewing A mobile crane incorporating a boom or jib that cannot be slewed, and includes:
mobile crane (a) an articulated mobile crane; or
(b) a locomotive crane,
but does not include vehicle tow trucks.
Operator A roll-over protective structure (ROPS), falling object protective structure

protective (FOPS), operator restraining device and seat belt.
device
Overturning The moment that tends to tip the crane over. When the overturning moment
moment exceeds the stabilising moment, the crane will overturn (see also Stabilising
moment).
Portal boom A boom crane or a jib crane that is mounted on a portal frame that, in turn, is
crane supported on runways along which the crane travels.
Powered Plant that is provided with some form of self propulsion that is ordinarily under
mobile plant the direct control of an operator.

Rated capacity The maximum gross load that may be applied to the crane or lifting attachment
while in a particular working configuration and under a particular condition of
use.
Reach stacker A powered reach stacker that incorporates an attachment for lifting and
lowering a shipping container
Rigging work Means:

(a) the use of mechanical load shifting equipment and associated gear to
move, place or secure a load using plant, equipment or members of a
structure to ensure the stability of those members; or
(b) the setting up or dismantling of cranes or hoists.
Self-erecting A crane:
tower crane (a) that is not disassembled into a tower element and a boom or jib element in
the normal course of use; and
(b) where the erection and dismantling processes are an inherent part of the
crane's function.
Slewing A mobile crane incorporating a boom or jib that can be slewed, but does not
mobile crane include:
(a) a front-end loader; or
(b) a backhoe; or
(c) an excavator; or
(d) other earth moving equipment,
when configured for crane operation.
Slinging Means the exercising of judgement in relation to the suitability and condition of
techniques lifting gear and the method of slinging, by consideration of the nature of the
load, its mass and its centre of gravity.
Stabilising The moment that tends to keep the crane upright. Moment is the engineering
moment calculation of force multiplied by the perpendicular distance between the force
and the turning point.
Structure Anything that is constructed, whether fixed or moveable, temporary or

permanent, and includes:
(a) buildings, masts, towers, framework, pipelines, transport infrastructure and
underground works (shafts or tunnels); and
(b) any component of a structure; and
(c) part of a structure.
(a) a fixed, mobile or suspended scaffold; or
Temporary
(b) an elevating work platform; or
work platform
(c) a mast climbing work platform; or
(d) a work box supported by a crane, hoist, forklift truck or other form of
mechanical plant; or
(e) building maintenance equipment, including a building maintenance unit; or
(f) a portable or mobile fabricated platform; or
(g) any other temporary platform that:
(i) provides a working area; and
(ii) is designed to prevent a fall.

Tower crane Means:
(a) a boom crane or a jib crane mounted on a tower structure; and
(b) in Schedule 3:
(i) the crane, if a jib crane, may be a horizontal or luffing jib type; and
(ii) the tower structure may be demountable or permanent,
but, in Schedule 3, does not include a self-erecting tower crane.
Vehicle- A crane mounted on a vehicle for the purpose of loading and unloading the
loading crane vehicle.
Workbox A personnel carrying device, designed to be suspended from a crane, to

provide a working area for a person elevated by and working from the device
Working Load See Rated capacity.

Limit (WLL)

APPENDIX B: TOWER CRANES
1. Pre-erection inspections and tests (on ground inspection)

Tower crane components should be inspected and tested by a competent person according to
the manufacturers instructions prior to being delivered to the workplace.
Where a tower crane owner is aware a crane will be erected when the scheduled annual
inspection is due, then the owner may consider carrying out an annual inspection during the
pre-erection inspection.
These inspections and tests should include the following:
Non-destructive Testing (NDT) of welds on vital components, such as boom clevises,
butt heal bosses, counterweight rope sheave brackets
NDT of tower crane bolts
NDT of slew ring bolts
NDT of aluminium sheaves
the condition of the power supply cable where used
the condition of motor brakes
the condition of the slew ring gear and pinions
air controls and associated valves
the condition of ropes and sheaves (for example, erection, hoisting, counterweight and
trolley) and correct rope tracking
the condition of limit switches and limiting devices
the condition of counterweights
the condition and fitment of machinery guarding
brake systems, are to be dismantled and inspected for wear and damage:
o dry brakes - prior to each erection or more frequently if directed by the manufacturer
o wet brakes - prior to each erection, after 5 000 hours of crane operation or as
directed by the manufacturer
all normal service items, including items supplied by the crane manufacturer (for
example, temperature control units and adequate seating) being maintained in a
serviceable condition according to the crane manufacturers instructions, and
other tests as specified by the manufacturer.
Further information on NDT is provided in part 7 of this Appendix.
Once the tower crane components have been delivered to the workplace, they must be
inspected for any possible damage and wear during transport.
Inspections must also be made of:
the crane base design and engineers report
crane ties and structure to support them where used
the power supply and earthing.
Crane owners should develop their own pre-erection inspection and test report that satisfies the
requirements of the WHS Regulations and the manufacturers instructions. The report should
also reflect the specific type and model of crane and reference all relevant design drawings and
test certificates.
2. Commissioning tower cranes

Failure to commission tower cranes in accordance with the crane manufacturers or suppliers
specifications may lead to decreased safety and efficiency in the operation of the tower crane.

Commissioning tower cranes involves performing necessary adjustments, tests and inspections
to ensure the crane is in full working order to specified requirements before the crane is used.
For further information on the inspection and testing is provided in section 5 of this code.
Written instructions regarding the commissioning of a tower crane should be available to all
relevant persons at the workplace. The commissioning of cranes must be carried out in
accordance with these written instructions.
If rated capacity limiters, overload cut-outs or motion switches have been bypassed or
disconnected during erection, they are to be reconnected and tested in accordance with a
written procedure before the crane is put into operation.
Responsibilities of persons who commission tower cranes
A person who commissions tower cranes should ensure that:
the process of commissioning the crane is without risk to health and safety
as a result of commissioning, the crane can be transferred to active service without risk
to health and safety when it is used properly, and for the purpose for which it was
designed and manufactured
the crane is inspected, to determine whether it has been erected in accordance with
design specifications
commissioning methods are in accordance with specifications of the crane manufacturer
or supplier
the commissioning sequence has been developed and implemented according to risk
management principles (that is, hazards identified, risks assessed and controls
implemented)
an erection plan is developed to cover such things as the sequence of operations, and
the safety procedures to be carried out during commissioning
tests are carried out to ensure the crane will perform within design specifications (for
example, dummy runs)
stresses which exceed design specifications are not imposed on the crane
the crane owner is notified of commissioning results and provided with appropriate
documentation.
The following information should be provided by the commissioner of the tower crane to the
crane owner:
any problems identified during commissioning that indicate the crane is not performing
safely
confirmation that the crane will perform the functions for which it has been
commissioned.
Commissioning inspections and tests
Commissioning inspections and tests should be carried out by a competent person once the
crane has been erected and before it is put into service. Once the performance of the crane has
been satisfactorily verified by the commissioning inspections and tests, the crane may be
placed into service.
Commissioning inspections and tests should include:
crane electricity supply where used
crane base weights or ballast where used
tower section identification and access
tower bolts to correct tension
climbing frame and connection
jib connection pins and retainers
A-frame connections and retainers

jib and deck pendant pins and retainers where used
machinery guarding
leakage in lines, tanks, valves, pumps, and other parts of air or hydraulic systems
the condition of the ropes and sheaves (for example, erection, hoisting, trolley and
counterweight) and correct rope tracking
isolating switches
the condition and phase of the power supply cable
verification that the crane wiring complies with AS/NZS 3000: Electrical installations
effective operation of controls including interlocks
effective operation of indicating devices
effective operation of travel deceleration switches
effective operation of hoist upper and lower (where required) working limit switches
effective operation of warning devices
effective operation of the hoist and travel brakes when the crane is laden to the
maximum rated capacity
effective operation of the rescue controlled descent device
other tests specified by the crane manufacturer.
Commissioning report
Crane owners should develop their own commissioning report that satisfies the requirements of
the WHS Regulations and the manufacturers instructions. It should reflect the specific type and
model of crane, and reference all relevant design drawings and test certificates.
3. Pre-operational inspection
A visual inspection and functional test of the crane should be carried out by the crane operator
before the commencement of each work shift. This should include inspection and testing of the
following:
all relevant items indicated in the operations manual
operating and emergency controls
brakes
safety switches and interlocks, including limiting and indicating devices
visual inspection of the structure
wire ropes to ensure they are on the drum and correctly reeved on the sheave
wire ropes for obvious damage.
The results of the inspection must be entered into a logbook and kept with the crane.
All personal protective equipment should be inspected to ensure it is functioning correctly. All
safety-related problems should be recorded and rectified prior to crane use.
4. Routine inspection and maintenance

