Crane Lift Plan

What Is a Crane Lift Plan?

A Crane Lift Plan is a written document used to control the risks associated with lifting operations. It is not just a paperwork exercise. Under Australian Work Health and Safety (WHS) laws, this plan serves as a critical control measure. It outlines how a specific load will be moved, the equipment required, and the steps taken to keep workers and the public safe.

For many construction and industrial tasks, using a crane is "High Risk Construction Work." The law requires you to manage these risks specifically. The plan acts as proof that you have thought through the lift. It shows that you have selected the right crane for the job, checked the ground conditions, and calculated the total weight.

This document applies to various lifting scenarios. It might be used for a standard lift on a small build or a complex critical lift involving massive loads. Regardless of the size, the goal remains the same. You must identify hazards and put controls in place before the crane starts the engine.

When to Use This Document

You must use a Crane Lift Plan for any lifting operation that carries significant risk. This is not just for massive infrastructure projects. If you are operating a mobile crane, you need to assess the situation carefully.

The law is clear on specific triggers. Under the WHS Regulation 2011, you must prepare a Safe Work Method Statement (SWMS) for High Risk Construction Work. This includes using mobile cranes with a rated capacity of 100 tonnes or more. It also includes erecting steel where a crane is required. Your Crane Lift Plan usually sits alongside or forms part of this SWMS.

You also need a detailed plan for "critical lifts." Industry practice and Australian Standards, such as AS 2550, define these. You should treat a lift as critical if:

• The load exceeds 75% of the crane's maximum rated capacity.
• You need to lift the load over live powerlines or other hazardous areas.
• The lift requires multiple cranes (tandem lifts).
• You are lifting personnel, which requires specific work boxes.
• The load is of unusual shape or balance, making it hard to control.

Even for smaller, routine lifts, a basic plan or pre-start check is vital. It ensures the operator and the dogger agree on the method. If you are the PCBU (Person Conducting a Business or Undertaking), you are responsible for ensuring this document exists before work starts.

Key Sections and Required Elements

A robust Crane Lift Plan covers several specific areas. Leaving these out can leave you open to prosecution and, more importantly, serious accidents.

Risk Assessment and Hazard Identification

This section is the foundation of the plan. You must list every hazard relevant to the site. This includes overhead powerlines, which are a major killer in the industry. You must identify "No Go Zones" as required by electrical safety regulations. Other hazards include ground conditions, wind, nearby structures, and public access.

You should reference your risk assessment matrix here. This shows how you rated the risk and what controls you put in place. For example, if the wind is a hazard, your control might be a mandatory wind speed check using an anemometer. You can link this to a broader risk assessment form to keep your records tidy.

Load Details and Rigging Configuration

You cannot guess the weight. This section must state the exact weight of the load. You must also add the weight of the rigging gear, the hook block, and any slings. This total is the "Lift Weight."

The plan must detail the rigging configuration. This includes the type of slings, the angle of the slings, and the use of spreader bars. If you are performing a tandem lift using two cranes, the law is strict. AS 2550 states that neither crane should carry more than 75% of its safe working load during a tandem lift. Your plan must show these calculations.

Crane Selection and Setup Data

You must prove the crane can handle the lift at the required radius. The plan needs the specific make, model, and year of the crane. It must include the relevant load chart for that specific machine.

Generic load charts are not acceptable. The plan should show the boom length, the radius, and the maximum capacity at that point. It must also detail the setup. This includes the use of outriggers, mats or pads to distribute the load, and the counterweight configuration.

Sign-Off and Authority

This section verifies that everyone knows their role. It serves as evidence of consultation, which is a legal requirement under the WHS Act. The plan needs signatures from:

• The Site Supervisor (representing the PCBU).
• The Crane Operator (who must hold a valid High Risk Work License).
• The Dogger or Rigger.

Signing the plan confirms they have read it and understand the controls. It does not transfer liability from the PCBU to the operator, but it shows that duty holders have communicated.

How to Write a Crane Lift Plan (Step by Step)

Writing a plan takes time. You should do it on site or with full knowledge of the site conditions.

Step 1: Assess the Site and Load

Visit the site before the lift date if possible. Look for overhead obstructions like powerlines. Check the ground where the crane will sit. Is it soft soil? Is it asphalt over pipes? You may need a geotechnical report to confirm the ground can bear the pressure.

Determine the exact weight of the load. Check manufacturer data sheets or weigh the load. Do not rely on guesses.

Step 2: Select the Right Crane

Choose a crane with enough capacity for the worst-case scenario. Do not cut it fine. If the load is 10 tonnes, do not pick a crane that can only lift 10.1 tonnes at that radius. You need a buffer for dynamic factors like wind or sudden movements.

