SMS-06-GD-1292 Mobile Cranes v1pt1 A

System Guide
Mobile Cranes
Title: Mobile Cranes Issue date: 12/11/08
Number: SMS-06-GD-1292 Review date: 12/11/11
Version control
Version Change from previous Date Comment
1.0 First version 1/11/08
1.1 Minor amendments to definitions 14/11/08 Introduced the requirement for crane
of High Risk crane activity use in rail corridor to be classified as
high risk only where the lift exceeds
50% of the crane’s lifting capacity.
Also amended definition of use in rail
corridor to only apply when electrical
infrastructure has not been isolated.
Removed reference to specific
inspection checklists for recording
pre-start inspections.
Custodian: Manager SMS Operations © RailCorp

Approved by: GM Safety Systems Version: 1.1
Uncontrolled copy when printed 2 of 30
Contents
1. Purpose and scope............................................................................................................... 5
2. Background........................................................................................................................... 5
3. Planning mobile crane use .................................................................................................. 6

3.1 Selecting the crane........................................................................................................................ 7
3.1.1 Design .............................................................................................................................................7
3.2 Assess the site and lift................................................................................................................... 8
3.2.1 Ordinary lifts ....................................................................................................................................8
3.2.2 High risk lifts and Mobile Crane Work Plans ...................................................................................8
3.3 Crane siting controls...................................................................................................................... 9
3.3.1 Overhead powerlines and other exposed electrical equipment .......................................................9
3.3.2 Risk of collision .............................................................................................................................10
3.3.3 Proximity to excavations................................................................................................................10
3.3.4 Proximity to underground services ................................................................................................11
3.3.5 Crane stability and outriggers........................................................................................................11
3.3.6 Sloping ground ..............................................................................................................................12
3.3.7 Wind speed ...................................................................................................................................13
3.4 Erecting and dismantling mobile cranes ..................................................................................... 14
4. Mobile crane operation ...................................................................................................... 14
4.1 Lifting gear................................................................................................................................... 14
4.2 Crane overload ............................................................................................................................ 15
4.3 Unsecured and dropped loads .................................................................................................... 15
4.4 Lifting materials ........................................................................................................................... 15
4.4.1 Material boxes...............................................................................................................................16
4.5 Exclusion zones .......................................................................................................................... 16
4.6 Multiple crane lifts........................................................................................................................ 17
4.7 Leaving the crane unattended..................................................................................................... 18
4.8 Workboxes and first aid boxes .................................................................................................... 18
4.8.1 Crane requirements when using workboxes and first aid boxes ...................................................18
4.8.2 Features of workboxes and first aid boxes ....................................................................................18
4.8.3 Safety of persons in crane-lifted workboxes..................................................................................19
5. Use of other mobile plant as a mobile crane ................................................................... 19

5.1 Telehandlers................................................................................................................................ 20
5.1.1 Design ...........................................................................................................................................20
5.1.2 Operation ......................................................................................................................................21
5.2 Rated capacity............................................................................................................................. 22
5.2.1 Load chart .....................................................................................................................................22
5.2.2 Lifting points on earthmoving plant................................................................................................22
5.2.3 Quick-hitches ................................................................................................................................23
5.2.4 Controlled lowering devices ..........................................................................................................23
5.2.5 Operator competency....................................................................................................................23
6. Use of mobile cranes for tree-lopping .............................................................................. 23
7. Vehicle-loading cranes....................................................................................................... 24
7.1 Mounting of vehicle-loading crane .............................................................................................. 24

7.2 Rated capacity indicators and limiters......................................................................................... 24

7.3 Operation of vehicle-loading cranes............................................................................................ 24
8. Inspection of cranes........................................................................................................... 25
8.1 Pre-start inspection ..................................................................................................................... 25
8.2 Routine maintenance and inspection .......................................................................................... 25
8.3 Periodic inspection ...................................................................................................................... 26
8.4 Major inspection .......................................................................................................................... 26
8.5 Records of inspections and maintenance ................................................................................... 26
9. Training and competency .................................................................................................. 27
9.1 General training and competency requirements ......................................................................... 27
9.2 Scheduled work ........................................................................................................................... 27
9.2.1 Crane operator ..............................................................................................................................27
9.2.2 Dogger ..........................................................................................................................................28
9.2.3 Rigger............................................................................................................................................28
9.2.4 Familiarisation training ..................................................................................................................28
9.2.5 Refresher training..........................................................................................................................28
9.2.6 Training records ............................................................................................................................29
9.3 Competency for carrying out crane inspections .......................................................................... 29
9.4 Competency for certifying crane alterations................................................................................ 30
10. References .......................................................................................................................... 30