A program of routine inspection and maintenance should be carried out by a competent person
in accordance with the crane manufacturers instructions. It should include a visual inspection of
those relevant items that can be safely done while the crane is erected.
Routine inspection and maintenance should include the following:
all functions and their controls for speed, smoothness of operation and limits of motion
all emergency and safety switches and interlocks, including limiting and indicating
devices
lubrication of all moving parts and inspection of filter elements and fluid levels

visual inspection and measurements as necessary of structural members and other
critical components such as brakes, gears, fasteners, pins, shafts, wire ropes, sheaves,
locking devices and electrical contactors
signage, including warning signs and control markings
wear on wheels and rails
additional items nominated in the crane manufacturers instructions.
All replacement parts and components should be identical or equivalent to the original parts or
components. A written report must be provided upon completion of the inspection.
5. Annual inspections
An annual inspection should be carried out by a competent person in accordance with the crane
manufacturers instructions.
Where a tower crane owner is aware a crane will be erected when the scheduled annual
inspection falls due, the owner may consider carrying out an annual inspection prior to crane
erection or during the pre-erection inspection.
An annual inspection should include all items specified by the crane manufacturer for annual
inspection, as well as relevant items included in the routine inspection and maintenance
programs.
Annual inspections should include:
all relevant items in the pre-erection inspection and tests that can be safely completed
while the crane is erected
the effective functioning and calibration of all limiting and indicating devices
detailed visual inspection and tolerance checking of all critical structural and wear
components
checking of tolerances for wear limit
a detailed visual check for corrosion, and
a detailed visual examination of critical areas for evidence of cracking.
6. Major inspection
Tower cranes must undergo a major inspection every 10 years and include inspection of the
structure as well as mechanical components.
The following are examples of some off the key items requiring inspection. Some of the items
may not be applicable to some types of tower cranes because the feature will not exist on the
crane. The full list of items to be inspected must be determined by the competent person.
Slew Ring
Remove the slew ring bolts and split the slew ring.
Measure the wear in the slew ring.
Replace worn bearings and spacers.
Carry out NDT and repair of bearing race.
Measure the backlash and teeth width in the pinion drives and ring drive to ensure they
are within the manufacturers specifications.
If the manufacturer specifies that slew ring bolts can be reused, the bolts are crack
tested by NDT, or replace all bolts with new bolts.
Hydraulic motors
Remove, strip down and inspect all hydraulic motors.
Replace all worn valves and other components where measurement identifies wear
has exceeded the manufacturers fail criteria.
Ensure tolerances comply with manufacturers specifications prior to reassembly.

Ensure motors are pressure and performance tested prior to re-entering service.
Hydraulic pumps
Remove, strip down and inspect all hydraulic pumps.
Replace all worn valves and other components where measurement identifies wear
has exceeded the manufacturers fail criteria.
Ensure tolerances comply with manufacturers specifications prior to reassembly.
Ensure pumps are pressure and performance tested prior to re-entering service.
Valve blocks (bodies)
Remove, strip down and inspect all valve blocks.
Replace all worn valves and other components.
Ensure tolerances comply with crane manufacturers specifications prior to reassembly.
Ensure valves are pressure and performance tested prior to re-entering service.
Hoist and luff drums
Remove luff drums and replace drive shaft bearings as required.
Inspect grooves on the luff drum.
Inspect the drive pinions for wear and correct allowable backlash.
Replace drive pinions if the tolerances are outside of the manufacturers specifications.
Inspect rope anchor points to ensure they are correct for rope dimensions.
Braking systems
Remove and dismantle all brakes from the crane.
Check pins, springs and bushes for correct tolerance.
Replace rubber seals.
Check pistons for correct operation.
Ensure welds in braking systems are crack tested by NDT.
Inspect hydraulic systems for leaks prior to reassembly on the crane.
Inspect wear limits on brake linings.
Rope sheaves
Remove all rope sheaves and replace bearings as necessary.
Check sheave groove size and replace the sheave if it is outside of the manufacturers
specifications.
Inspect sheaves for cracking, alignment and damage.
Replace synthetic sheaves if recommended to do so by the sheave manufacturer.
Hydraulic luffing cylinder
Remove cylinder and ram from the crane and strip the cylinder and valve blocks.
Ensure gland nuts are crack tested and threads are checked for wear.
Replace seals and re-chrome ram where necessary.
Ensure the reassembled cylinder is pressure tested and checked for operation and
leaks.
Ensure welds on rod ends and caps are crack tested by NDT.
Gear boxes and drive shafts
Remove and dismantle gear boxes, drive shafts and flexible couplings to the extent that
a thorough inspection is possible.
Replace worn and damaged bearings and gears.
Boom
Ensure all NDT on boom components required in the pre-erection tests is carried out.
Ensure ultrasonic chord thickness of boom is performed.

Ensure a minimum of 10% of lacing welds on each boom section are crack tested by
NDT. If any cracks are found, ensure all lacing welds on the boom section are tested.
A-frame
Remove all pins.
Ensure NDT is carried out on all connector welds on primary chords.
Ensure a minimum of 10% of lacing welds are crack tested by NDT.
Pins with moving parts (for example, boom heel pins, ram pins)
Remove and inspect all pins with moving parts.
Measure the diameter of the pin and bush to ensure it is within the manufacturers
tolerance. If not, the pin must be re-machined or replaced and the bush replaced.
Inspect restraint systems (that is, cheek plates) and grease nipples.
Static pins
Remove and inspect all static pins.
Repair pins if necessary.
Steel wire ropes
Inspect all ropes for wear, including hoist, luff, pendant, trolley and counterweight ropes.
Ensure ropes are only replaced with the type of rope specified by the crane
manufacturer unless a competent person specifies otherwise.
Inspect pins and terminations on pendant ropes.
Electrical systems (hazardous voltage)
Ensure a qualified and licensed electrician inspects switchboards, wiring, motors and
other electrical components in accordance with AS 3000: Electrical installations and
other relevant standards.
Replace damaged or worn components.
Ensure sign-off is provided by the electrician.
Control systems (non-hazardous voltage)
Ensure electrical control systems and components are inspected by a competent
person.
Replace damaged or worn components.
Ensure sign-off is provided by the competent person.
Electric motors
Remove and dismantle electric motors from the crane.
Inspect brushes, bearings, switches and motor wiring for damage and wear.
Inspect splines and shaft keyways for wear and cracks.
Ensure sign-off is provided by the competent person.
Hook trolley (non-luffing cranes)
Inspect hook trolley wheels for damage and wear.
Replace hook trolley wheels if necessary.
Ensure welds on the trolley are crack tested by NDT.
Hook assembly
Dismantle and dimensionally inspect the hook assembly to ensure it is within the
manufacturers specifications.
Ensure the hook is crack tested by NDT.

7. Requirements for non-destructive testing (NDT)
Non-destructive testing is the testing of materials to detect internal, surface and concealed
defects or discontinuities, using methods which do not damage or destroy the material under
test.
All NDT must be carried out by a competent person (for example, a person accredited by
NATA). The results of NDT must be available at the workplace where the crane is erected.
When using NDT for the detection of cracks in metals, the paint must be removed from the
metal surface.
NDT of specific tower crane components should take place at set intervals (for example, pre-
erection tests and major inspection). The following table indicates the minimum frequency of
NDT for particular crane components.
Component tested NDT description NDT frequency

Boom clevises Crack test Pre-erection
Counterweight sheave bracket welds Crack test Pre-erection
- moving counterweights only
Cruciform welds (luffing cranes only) Crack test Pre-erection
Butt heal bosses (luffing cranes only) Crack test Pre-erection
Band brake welds Crack test Pre-erection
Slew ring bolts (where slew ring has Crack test minimum 10 % bolts Pre-erection
to be split at disassembly)
Tower bolts Crack test minimum 10 % bolts Pre-erection
Aluminium sheaves Crack test Pre-erection
Slew ring bolts (all slew rings) Crack test all bolts 5 years
Boom chord thickness Material thickness testing 10 years
Slew ring Crack test 10 years
Hydraulic luffing cylinder gland nut Crack test 10 years
Hydraulic luffing cylinder and ram Crack test 10 years
(rod ends and caps)
Boom lacing welds Crack test minimum 10% 10 years
A-frame (all connector welds on Crack test 10 years
primary chords)
A-frame lacing welds Crack test minimum 10% 10 years
Hook Crack test 10 years
Welds on hook trolley Crack test 10 years
Crack testing of booms and counterweight sheave bracket welds

Booms on non-self-erecting tower cranes are connected by pins that pass through male and
female clevises on the ends of each boom section. All welds on male and female clevises on
the ends of every boom section should undergo NDT prior to each crane erection for non-self-
erecting cranes. Magnetic particle testing is the usual method used for performing these tests.
In addition to carrying out crack testing of connection clevises, luffing crane booms have a
history of cracking in the following areas:
counterweight sheave bracket welds
welds in cruciform area
butt heal bosses.
These areas should also be crack tested by NDT prior to each crane erection.