Select the rigging gear. Ensure all shackles, chains, and slings are tagged and in test date. Record these details in the plan.

Step 3: Complete the Document

Fill out the Crane Lift Plan template. Be specific. Write down the serial numbers of the crane and the lifting gear. Attach the specific load chart pages.

Calculate the "Working Load Limit" (WLL) of your rigging configuration. Ensure it exceeds the weight of the load. Detail the emergency procedures. What happens if the crane fails? What happens if a storm approaches?

Step 4: Brief the Team

Hold a toolbox talk before the lift. Walk the crew through the plan. Point out the hazards you identified. Show them the "No Go Zones." Ensure the operator and dogger agree on the hand signals.

Step 5: Review and Sign

Get the signatures. The operator must sign before the lift begins. Keep the document on site while the work is underway. If conditions change, such as the wind picking up, stop work and review the plan.

Common Mistakes to Avoid

Many mistakes happen because people rush or treat the plan as a "tick and flick" exercise.

Ignoring the Environment

A common error is planning for perfect weather. Australia can experience sudden wind changes. If your plan does not state the maximum wind speed limit for the lift, it is incomplete. The crane manufacturer's manual will state the maximum wind speed. You must include this in your plan.

Blind Signatures

Never sign a plan after the work is done. Inspectors from Safe Work NSW or WorkSafe Victoria will check the dates. If the signature is dated after the lift occurred, you face heavy fines. The signature confirms that a pre-lift briefing happened.

Poor Ground Management

Failing to account for ground bearing pressure is a major cause of accidents. If the outriggers sink, the crane can topple. You must specify if you are using timber mats or steel pads. Do not assume the concrete driveway is strong enough to support a 100-tonne crane. You need to know the rating of the concrete.

Using the Wrong Load Chart

Every crane model has a different load chart. Using a chart for a similar model is not safe. The plan must reference the chart for the exact crane serial number. If you change the crane on the day, you must update the plan.

Legal Considerations (AU)

The legal framework in Australia is strict. The laws aim to ensure that PCBUs take responsibility for safety.

The WHS Act and Regulations

Most Australian states follow the model WHS laws. This includes NSW, Queensland, South Australia, Tasmania, the ACT, the Northern Territory, and Western Australia.

Under Section 19 of the Work Health and Safety Act 2011, the PCBU has a primary duty of care. You must ensure, so far as is reasonably practicable, the safety of workers. This means you must eliminate or minimise risks. A Crane Lift Plan is your main tool to show you have done this.

High Risk Work Licenses

The crane operator must be licensed. Under the WHS Regulation 2011, operating certain cranes requires a High Risk Work License (HRWL). This includes classes like C0, C1, C2, C6, CN, CV, and others. Your plan must record the license number of the operator. If an unlicensed operator performs the lift, you are breaking the law.

Victoria and Non-Harmonised Jurisdictions

Victoria uses the Occupational Health and Safety Act 2004 (Vic) and the Occupational Health and Safety Regulations 2017. While the wording is different, the duty is similar. Regulation 215 covers high-risk work, including lifting with powered mobile plant. You must identify risks and provide controls. A Crane Lift Plan meets this requirement.

Consulting with Workers

Section 46 of the WHS Act requires you to consult with workers. You cannot write the plan in an office and hand it down without input. The operator and dogger must have the chance to review it. Their signature on the document is proof that this consultation took place. Ignoring this duty can lead to notices from regulators.

Duty to Retain Records

You must keep your SWMS and Lift Plans. If an inspector visits your site, they will ask to see them. In the event of an incident, these documents are critical evidence. You should store them securely, either physically or digitally, as part of your business records.

Frequently Asked Questions

Do I need a plan for every lift?

For simple, routine lifts within the crane's safe working load and clear of hazards, a daily pre-start check or a "standard lift" checklist may be enough. However, for critical lifts, high-risk work, or whenever safety is in question, a full written plan is required.

Who is responsible for writing the plan?

The PCBU is ultimately responsible. However, they often delegate the writing to a competent person. This might be the site supervisor, a qualified rigger, or an engineer. The PCBU must ensure the person writing it has the skills and knowledge to do so.

Can I use a digital template?

Yes. Digital tools are becoming the standard. They allow you to include photos, GPS locations, and digital signatures. Just ensure the template covers all the legal requirements of the WHS Regulations.

What happens if the weather changes?

If the weather worsens, the plan may become invalid. For example, if wind speeds exceed the limit set in the plan, you must stop the lift. You should not proceed unless you review the risk and update the controls.

Is the plan a contract?

It is a legal record, not a contract for service. It proves that the PCBU and workers have identified risks and agreed on a method. It helps ensure everyone meets their duties under the Act.