1. Purpose and scope

To ensure that the planning of lifts by mobile crane and their operation considers the:
• safety of workers and other people
• protection of the environment
• protection of property and services.
This guide applies to RailCorp managers, supervisors, employees, contractors and sub-
contractors involved with the use and operation of mobile cranes.
This guide applies to use of:
• slewing mobile cranes (including vehicle loading cranes)
• pick and carry cranes, such as telehandlers and articulated cranes
• excavators, loaders, tractors etc fitted with lifting attachments
• rail-mounted cranes
• truck-mounted cranes.
It does not apply to fixed cranes, such as tower cranes and gantry cranes, elevating
work platforms or boom-type concrete pumps.
2. Background
Competent and trained personnel must oversee and undertake all mobile crane
operations. All lifts must be planned, prepared and conducted to ensure the safety of
people, environment and property.
Examples of hazards specific to mobile cranes and their use that may need controlling
include:
• mechanical or structural failure of the crane, or a component
• supporting structure collapsing
• crane tipping over
• ground giving way
• overloading
• contact or collision with other plant or structures, particularly rollingstock and track
infrastructure
• contact with overhead powerlines or other electrical equipment
• persons being struck or crushed by operating crane or movement of suspended
load
• falls associated with access for cranes or for erecting or dismantling activities
• falling objects
• noise
• ergonomic hazards associated with manual handling of loads and lifting gear.

High risk crane lifts require a greater level of assessment, planning and control and the
completion of a crane siting and lift plan. The Mobile Crane Work Plan template is to be
used when a RailCorp employee is to control a crane lift.
A ‘high risk lift’ is any mobile crane lifting operation involving one of the following:
• the load exceeds 75% of the rated capacity of the crane during the course of the lift
• the load exceeds 50 tonnes
• multiple crane lifts, where more than one crane is used to lift a load at any one time
• any crane operation within the Rail Corridor where 50% of the crane’s rated
capacity is exceeded
• lifting over the Rail Corridor
• lifting over a public space
• lifting and erection of tilt-up concrete panels
• lifting large pressure vessels or tanks
• lifting in the vicinity of live overhead powerlines or other live exposed electrical
equipment
• lifting persons in workboxes
• lifting likely to be carried out in conditions where wind speed is 36km/h (10m/s) or
more
• using a crane on suspended ground or floor
• using a mobile crane for tree lopping
• using a mobile crane on a barge
• using a crane above buried services
• installing bridge beams during bridge installation work
• where pick and carry cranes are required to travel over sloping or uneven ground
• the crane is standing on soft or previously disturbed (excavated) ground or fill.
3. Planning mobile crane use
Warning
Failure to comply with these procedures could result in serious injury,
electrocution, damage to property, or the failure of RailCorp services,
power, and signalling or communication systems. The loss of any rail
infrastructure service could have major consequences to rail safety.
A range of competent persons may be required to assess, plan and carry out crane
lifting operations including:
• licensed crane operators, riggers and doggers trained and instructed in the safe
operation, maintenance and inspection of cranes and associated equipment
• qualified engineers to calculate loads, centre of gravity and ground bearing
capacity
• qualified mechanical assessors to undertake periodic inspections in accordance
with codes and Australian Standards.

3.1 Selecting the crane

If crane characteristics do not match job requirements, then unsafe conditions are
created before any work is done. The person responsible for the job is to select the type
and number of mobile cranes to suit the particular needs of the lifting operation and
workplace. Where necessary, safety and/or crane specialists should be consulted for
advice.
When selecting a mobile crane, assess the size and characteristics of the crane against
the following criteria:
• the weights, dimensions and lift radii of the heaviest and largest loads to be lifted
• the maximum lift height and radius, and the weight of the loads to be handled at
these points
• the number and frequency of lifts to be made
• how long the crane will be required at the workplace
• the type of lifting to be done (e.g. precise placement of loads)
• the type of carrier required—this depends on ground conditions and machine
capacity in its various operating quadrants
• whether loads are to be walked or carried
• whether loads are to be suspended for lengthy periods of time
• the workplace conditions, including the ground on which the crane is to be set up,
access roads and ramps it must travel on, space for erection, and any obstacles
that may impede access or operation.
Each of the basic mobile crane types has advantages and disadvantages. Supervisors
are to:
• select the best crane type for the job to be undertaken
• as necessary arrange a planning meeting at which all potentially affected parties to
discuss the most appropriate type of crane to perform the lifting operation and the
safe method of work to be employed
• for high risk lifts, consult with a range of experts to safely plan the lifting operation,
including as necessary:
− persons with crane safety expertise
− riggers
− mechanical engineers
− geotechnical engineers.
3.1.1 Design
Supervisors are to make sure that all mobile cranes used by RailCorp are certified by
the supplier that the crane is compliant with the applicable part of AS1418 Cranes,
hoists and winches.