Crack testing of band brakes
Older designed luffing tower cranes are provided with band brakes. On some of these cranes,
the steel band is welded to an end fitting that has a pin passing through it. These welds have
been known to crack.
All luffing tower cranes fitted with band brakes must have the weld between the band and the
end fitting crack tested by NDT prior to each erection. Note that there may not be a weld on
some brake bands.
Crack testing of slew ring bolts
The integrity of slew ring bolts is critical for ensuring both the machine deck and boom remain
attached to the tower. Slew ring bolts may become damaged, and their effective life reduced if
bolts are either under or over-torqued. Once removed, slew ring bolts should be replaced unless
the manufacturers instructions state they can be reused. If bolts can be reused they should be
tested.
For tower cranes where the slew ring must be split each time the crane is moved, 10% of slew
ring bolts must undergo NDT. Bolts to be tested are to be selected from the slew ring by a
competent person. If any cracks are detected, all bolts should be discarded and replaced with
new.
The preferred system of testing slew ring bolts is to completely remove the bolts from the slew
ring and examine them by magnetic particle testing.
Crack testing of tower bolts
Tower bolts are a critical part of the crane, and permit the effective transfer of load from the
crane boom to the crane base. Tower bolts may become damaged from job to job. Their
effective life may also be reduced if the bolts are either under or over-torqued. While all tower
bolts are high tensile bolts, some are made from extremely high grade steel and may be more
susceptible to cracking.
Once removed, tower bolts should be replaced unless the manufacturers instructions state they
can be reused. If bolts can be reused, a minimum of 10% of tower bolts must be crack tested by
NDT prior to each crane erection. If any cracks are found, all tower bolts should be discarded
and replaced with new.
A system that ensures all tower bolts are tested over time is preferred, however a random
system of testing may also be used. A crane owner may decide to test more than 10% of bolts
where deemed necessary (for example, due to a history of cracking). The tested bolts should be
identified by a method that does not damage the bolt.
Chord thickness testing
Lattice-type tower crane booms are constructed from steel. The components of these may be
prone to internal and external corrosion affecting the thickness of the boom. The thickness of
the chord wall may also be reduced through abrasive blasting of the boom.
All main chord sections on tower crane booms should undergo thickness testing at intervals not
exceeding ten years. Ultrasonic thickness testing is one method of verifying whether there is
adequate strength in the chords of the boom.
Chord sections must be reviewed for structural adequacy when the thickness is shown by
testing to be 90% or less than 90% of the original thickness.
Records of inspections and maintenance
A crane service record, such as a maintenance logbook, of the significant events concerning the
safety and operation of the crane must be kept and readily available. Records may be kept in

any suitable format, and must be transferred with ownership of the crane. All entries in the
maintenance logbook are to:
clearly describe the work undertaken and parts replaced
be dated
note the name of the person carrying out the work, and
be signed by the person carrying out the work.
Documentation stating that the crane has been inspected by a competent person, and is in a
safe and satisfactory condition, should be readily available.
The checks, adjustments, replacement of parts, repairs and inspections performed, and all
irregularities or damage concerning the units safe use, must be recorded.
In addition, all complete routine, annual inspection and major inspection reports must be
maintained and made available for examination as required.
8. Tower crane maintenance and repair

A tower crane preventative maintenance program should be established based on the working
environment and the frequency and severity of use of the crane. The following items should
form part of an effective maintenance program:
replacement parts and components should be identical or equivalent to the original
equipment parts and components
a specific rectification program should be carried out where past experience has shown
particular problems with a crane
all safety-related malfunctions and problems should be corrected before the crane is
returned to service.
The owner of the tower crane must ensure that:
the necessary facilities and systems of work are provided and maintained so as to
minimise the risks to health and safety of persons maintaining, inspecting, repairing or
cleaning the crane
inspections, maintenance and cleaning are carried out having regard to procedures
recommended by the crane designer and manufacturer, or the relevant Australian
Standard, or as developed by a competent person
repair, inspection and, where necessary, testing is carried out by a competent person
all safety features and warning devices of the crane are maintained and tested
when the crane has been damaged to the extent that its function or condition is
impaired, resulting in increased risk to health or safety, a competent person assesses
the damage and advises the owner of:
o the nature of the damage
o whether the crane is able to be repaired, and if so, what repairs must be carried
out to minimise risks to health and safety
repairs to the crane are carried out so as to retain the crane within its design limits
annual maintenance, repair and inspection records are kept for the crane.
Tower crane repair
All worn or damaged parts of a crane that constitute a hazard, impair the operation of the crane,
or may constitute a hazard before the next routine inspection, are to be repaired or replaced. All
repaired or new parts must comply with the crane manufacturers recommendations or
specifications. Where these are not available, the repaired or new parts must comply with the
recommendations of a competent person.

9. Safe design of tower cranes
Crane stability
Stability is a crucial safety issue for tower cranes. Failing to maintain stability may lead to a
serious incident through mechanical or structural failure, or crane collapse. A tower crane
should be designed to be stable, and without risk of overturning, falling or moving unexpectedly
during erecting and dismantling, and under all operating conditions.
Tower crane stability depends on:
the stabilising moment of the cranethe crane counterweight generally provides the
primary stabilising moment
the overturning moment applied by the suspended load and wind
the footings and foundations designed for the specific crane installation
the design, number and location of crane ties
wind conditionsstability will vary according to the size and shape of the suspended
load and crane boom.
Stabilising and overturning moments
Load charts
Load charts, also called rated capacity charts, identify what the crane is able to lift safely.
Load charts must be written in English, and use metric units. Lifting operations should not take
place unless the load chart is fixed in the operators cabin in a clearly visible location. The load
chart must be available for the crane operator to verify that the crane is not being overloaded.
The lifting capacities specified on a load chart must never be exceeded, except during testing of
the crane, by a competent person, under controlled conditions or in emergency situations.
Counterweights
Tower crane counterweights are critical in ensuring crane stability. A counterweight that is too
light for a load and boom configuration may cause the crane to overturn in the direction of the
suspended load. A counterweight that is too heavy for the load and boom configuration may
cause the crane to fall over backwards.
Counterweights must be secured to the crane in the manner specified by the crane
manufacturer.
Footings and foundations
Footings and foundations for a tower crane installation must be designed in accordance with
engineering principles or relevant technical standards. This design must consider the results of
geo-technical inspections specific to the location of the crane installation.
Crane ties
Crane ties play a critical part in ensuring the stability of a tower crane as the height of the crane
increases. Crane ties must be secured to the supporting structure at set intervals in accordance
with the instructions specified by the crane manufacturer and the designer of the crane
installation.
Wind conditions
Operational wind speeds
Strong winds will impose additional loads on a crane and may affect the cranes stability. A
maximum permissible operational wind speed will be included for in the tower crane design but
this may not apply for operational purposes (that is, when a crane operator is at the controls,
and in the process of lifting a load).

Tower crane installations can be designed for a maximum operational wind speed of
72 km/hour (20 metres/second) as set out in AS 1418.4: Cranes, hoists and winches Tower
cranes. Although the tower crane base and crane ties may have been designed for this higher
operational wind speed, crane operators should not operate the crane in wind speeds that
exceed the manufacturers specifications or they consider to be unsafe.
A crane manufacturer will generally only specify a maximum wind speed in which to operate the
crane, ignoring the type of load to be lifted. In some cases, there may not be a maximum wind
speed specified for the crane itself. The effect of wind gusts will also have a different effect on
the crane than a constant wind. A crane operator must base the decision to make a lift on
information provided by the crane manufacturer, and prior experience as a crane operator. If the
operator believes a specific crane operation is hazardous, the operator may choose not to
operate the crane. Guidance should be sought from the crane manufacturer or a competent
person regarding the conditions under which a lift can take place safely.
Dual braking systems
Dual braking systems should be used in accordance with relevant technical design standards.
Dual braking systems must be provided on the luff function of all rope luffing tower cranes and
any other function specified by the crane manufacturer.
10. Ensuring stability of tower cranes

Tower cranes must be operated within their engineered design capacity. To ensure the stability
of a tower crane in windy conditions, the following factors should be addressed:
The crane manufacturer should state the maximum wind speed that the crane may be
operated in. However, such maximum operating wind speeds as stated by the
manufacturer may in particular circumstances be excessive, especially when the crane
boom and loads have large surface areas.
An anemometer (wind gauge) should be fixed on each tower crane, in an appropriate
location, to provide an accurate wind speed reading. The placement of the anemometer
should not be shielded from the wind, and will vary according to the type of crane. For
example, anemometers should be fixed on:
o the top of the A-frame on luffing tower cranes, or
o either the A-frame or machine deck hand-rail on non-luffing tower cranes.
Where a non-standard lift with a suspended load or large surface area is to be
undertaken in windy conditions, the competent person should provide written advice on
safe lifting conditions.
Climbing operations should not proceed where wind speed exceeds 36 km/hour (10
metres/second). However, it should be noted that this is a maximum wind speed, and
performing the climbing operation is up to the discretion of the rigging crew.
Operating tower cranes in wind speeds greater than 54 km/hour
If a tower crane must be operated in wind speeds greater than 54 km/hour, a documented risk
assessment should be carried out to determine:
the types of loads that can be lifted under these conditions
the control measures that need to be applied.
The risk assessment should involve a consultative process between the principal contractor,
crane owner and operator, and other members of the crane crew. Matters to be considered
during this consultative process include:
load surface area
size to weight ratio (density) (for example, a timber wall form will be more easily affected
by the wind than a concrete panel of the same frontal area)
boom length and surface area of the boom, including any attachments

the ability of the cranes slew motors and brakes to operate safely in high winds
the ability of doggers to control load movement, particularly when it is being slung or
unloaded
the ability of the crane operator to see the load, particularly when the load is being slung
or unloaded, and
the effect of wind on crane movement (for example, slewing against wind or luffing down
against wind), which may present a risk of rope bunching on the drum and the boom
dropping on rope luffing tower cranes.
Only tower cranes that have been designed to operate in wind speeds greater than 54 km/hour
may be operated under these conditions.
11. Signage on tower cranes

The attachment of signage on tower crane booms is not recommended as the signage will
affect the operation of the crane in windy conditions. Signs that are inappropriately attached to
the boom may detach during crane operations, and result in injury to persons in the vicinity of
the crane.
The design engineer for a tower crane installation must be aware of any requirement to attach
signage to the boom in order to make allowance for the size and weight of the signage. This
information must be included and allowed for in any crane base drawing. Signs should not be
attached to the tower crane boom unless consideration has been given to the potential wind
loading of the sign, and the resulting impact on the design of the crane base, tower sections and
crane ties.
Certification must be obtained from an engineer that the design of the sign and its attachments
to the crane are fit for purpose. This includes ensuring that maintenance on the sign will not be
required for as long as the crane is on site.
Flexible signs should be made of a UV resistant material that will not deteriorate over the life of
the crane installation. Flexible signs should be securely attached to the crane boom using an
appropriate tying system that will withstand potential wind loadings.
Solid signs should be attached to the boom by bolted connections that clamp around the
outside of the chords or lacings of the boom. An appropriate means of locking the nuts on the
bolts must be used.
When attaching solid signs:
holes should not be drilled into the boom
joints should not be welded on to the boom
strapping should not be used
cable ties should not be used.
12. Erecting and dismantling tower cranes

Failure to erect or dismantle tower cranes in accordance with the crane designers or crane
manufacturers instructions may result in injury to persons from:
crane collapse
falls from heights
falling objects.
Responsibilities for persons erecting or dismantling tower cranes
The process of erecting or dismantling a tower crane must minimise the risks to health and
safety.

A work method statement for the high risk construction activity of erecting or dismantling a tower
crane must be prepared and consider the following:
the crane designers or crane manufacturers instructions
technical standards relevant to access and egress
the cranes stability
any adverse effects on other plant, structures or work processes at the workplace
the use of special tools, jigs and appliances necessary to minimise the risk of injury
control measures for securing crane components
the interaction of the crane with other plant
environmental factors, such as wet or windy conditions
all relevant electrical installations associated with the crane comply with AS 3000:
13. Minimising risk of injury from crane collapse

Erecting and dismantling
Tower crane components must be inspected and tested before being delivered to the
workplace.
Written instructions about erecting and dismantling activities are to be readily available on site.
Tower cranes must not be erected or dismantled in conditions exceeding the crane
manufacturers specifications, or where the wind is such that components may become
uncontrollable when suspended. Wind loading must be considered during all erecting and
dismantling, including increased wind loads caused by funnelling effects between adjacent
buildings or structures, and the wind effect on large sections.
Erecting and dismantling activities should be supervised by a competent person and be in
accordance with the manufacturers instruction or those prepared by a competent person.
Obligation holders should ensure that the crane manufacturers instructions are followed for the
assembly of components in the correct sequence, and that the correct equipment and tools are
used. Crane manufacturers may require sequential installation or removal of counterjib,
counterweights and boom components.
Only parts and components that meet the specifications of either the crane manufacturer or a
competent person should be used when erecting a tower crane. Tower sections should be
clearly and permanently identified with their model type and serial number. Tower sections of
the correct model, or a model of greater strength, must be used. The tower sections used must
be the same as those specified on the engineers crane base drawing.
When erecting a tower crane, precautions should be taken to ensure:
only the correct type and grade of tower bolts are used when connecting tower sections
bolts and pins used to connect tower sections are compatible with crane components,
and are not defective
tower bolts are correctly torqued to ensure normal operating conditions do not cause
them to become loose or fatiguedover tightening of bolts can be as potentially
dangerous as insufficient tightening
crane ties are installed in accordance with instructions specified by the crane
manufacturer and designer of the crane installation.
Climbing tower cranes
The risk of serious or fatal injury from crane collapse is very high during tower crane climbing
operations. The climbing frame has to cope with significant static and dynamic forces involved
in climbing.
The risk of injury from crane collapse during climbing operations can be minimised by:

conducting climbing operations where practicable outside of normal work hours to
minimise the potential for persons to be at risk
excluding all unnecessary persons from the workplace during climbing operations
maintaining an exclusion zone of sufficient size to contain structural failure
prohibiting persons from entering the area directly behind the tower crane (under the
counterweights) during climbing operations
avoiding slew operations at all times during climbing operations
conducting a physical inspection of the counterweight trolleys, including side plates,
bolting and pins, safety gear, ropes and turnbuckles, prior to commencing climbing
operations.
All persons involved in climbing operations must receive thorough training and instruction in the
climbing procedure for the particular model and type of crane involved in the climbing sequence.
The climbing sequence should be carried out in accordance with the crane manufacturers
instructions. Climbing operations should not be attempted at wind speeds greater than
36 km/hour. However, this does not preclude the crane rigging crew from ceasing work at their
discretion if they think safety will be compromised at a lesser speed. Climbing operations should
not commence if either the recommended maximum wind speed or the actual wind speed is
unknown.
Precautions for certain tower cranes with moving counterweights
Some tower cranes are provided with moving counterweights on rails that slope downwards
away from the crane. These types of tower cranes require the counterweight to be positioned at
the top of the counterweight rail during the climbing process. The counterweight is kept in
position by means of a latch that locks onto a lug on the bottom of the rail. To help prevent
inadvertent release of the latch, a secondary means of securing the latch in place should be
provided (for example, connecting the latch lever to the machine deck with a rope or chain).
14. Safe access on tower cranes

Failure to provide safe access for crane operators and other persons carrying out inspection
and maintenance work on a tower crane will place these persons at risk of falling from a height.
Tower ladders
Wherever practicable, hoists should be used to access free-standing tower cranes. These are
typically available for new cranes or can be retrofitted. Workers should not have to climb more
than 30 metres to reach the operators cabin.
Where ladders are used, the type of ladder access may be determined by available space in
the tower. Landings, with changes in direction of the ladder, should be provided where there is
available space in the tower. This system will minimise fatigue, by allowing for rest breaks, and
the risk of injury to workers, for example, in the event of them falling off the ladder. It also allows
workers to take rest breaks while climbing.
Where practicable, the vertical distance between landings should not exceed six metres.
However, where the crane manufacturer has designed otherwise, the length of the lowest
ladder in the tower may be up to 12.5 metres and subsequent ladders may be up to 10 metres..
The use of continuous vertical ladders for accessing the total length of the tower is not
recommended. However, where it the tower design results in long ladders, the risk of fall must
be controlled, for example, by using a fall-arrest system that does not require the person to
constantly hook on and off. The system may incorporate a vertical rail or rope with a locking
cam device. The risk of injury to a person falling off a ladder can be reduced by ensuring the
length of lanyard between the person and the vertical rail or rope, does not exceed 300 mm.

The provision of rest platforms beside a vertical ladder is not an adequate control measure on
its own to reduce the potential fall distance of the person. The use of fold-down type platforms is
also not recommended because they can hinder rescue procedures, and increase the risk of a
person falling down the ladder.
Self-erecting tower cranes without cabins
Generally, the towers on most self-erecting tower cranes do not have to be climbed by persons
while in use. Instead, any maintenance required on the crane can often be carried out by
collapsing the crane. However, some self-erecting tower cranes are provided with ladders on
the towers for maintenance access. If a ladder is provided for maintenance activities only, the
ladder can be vertical and a permanent vertical rail or rope does not have to be provided.
However, any person climbing the ladder must be provided with a fall-arrest system. The use of
work platforms, such as elevating work platforms, should be considered for performing
maintenance activities.
Internal guardrail on tower landings
Internal guardrails on tower landings will minimise the risk of a person falling internally down the
tower. Some tower cranes should be provided with an internal guardrail to tower landings to
protect persons from falling down the access hole. For example, either a guardrail on the
internal side of the access hole, or a rail that extends around the back of the access hole could
be provided. It may be impractical to provide an internal guardrail on the top tower landing, as
slewing of the crane may cause:
the lower end of the ladder to strike and damage the internal guardrail
entrapment of any persons on the top tower landing.
Guardrails on machine deck and A-frame platform
Tower cranes should be provided with perimeter edge protection that extends around the
machine deck to prevent the crane operator and maintenance workers from falling. The edge
protection should consist of a top rail, a mid-rail and a kickboard.
A-frame ladder cage issues
A ladder cage should be provided on the A-frame to ensure that if a person falls off the ladder,
the person will be confined within the cage and fall onto the machine deck, not off the tower
crane. The lowest part of the ladder cage should be between 2 m and 2.2 m above the lower
deck. The horizontal spacing between the vertical bars on the ladder cage should not exceed
150 mm. Mesh infill may be used instead of vertical bars.
Saddle bag platforms
Saddle bag platforms may be required on tower cranes with moving counterweights to provide
access for riggers during the erection process, and for persons carrying out maintenance.
Climbing over the machine deck guardrail and down a ladder leading onto the platform is not
recommended to ensure persons do not fall off the tower crane when accessing the saddle bag
platform.
Safe access to the saddle bag platform can be achieved by either providing a trapdoor in the
machine deck, or a ladder cage on the saddle bag ladder. This platform should also be provided
with a top rail, mid-rail and kickboard.
Crane jib - non-self-erecting types
Tower cranes that require riggers and crane operators to access the jibs during erection,
inspection and maintenance should be fitted with a riggers run and static lines that extend for
the complete length of the jib. When persons use the static line, two lanyards, or a lanyard with
a pigtail at one end, should be used to ensure the person is attached to the crane at all times.

15. Self-erecting tower cranes
The use of self-erecting tower cranes more common, particularly on small to mid-sized building
sites. A self-erecting tower crane can be erected on site without using a mobile crane. Self-
erecting tower cranes are generally made up of a horizontal boom that folds out during erection,
and can include a telescopic boom. The counterweight is provided at the base of the crane.
Figure 1: Self-erecting tower crane
Unlike most other tower cranes, self-erecting tower cranes do not require fixing to a crane base.
On both hammerhead and luffing tower cranes, the operators cabin is typically located at an
elevated position, close to the butt of the boom. However, self-erecting tower cranes are rarely
provided with a cabin and instead are operated by remote control. While this feature can
sometimes be an advantage, as it allows the operator to walk around the site, it has also led to
incidents where the crane has collided with electric lines or other obstacles because the
operator was not located in the best position.
Operation of self-erecting tower cranes
Self-erecting tower cranes should be operated from a designated area. At all times during the
lifting operations, the crane operator should:
remain in close proximity to the crane, and
maintain good visibility of the load.
Where it is not possible for the operator to keep the load in sight, a dogger must report to the
operator on the position of the load to ensure safe operation.
Remote operation
Self-erecting tower cranes may be operated remotely by either:
hard-wired or pendant controls, or
wireless controls.
The reliability of the circuits on the controls should be the same as that achieved by controls in a
cabin. Wireless remotes should be uniquely coded to avoid corruption of signals and
interference from other devices.

Remotely operated tower cranes, including self-erecting tower cranes, should have a dedicated
operator who is available to operate the crane at all times. A sufficient number of competent
persons should be available to safely complete the lifts, especially where there are multiple
drop-off points that are out of sight of the operator. A dogger must direct the crane operator
whenever the load is out of sight of the operator.
The crane operator should remain stationary when the load is in motion. If the operator is
required to move to a different location, the crane should not be operated while moving and the
travel path is to be free from obstacles, penetrations and other hazards.
If the crane operator is also acting as the dogger or undertaking other tasks:
the remote control should be turned off and secured to prevent accidental activation of
remote functions or other persons using the crane
effective communications are to be maintained between the crane operator and other
personnel at all times.
When the self-erecting tower crane is not in use, appropriate control measures must be in place
to prevent unauthorised operation of the crane.
Erection of barricade around self-erecting tower cranes
Counterweights on self-erecting tower cranes are located at the base of the crane. Persons who
encroach into the slewing arc of the counterweights face the risk of being hit by them.
An 1800 mm high barricade (for example, mesh fence), should be erected around the base of
self-erecting tower cranes to prevent people from entering this area, and being hit by the
cranes counterweights. The barricade should be positioned to provide enough room to avoid
entrapment between the barricade and the counterweights.

APPENDIX C: REGISTRABLE CRANES AND HIGH RISK WORK LICENCES
The following matrix shows for specific types of plant which require design registration, item
registration or a High Risk Work licence to operate in relation to cranes:
Type of plant included in
HRW license required to

operate or erect this
Design registration
Item registration
Class of plant
this class
plant
Boom type elevating Self propelled No
work platform if boom extends
>11m
Trailer mounted No
if boom extends
>11m
Vehicle mounted No
if boom extends
>11m
Bridge crane Top running bridge crane No
if WLL if certain
>10 t conditions apply
Underslung bridge crane No
if WLL if certain
>10 t conditions apply
Concrete placement Static mounted with
units delivery boom
Truck mounted with
delivery boom
Gantry crane Gantry crane No
if WLL >5 if certain
t conditions apply
Semi-gantry crane No
if WLL >5 if certain
t conditions apply
Portside container crane No
Hoist Scaffolding hoist No
if lift is if lift >2.4m
>2.4m
Personnel and materials No
hoist if lift is if lift >2.4m
>2.4m
Platform hoist No
if lift is if lift >2.4m
>2.4m
Mast climbing work Single mast climber No
platform to install
Double mast climber No to install

Type of plant included in
HRW license required to

operate or erect this
Design registration
Item registration
Class of plant
this class
plant
Mobile crane Articulated crane
if WLL if WLL >10 t
>10 t
Crawler crane
if WLL if WLL >10 t
>10 t
Trailer mounted crane
if WLL if WLL >10 t
>10 t
Truck mounted crane
if WLL if WLL >10 t
>10 t
Vehicle self loading crane
if WLL if WLL >10 t
>10 t
Non slewing mobile crane
if WLL if WLL >3 t
>10 t
Multipurpose tool When equipped as an No
carrier elevating work platform if boom extends
>11m
When equipped as a No
crane if WLL >10 t
Tower crane Articulated jib crane
Luffing crane
Self-erecting crane
Trolley jib crane
Workbox Personnel work box No
to control
workbox

APPENDIX D: CRANE STABILITY
1. Mobile cranes
Stability function of load charts
The stability factors allow for variables such as:
dynamic factors caused by the crane motion and the load (for example, for boom
movement, application of brakes, swaying of the load), and
wind effects on the load and boom.
The stability factor of mobile cranes is typically based on 75% of tipping for stationary mode and
66.6% for pick-and-carry mode. All mobile cranes should comply with this design requirement
and the stability factor should be written on all load charts for the crane.
Where second-hand cranes are imported from overseas, the crane should be stability tested to
demonstrate it complies with these stability requirements
When the load chart is based on 75% of tipping, the maximum capacity in the stability range of
the load chart will be 75% of the suspended load that will cause the crane to overturn. In other
words, the actual overturning load will be 33.3% greater than the load being lifted. Therefore, if
a cranes maximum capacity at a given radius in the stability range of the load chart is 10
tonnes, a 13.3-tonne load will cause the crane to overturn. However, it is also possible for a
crane to overturn with smaller loads when operating in windy conditions or on sloping ground, or
if the crane is not operated smoothly.
Counterweights
The crane counterweight is critical in ensuring crane stability. A counterweight that is too light
for a load and boom configuration will cause the crane to overturn in the direction of the
suspended load. Additionally, a crane can fall over backwards due to the effect of the
counterweight in situations when:
the counterweight is too heavy for the boom configuration
the crane is travelling up a slope with the boom luffed up
inadequate timbers are placed under the outrigger pads below the counterweight when
the crane is positioned on soft ground
outriggers are not extended or lowered into position.
On the majority of smaller mobile cranes, the counterweight is fixed and cannot be easily
removed. However, on an increasing number of larger cranes, some of the counterweights are
designed to be removed for road travel, or when lighter loads are lifted. In this situation, it is
particularly important to attach the correct type and number of counterweights to the crane for
the particular lift to be undertaken.
Counterweights must be secured to the crane in the manner specified by the crane
manufacturer. Where counterweights are removable, each counterweight must be clearly and
permanently identified with the crane manufacturers name or trademark and the mass of the
counterweight (preferably in tonnes).
Where the crane is fitted with a rated capacity limiter, the data input into the computer must be
correct for the counterweight configuration on the crane, and related to that shown on the
appropriate load chart. This also applies to the boom configuration being used on the crane.
In some unusual circumstances, additional counterweights not included in the load charts or not
authorised by the manufacturer are attached to the crane to increase its capacity. If this is done,
an engineer should check the complete crane design and certify that the amended design
complies with relevant technical standards.

Roles and responsibilities regarding crane stability
While the crane operator is primarily responsible for crane stability to ensure a crane will not
overturn, other persons who are also responsible for the stability of a crane include:
the crane manufacturer and supplier
the principal contractor or relevant person
the crane owner, and
doggers.
The crane operator
Crane operators must have a comprehensive knowledge of the operating capabilities of the
crane and be competent to carry out the lifting operation to ensure the crane does not overturn.
The operator should have the final say about whether a lift should proceed and must be
satisfied that:
the crane is adequately supported on the ground and the crane is level to within the
tolerance specified by the crane manufacturer
materials placed under the outriggers or crawler tracks, to help ensure the crane does
not overturn, are set up to comply with the crane manufacturers specifications, or the
crane owners specifications if the former do not exist
the suspended load will remain within the rated capacity of the load chart
the functions of the crane are operating properly, including all crane motions, brakes,
load moment systems and indicators
the wind is not excessive for the load being lifted, particularly for loads with a large
surface area, and when the load is high above the ground.
Crane operators and doggers should also regularly inspect the ground to ensure that
continuous operation of the crane has not compressed the ground to the extent that further
operation of the crane will be unsafe.
An operator should not operate a pick-and-carry crane on gradients exceeding those specified
by the manufacturer. Operators should not be expected to calculate how much to de-rate the
capacity of the crane where the crane manufacturer does not provide written guidance on this
issue.
The crane manufacturer and supplier
The crane manufacturer must ensure that the crane complies with the strength and stability
requirements of the design standard to which the crane has been manufactured. The crane
manufacturer should be able to demonstrate that the stability of the crane with the stability
factor marked on the load chart.
The crane supplier must ensure that the information about the cranes stability factor is provided
to the crane user.
A principal contractor or relevant person
A principal contractor or relevant person should supply the crane crew with all relevant
information on the location of trenches, underground pipes, backfilled excavations and covered
penetrations at a construction workplace. In some situations, it will not be obvious that the
ground will support the crane by simply looking at the ground surface. Where documentation is
available to the principal contractor or the relevant person on ground bearing capacity, this
information must be made available to the crane operator.
The principal contractor or relevant person should obtain documented information about
the ground bearing pressure from a geo-technical engineer when a mobile crane is

required to perform heavy lifts including bridge beams and tilt-up or precast concrete
elements.
A principal contractor or relevant person must provide this information to the crane owner to
ensure the crane owner can verify that the mobile crane will have adequate support to carry out
the heavy lift.
A principal contractor or relevant person must not attempt to unduly influence a crane crew to
perform a lift that the crane operator considers to be unsafe.
The crane owner
Information on the loads imposed by each of the outriggers should be available from the
manufacturer. The crane owner should ensure that the timbers or pads supplied with the crane
will adequately support the crane. The crane owner may need to seek the advice of a
competent person when selecting appropriate materials to support the outriggers.
Where the timbers or pads supplied by the crane owner will not ensure adequate crane support
on soft ground with a bearing capacity of less than 10 tonnes per m2 the crane owner should
clearly state the minimum ground bearing capacity. This information should be placed in the
operators cabin.
The crane owner must be given information about the ground bearing capacity from the
principal contractor or relevant person before a mobile crane can be supplied to heavy lifts
including bridge beams and tilt-up or precast concrete elements.
Once this information is obtained, the crane owner can ensure that adequate control measures
are available to ensure the crane has adequate support to carry out the heavy lift.
The dogger
The dogger is responsible for the safe slinging and movement of the load and providing
accurate directions to the crane operator on load movement to ensure crane stability. This
includes:
communicating the weight of the load to the crane operator, where this is known, to help
ensure the rated capacity of the crane and lifting attachments is not exceeded
calculating the safe working load of the ropes, slings, chains and other lifting accessories
to be used in the lift
providing the crane operator with clear and accurate directions
communicating with other persons in the crane working area
taking adequate precautions when directing a pick-and-carry crane across rough
surfaces and checking the area for other hazards.
2. Ground conditions and crane support
Ground conditions can vary dramatically from one workplace to another, and even within the
one workplace. Failure to address poor ground conditions to ensure crane stability may cause
the crane to overturn resulting in serious injury to the crane operator and other persons in the
vicinity of the crane.
Ground factors
Factors that will affect the ability of the ground to provide adequate support include the
following:
the presence of water, including when it is mixed with the soil as mud, and where it is
present under the surface (for example, underground springs or streams)
the type of ground (for example, clay, sand, rock or a mixture of these)
backfilled ground that was previously an excavation or trench
cavities or penetrations in the ground that have been covered but still exist

continued operation of the crane in one location.
When a mobile crane is being set up, the crane operator can only make a decision based on the
surface of the ground. Where there is a concern, documented information about the ground
bearing pressure should be obtained from a geo-technical engineer. Generally, rock provides
the most stable supporting surface for a mobile crane. However, although rock may be present
on the surface, it may not extend far below the surface. One way to establish how far rock may
extend below the surface is to examine nearby excavations or trenches at the workplace. Rock
that extends far below the surface provides a good indication of the grounds integrity. However,
this will only provide a reasonable indication of the grounds strength when the excavation is not
too far from the crane. Additional risks must be managed when outriggers are positioned close
to an excavation.
Care must also be taken with ground that has a crust on its surface. The surface of this type of
ground is usually firmer than the ground underneath. The firm surface may give the perception
that the ground is more stable than it actually is. If the ground is punctured by an outrigger, or
the end of a crawler track, the softer ground will be exposed, which may cause the crane to
overturn.
Where a mobile crane is continuously operated in one location, the ground underneath the
outriggers will compact. Additional care must be taken to ensure that the crane has not
compacted the ground to the extent that the minimum overturning moment of the crane is
reduced (that is, the crane is more likely to overturn).
Crane proximity to excavations and trenches
When cranes are set up close to excavations or trenches, there may be an increased risk of the
sides of the excavation or trench wall collapsing, causing the crane to overturn. This risk
increases with softer ground, and the presence of groundwater. Additionally, the risk of collapse
is greater for vertical cuts in the excavation wall in comparison to walls that have been battered
back at an angle. The presence of slippery back, where there is a naturally occurring slip plane
such as a fracture in the ground, can also increase the risk of excavation or trench collapse.
Generally, the following principles should be applied when setting up mobile cranes near
excavations:
Where the ground is compact and non-friable (that is, not crumbling) the distance of any
part of the crane outrigger support dunnage from the excavation should be at least equal
to the depth of the excavation (general 1:1 rule).
Where the ground is loose or backfilled (that is, crumbling) the distance of any part of the
crane outrigger support dunnage from the excavation should be determined by a
competent person, for example a geotechnical engineer.
Timbers, pads and bog mats
A variety of materials can be used to distribute the mass of the mobile crane and the suspended
load to the ground. Lengths of timber (timbers) with rectangular cross sections (as shown in
Figure 2) are the most common form of outrigger pad. However, timber and plastic pads are
also provided for some cranes (see Figure 3).

Figure 2: Typical outrigger pad of timbers
Figure 3: Crane specific outrigger pads

For heavier lifts, bog mats usually consisting of steel plate, are often used under mobile cranes
and may be used under the tracks of crawler cranes or where larger lifts are carried out.
Crawler cranes will generally apply considerably less point load to the ground than a crane on
outriggers. This is because of the large area of tracks in contact with the ground in comparison
with the smaller contact area of the outriggers on cranes of similar capacity. However, for heavy
lifts, and where the ground has poor bearing capacity, bog mats or other supporting materials
may be required.
Timbers, pads and bog mats should be of dimensions and materials as specified by the crane
manufacturer. If the manufacturer has not provided this information, a competent person should
specify the minimum size of the material to be used.
Generally, the following principles should be applied to timbers, pads, steel plates and bog mats
used as outrigger pads:
timbers should have a minimum width of 200 mm and minimum thickness of 75 mm

timbers should be laid together so that the width of the timber pad is wider than the
outrigger foot with no gaps between timbers
the dimensions of steel plates and bog mats should be determined by a competent
person, based on the type of mobile crane.
Performing heavy lifts
The likelihood of a mobile crane overturning is greater when the crane is operated near its
maximum rated capacity or with loads at long radius and maximum load chart capacity.
The crane owner should compare the ground bearing capacity with the maximum pressure the
crane will apply to the ground for the lift. The maximum pressure applied by a crane is a
function of the crane mass, crane configuration (that is, boom length and centre of gravity) and
the mass of load on the hook. The ground bearing capacity must be greater than the maximum
pressure applied by the crane to the ground to ensure adequate crane support. If not, then
appropriate control measures, such as the use of appropriate outrigger pads, must be in place
to increase the ground bearing capacity before the lift is performed.
Cranes on outriggers (or stabilisers)
The use of outriggers on mobile cranes helps to provide greater stability to the crane when
lifting loads. Irrespective of the ground conditions, timbers or other means of distributing the
load should always be placed under the outriggers.
Outriggers should be set according to the manufacturers operating instructions for the specific
type of mobile crane. The outriggers are also used to level the crane.
Many older cranes are not designed for lifting with partially extended outriggers. However,
modern cranes do have multiple position outriggers. If one or more outriggers are not fully
extended, the crane may become unstable during lifting operations. In some instances, it may
not be possible to fully extend all outriggers. Only cranes that have the manufacturers approval
and appropriate overload interlocks to lift with partially extended outriggers should be used this
way. If a lift is to be undertaken with partially extended outriggers, the correct outrigger
configuration, according to the appropriate load chart, must be used.
Manufacturers of cranes should provide documented information on the maximum load and
pressure applied by the outriggers to the ground for the different boom configurations supplied
with the crane. This information should be included in the operation manual kept in the
operators cabin.
Calculating pressure applied by outriggers
A number of crane manufacturers provide information on the maximum ground pressure that is
applied when the crane is at maximum capacity, in the stability range of the load chart. Different
ground types will have different ground bearing capacities. Where the ground consists of a
combination of ground types, the poorer ground type should be used for determining the
maximum ground pressure that can be applied to the ground when the crane is set up on
outriggers. The table below indicates the typical maximum permissible ground pressure
according to the ground type.
Ground type Maximum permissible ground pressure, PMAX

(tonnes per m2)
Hard rock 200
Shale rock and sandstone 80
Compacted gravel (with up 40

to 20% sand)
Asphalt 20
Compacted sand 20
Stiff clay (dry) 20
Soft clay (dry) 10
Loose sand 10
Wet clay Less than 10
The greatest force applied by any outrigger to the ground will be:
at the point of tipping, just as the crane is about to overturn
when the crane boom is located directly above an outrigger foot.
Most cranes will overturn within the stability part of the load chart when the maximum rated
capacity is multiplied by a factor of 1.33. A crane will not approach this condition if set-up
correctly with safety devices and the operator does not overload the crane.
Crawler cranes
The ground pressure applied by crawler cranes is different to that applied by a crane on
outriggers. It is sometimes assumed that the ground pressure will be the same at any place
where the track is in contact with the ground. However, in practice this is rarely the case.
When the crawler crane is being used with a suspended load, the ground pressure will be
greater under the boom of the crane. If there is no load suspended on the crane, the ground
pressure will be greater under the counterweight
The distribution of ground pressure applied by a crawler crane will vary according to the working
radius, load mass, counterweight mass, and slew.

APPENDIX E: LIMITING AND INDICATING DEVICES
The purpose of limiting devices is to stop a specific crane motion before the crane moves out of
its load-radius limits into an unsafe situation. Indicating devices are used to visually or audibly
warn the crane operator that the crane may be approaching its set limits or an unsafe situation.
These devices may be used individually, or together, for specific crane motions.
Reliability of devices
Limiting and indicating devices are intended as an aid to crane operators. The devices should
not be relied upon to replace the use of the cranes load chart and operating instructions under
any circumstances. Sole reliance on these devices, especially indicating devices, in place of
good operating practices may cause an accident.
Where limiting and indicating devices are to be installed on a crane, the safety circuits of these
devices should generally meet either:
a reliability level of Category 4 under AS 4024: Safety of machinery, or
a safety integrity level (SIL) of 3 under AS 61508: Functional safety of
electrical/electronic/programmable electronic safety-related systems.
These categories of reliability level and SIL are related to the concept of fail-safe.
Rated capacity limiters
When an overload is detected a rated capacity limiter prevents further overloading of the crane
by stopping all relevant crane functions that will increase the overload. Rated capacity means the
maximum load that may be attached and handled by the crane in its current configuration, and
may not include the weight of the hook block, falls of rope, slings and rigging hardware. The
load to be raised must include the weight of all lifting appliances that are not permanently
attached to the crane. The cranes load chart will provide guidance on any deductions that may
need to be made.
Mobile cranes
Rated capacity limiters must be provided on all mobile cranes manufactured since 2002 with a
maximum safe working load of more than three tonnes. The limiter should prevent:
hoisting of a load, within the tolerance of 100 to 110% of the maximum rated capacity
the radius being increased when the load exceeds 100 to 110% at the particular radius.
Tower cranes
Rated capacity limiters must be provided on all tower cranes regardless of the age of the crane.
The limiter should prevent:
hoisting a load exceeding 110% of the maximum rated capacity
the radius being increased when the load exceeds 100% at the particular radius.
If the tower crane is designed and manufactured with a load indicator, the load indicator should
be maintained in a serviceable condition. Where a self-erecting tower crane is not fitted with a
load indicator, the crane owner should ensure that a system is in place to regularly test the
reliability and accuracy of the rated capacity limiter.
Vehicle-Loading Cranes
Rated capacity limiters should be provided on all vehicle loading cranes with:
a maximum rated capacity of one tonne or greater
a gross lifting moment of 40 kNm (kilonewton metres) or greater.

The purpose of the rated capacity limiter is to prevent movements that may increase load
moment in excess of the rated capacity, and to also prevent an increase of the load radius or
permissible stresses in the structure.
Where smaller vehicle-loading cranes are not fitted with a rated capacity limiter, relief valves
and fittings should be used to provide overload protection.
Motion limiting devices
Motion limiting devices are used to prevent physical damage to the crane or part of the crane
due to movement of the crane or part of the crane past its designed range of motion.
Mobile cranes
Motion limiting devices must be fitted to a mobile crane to prevent motion out of its service
limits. These devices cause braking, including deceleration where appropriate and stopping,
when the following extreme permissible positions have been reached:
the highest position of the hook (this is generally known as anti-two block)
the extreme permissible operating positions of the jib (luff limiter)
the end positions of horizontally telescoping or movable jibs.
Tower cranes
Motion limiting devices must be fitted to tower cranes to prevent motion out of their service
limits. These devices cause braking, including deceleration where appropriate and stopping,
when the following extreme permissible positions have been reached:
the highest position of the hook
the lowest position of the hook when persons are lowered in a workbox into a shaft
the extreme permissible operating positions of the jib (luff limiter) where a luffing motion
is part of normal working operations
the end positions of the trolley track on the jib
the end positions of horizontally telescoping or movable jibs
the end position of the tracks for rail-mounted travelling tower cranes.
Working radius indicator
Mobile cranes
A radius indicator displays the radius of the suspended load generally measured from the centre
of the slew ring. A radius indicator should be fitted on all mobile cranes that were originally
designed with this feature. The indicator should be displayed in metres and be accurate to
+10% and -3% of the actual radius.
Tower cranes
A radius indicator must be fitted on all tower cranes. A radius indicator displays the radius of the
suspended load generally measured from the centre of the slew ring. The working radius should
be displayed in metres and be accurate to +10% and -3% of the actual radius. Where the crane
is operated by remote control, and the jib is horizontal and fully visible to the operator, the
indicator may consist of one metre graduations marked on the jib with numbers written at
intervals that are not excessive (for example, every five metres).
Load indicators
Mobile crane
Load indicators should be fitted to all mobile cranes with a maximum rated capacity of more
than three tonnes. Load indicators measure and display the mass of the load being lifted. This
indicator assists the crane operator to stay within the load chart and safe working limit of the

crane. The load indicator should be capable of displaying the mass of the suspended load at all
times.
Vehicle- Loading Cranes
All vehicle-loading cranes manufactured after 2003 are to be fitted with a load indicator. The
load indicator must warn the crane operator when the load exceeds 90% of the rated capacity.
The load indicator must give a separate warning to the operator and persons in the vicinity of
the crane if the rated capacity is being exceeded.
The warning for approach to rated capacity must be clearly distinguishable from the warning for
exceeding the rated capacity by all persons while the crane is being operated. Both warnings
must be continuous.
Free fall lock-out
When a crane is fitted with a free fall facility, the free fall function is to be activated with a keyed
system that incorporated a non-adjustable timed reset function.

APPENDIX F: USING OTHER PLANT AS A MOBILE CRANE
Competency of operators
All operators of mobile plant must receive training in the use of the particular equipment they
are required to operate. When the mobile plant is used as a mobile crane, the operator of the
mobile plant may require additional training and competencies. In some circumstances, the
operator of the mobile plant may also need to hold the appropriate mobile crane licence class.
Rated capacity of other mobile plant
The rated capacity of other mobile plant is the maximum mass that may be handled at the
maximum lift point radius, or reach, for each lift point, without the strength and stability
requirements being exceeded. When determining the allowable load to be lifted, the mass of
any attachments, such as buckets or quick-hitch, must be deducted, unless the rated capacity
chart allows otherwise.
To ensure the stability of the mobile plant, the rated capacity of the plant must not be greater
than:
75% of tipping load in the stationary mode
66% of tipping load in the pick-and-carry mode
50% of tipping for articulated wheel loaders and tool carriers.
Rated capacity limiters
A rated capacity limiter prevents overloading of the plant by stopping all relevant functions when
an overload is detected. Rated capacity means the maximum load that may be attached and
handled and may not include the weight of the hook block, falls of rope, slings and rigging
hardware. The load to be raised must include the weight of all lifting appliances that are not
permanently attached to the plant.
Load chart
The load chart for the mobile plant should identify each lift point location, and the corresponding
rated capacity for each position. The appropriate load chart should be fixed inside the operators
cab and show the following information:
manufacturers name and model
boom and dipper arm identification and length, particularly where different boom
configurations may be used
track width, where this is variable
deductions for attachments, such as bucket or quick-hitch devices, so that the net
allowable load to be lifted can be determined
one of the following:
o the rated load at the least stable position
o where variable load rating is provided for, means to clearly determine the load
position in accordance with the rated capacity chart.
Lifting points on earthmoving plant
Lifting attachments on earthmoving plant are sometimes supplied by the plant manufacturer. If
this is not the case, the attachments should be designed by an engineer. Lifting attachments
often consist of a welded assembly that fits onto the end of the dipper arm when the bucket is
removed. All lifting points on earthmoving plant should form a closed eye, to which a load rated
shackle may be attached.
A static strength test at 200% of the rated capacity of each lift point should be carried out. The
lift points should not show any permanent deformation after testing. The test may be performed

with the component dismantled from the machine - this should be done if application of the test
load could result in damage to the earthmoving plant.
Hooks should not be used on the dipper arm or other attachments of earthmoving plant,
because the load may become unintentionally disengaged as the arm rotates. This can even
occur when the hook is fitted with a latch, because the latch may be damaged (for example,
with a mobile crane, the hook hangs vertical, with an excavator, the lifting point rotates).
When lifting lugs are welded to attachments or other parts of the earthmoving plant, the material
specifications for the two different components are to be compatible for welding, and the
appropriate welding procedures must be followed.
The attachment of lifting lugs to buckets is strongly discouraged for the following reasons:
Application of the lifted load to the outside of the bucket can load the pins and linkages
in a way other than the designer intended.
It is easier for the operator to unintentionally overload the plant by not allowing for the
dead weight of the bucket or because the bucket has earth stuck to the inside.
The lifting chain or sling can be damaged when a bucket is fitted because it may pass
over the front edge of the bucket.
Lifting lugs on buckets may be damaged when the bucket is used for digging activities.
Quick-hitches
A quick-hitch is a latching device that enables attachments to be rapidly connected to the dipper
arm or boom end of the plant. While the device saves time and effort, a number of fatalities
have occurred in Australia when excavator attachments have fallen off the quick-hitch due to
loss of hydraulic pressure.
Locking pins are generally used on quick-hitches to ensure the attachment is correctly engaged
and remains locked in position on the dipper arm. All quick-hitch devices should be fitted with a
locking pin unless the following can be ensured:
A system is provided to ensure the quick-hitch device is fully engaged on the bucket or
other attachment. Note: the system must not rely on the operator carrying out a visual
check on the quick-hitch attachment from the operators cabin.
Where the quick-hitch latching device relies on stored energy (for example, hydraulic
fluid pressure or a spring) to be activated, the latching device must be designed so that it
remains engaged in the event of failure of the source of stored energy (for example, drop
in hydraulic pressure or spring breakage).
Any factors that will affect the reliability of the latching device are listed in the quick-hitch
manufacturers instruction manual. This includes the need to ensure any contaminants in
the hydraulic fluid do not exceed limits as specified by the manufacturer of the pilot-
operated check valve, or other equivalent device. Evidence to demonstrate these
conditions are being complied with must be provided and kept with the earthmoving
plant (for example, in the plants logbook).
Burst protection and rated lifting capacities
Burst protection should be fitted on all earthmoving plant used as a crane, where the rated
capacity exceeds 1 tonne. The burst protection is to be fitted to both the boom and dipper arm
of the plant. Burst protection should comply with the performance requirements of ISO 8643:
Earthmoving machinery Hydraulic excavator and backhoe loader boom-lowering control
device Requirements and tests.
The following additional conditions should be applied:
The maximum rated capacity is to be in accordance with the manufacturers
specifications for the plant.

Single rated capacity: Unless the excavator is fully compliant with design requirements
of a mobile crane the lifting capacity of the plant at its maximum lifting radius is the rated
capacity and is to be marked on the boom or dipper arm. The rated capacity must then
be strictly observed at all times, irrespective of the radius of the load. Information should
be available on site to confirm that the rated capacity marked on the unit is the same as
that specified by the manufacturer.
Variable rated capacities: Where the plant has variable lifting capacities it should be fully
compliant with the design requirements for mobile cranes The manufacturers rated
capacity chart (load chart) is to be fixed to the inside of the operators cabin. For plant
with variable rated capacity, the lifting capacity at minimum radius is to be used to
decide whether burst protection is required.
Burst protection device must not be provided with the ability for the operator to switch
the device off.
Where the rated capacity of the plant is 1 tonne or less and the decision is made not to
fit burst protection, the plant must not be used to lift loads near workers.
Earthmoving plant owners should seek advice on fitting of burst protection from original plant
manufacturers, to help avoid fitting faulty or unsafe systems.

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Draft

1. Referencing technical standards (e.g. Australian Standards)

PAGE 2 OF 86 JUNE 2012

PAGE 3 OF 86 JUNE 2012

SCOPE AND APPLICATION .............................................................................................. 6

1.1 What is a crane? ............................................................................................... 7

2. MANAGING RISKS WITH CRANES IN THE WORKPLACE ....................................... 9

2.1 Identifying hazards ............................................................................................ 9

3. BEFORE USING CRANES IN THE WORKPLACE .................................................... 13

3.1 Planning the work ............................................................................................ 13

4. USING CRANES IN THE WORKPLACE.................................................................... 21

4.1 Crane documentation and markings ................................................................ 21

5. INSPECTION, MAINTENANCE, REPAIR AND DISMANTLING ................................ 34

5.1 Inspecting and testing cranes .......................................................................... 34

PAGE 4 OF 86 JUNE 2012

6. CONTROLLING RISKS IN SPECIFIC CRANE OPERATIONS .................................. 41

6.1 Mobile Cranes ................................................................................................. 41

APPENDIX A: DEFINITIONS ............................................................................................ 51

APPENDIX B: TOWER CRANES ..................................................................................... 55

APPENDIX C: REGISTRABLE CRANES AND HIGH RISK WORK LICENCES .............. 72

APPENDIX D: CRANE STABILITY................................................................................... 74

APPENDIX E: LIMITING AND INDICATING DEVICES .................................................... 81

APPENDIX F: USING OTHER PLANT AS A MOBILE CRANE ........................................ 84

PAGE 5 OF 86 JUNE 2012

How to use this Code of Practice

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1.1 What is a crane?

1.2 Who has health and safety duties in relation to cranes?

PAGE 7 OF 86 JUNE 2012

PAGE 8 OF 86 JUNE 2012

2.1 Identifying hazards

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2.2 Assessing the risks

2.3 Controlling risks

PAGE 10 OF 86 JUNE 2012

2.4 Maintaining and reviewing risk control measures

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3.1 Planning the work

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3.3 Hiring cranes

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3.4 Registering cranes

Further information on registering plant is available in the:

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3.5 Training, information, instruction and supervision

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3.6 Installation and commissioning of cranes

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3.7 Public safety and site security

3.8 Emergency Plan

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4.1 Crane documentation and markings

4.2 Crane operating personnel

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4.4 Setting up the crane

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