Registration and modification
Mobile cranes with a rated capacity over 10 tonnes must be:

• design registered with WorkCover. Any modifications that may affect the safety of
the crane must be submitted to WorkCover for approval before use
• item registered with WorkCover.
In addition to certification of compliance to AS1418, supervisors are to sight proof of
design and item registration before use of hired cranes.
3.2 Assess the site and lift

The siting of mobile cranes is very important in maintaining safe lifting operations,
particularly crane stability.
Before any mobile crane is used or operated, the RailCorp Supervisor (or their
delegate) must use the Mobile Crane Use Checklist to assess the planned lifting
operation. The outcome of the assessment will determine if the lifting operation is an
‘ordinary’ lifting operation or a ‘high risk’ lifting operation.
3.2.1 Ordinary lifts

Whilst lifting operations assessed as ‘ordinary’ do not require the development of a
specific Mobile Crane Work Plan, these lifting operations must still be carried out in
accordance with this guide, the relevant part of AS2550 and any applicable SWMS or
SWIs.
If repetitive tasks are carried out in a static environment and where circumstances will
not change (e.g. where mobile cranes are used to perform the same task in a
Maintenance Centre) the completed Mobile Crane Use Checklist must be kept with the
Plant Risk Assessment for that particular mobile crane.
3.2.2 High risk lifts and Mobile Crane Work Plans

If the assessment indicates the lift is a ‘high risk lift’, a competent person such as a
qualified rigger, engineer, or WorkCover certificated crane operator must prepare a
Mobile Crane Work Plan.
If the competent person is employed by RailCorp they must use the Mobile Crane Work
Plan template.
If the competent person is a contractor, their Mobile Crane Work Plan must contain, as
a minimum:
• marking of rated lifting capacity
• a diagram of the position of the cranes
• maximum load radius to be used for the cranes
• the load to be lifted and the final position to which it is to be lifted
• position of set down and pick up of loads, including any intermediate stages/lifts,
such as initial pick up and set down off delivery truck and associated rated lifting
capacity details
• location of overhead powerlines or other exposed electrical equipment

• location of underground services

• position of outriggers and load distribution area details, i.e. area and position of
load mats or timbers
• position of doggers, where more than one and load will move out of the crane
operator’s sight
• maximum permissible wind speed.
Where required the Mobile Crane Work Plan must also address:
• position of spotters
• traffic management and control measures
• barricading and details of other restrictive measures
• verification of the maximum allowable ground bearing pressure; this is mandatory
for the lifting of loads over 50 tonnes, concrete panels and bridge beams
• allowance for any factors that may require the crane to be de-rated (e.g. for
multiple crane lifts, additional radius caused by tilting of tilt-up panels)
• rigging requirements of the job.
3.3 Crane siting controls
Warning
Wherever practicable, work in the vicinity of overhead power lines or other
exposed electrical equipment is to be carried out after the electrical supply
has been isolated and all permit requirements fulfilled.
3.3.1 Overhead powerlines and other exposed electrical equipment

The person planning the use of the crane must:
• establish the crane’s likely proximity to and operating reach with overhead
powerlines or other exposed electrical equipment present and
• determine the applicable safe approach distance requirements.
The planner must consider the crane and its load’s full range of movements (design
envelope), including movements during set up and inadvertent movement due to
operator error. Refer to Section 14 of the Safe Use of Mobile Plant guide for full details.
When work will occur near or in vicinity of overhead powerlines or other exposed
electrical equipment, the RailCorp Supervisor is to consider the practicability of either
temporarily or permanently relocating the electrical equipment so it no longer
represents a hazard to workers. Where this is not practicable, eg for short duration low
value construction projects, then the next consideration must be to eliminate the
electrical hazard by isolating the power for the duration of the lifting operation.
Where overhead powerlines or exposed electrical equipment is de-energised an
electrical permit must be obtained from the service owner. All persons involved in the
lifting operation are to sign off on the electrical permit.
Where RailCorp owns the overhead power line or exposed electrical equipment an
Electrical Permit to Work must be obtained as follows:

• situations that require electrical permits are specified in Section 7.1 of SMS-06-GD-
0268 Working around Electrical Equipment document. For isolation to be achieved,
the SMS-06-FM-0484 Request for Electrical to Work form must be completed and
submitted to the respective regional nominated electrical representative
• compliance with the provisions of SMS-06-SW-0267 Working in Accordance with
an Electrical Permit and SMS-06-EN-0598 Electrical Permit to Work
• persons holding or receiving electrical permits must be Accredited Electrical Permit
Holders as stipulated in SMS-11-GD-0244 Personnel Certifications – Electrical
Authorisations guide.
Generally, it will harder to obtain isolation of 1500vDC overhead traction system than it
will be to obtain isolation for the high voltage network. If short term crane operation is
required in the vicinity of the 1500v DC overhead traction system and isolation will not
be granted due to the impacts on train movements, then the person planning the crane
operation must consider rescheduling the lifting operation until a time when isolation will
be granted, e.g. during a possession.
Elimination not practicable
Where the work may infringe the relevant safe approach distance at any stage, and it is
not practicable to isolate the electrical supply, the person in control must use the
highest practicable control measure, or combination of measures as set out in the Safe
Use of Mobile Plant guide, to control the risks. These controls may include the use of
one or more of the following – limiting devices, physical barriers, bunting, signage and
trained safety observers.
3.3.2 Risk of collision

Mobile cranes are to be positioned to minimise the risk of injury from collision with rail
traffic, plant and vehicles. Supervisors are to follow the requirements of SMS-06-GD-
0333 Worksite Traffic Management and SMS-06-GD-0372 Working in or near Public
Roads guides and develop and implement appropriate traffic management plans.
When used in the Rail Corridor, or where the crane design or its load could impact upon
the safe operation of the railway, worksite protection is to be applied in accordance with
the Network Rules and Procedures.
When considering the potential to impact the railway, the Protection Officer must
consider operator error and/or failure of the crane.
3.3.3 Proximity to excavations

When cranes are set up close to excavations, there is an increased risk of the
excavation side 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 plain such as a fracture in the ground, can also increase the risk of
excavation collapse.
The following principles must be applied when assessing the site of mobile cranes near
excavations:

• Where the ground is compact and non-friable (i.e. not crumbling), the distance of
any part of the crane support timbers from the excavation must be at least equal to
the depth of the excavation (1:1 rule).
For example, for a three metre deep trench in compact ground, the outrigger
timbers or pads should be a horizontal distance of at least three metres away from
the closest edge of the trench wall.
• Where the ground is loose or backfilled (i.e. crumbling), the distance of any part of
the crane support timbers from the excavation should be at least twice the depth of
the excavation (2:1 rule).
For example, for a three metre deep trench in backfilled ground, the outrigger
timbers or pads should be a horizontal distance of at least six metres away from
the closest face of the trench wall.
Where the above principles cannot be adhered to advice from a competent person such
as a geotechnical or civil engineer must be sought.
3.3.4 Proximity to underground services

Where the mobile crane will use outriggers for stability, the person in control of the
lifting operation is to:
• identify all underground services that may be affected by the bearing load of the
outriggers, and
• make sure the crane is sited where it will not damage underground services.
To locate RailCorp owned services fax/email the Regional Services Search
Coordinator, Asset Management Group a completed Services Search Request form to
request either:
• a Detailed Service Search (DSS) to identify all services, including those above and
below ground and those owned by other organisations (e.g. Energy Australia), or
• an Internal Service Search (ISS) that identifies RailCorp’s services only.
Persons should allow a minimum of:
• 16 weeks for a DSS
• 6 weeks for an ISS.
To locate non-RailCorp underground services outside or within the Rail Corridor contact
Dial Before You Dig (DBYD) by phone on 1100 or electronically at
www.dialbeforeyoudig.com.au.
Irrespective of load weight and depth of service, where there are underground services
located beneath the crane’s outriggers, Supervisors must seek advice from RailCorp’s
Underground Asset Manager. Where the service is owned by another utility, the person
in control of the job must contact the service owner for advice.
3.3.5 Crane stability and outriggers

The person in control of the lifting operation is to ensure the ground on which the crane
is sited has adequate bearing capacity to support the crane during the lifting operation.
The likelihood of a mobile crane overturning is greater when the crane is used to lift
heavy loads.
Certification of the ground bearing capacity is to be obtained from a geo-technical
engineer before lifting the following:

• bridge beams
• tilt-up panels
• other loads of 50 tonnes or more.
Outriggers are used on mobile cranes to help level the crane and provide greater
stability when lifting loads. Irrespective of the ground conditions, timbers or other means
of distributing the load must be placed under the outriggers. Outriggers are to be set
according to the manufacturer's operating instructions for the specific mobile crane
type.
Many cranes are not designed for lifting with partially extended 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. Supervisors
must make sure that:
• only cranes that have the manufacturer's approval to lift with partially extended
outriggers are used this way
• if a lift is to be undertaken with partially extended outriggers, that the correct
outrigger configuration according to the appropriate load chart is used.
Generally, the following principles are to be applied to timbers, pads, steel plates and
bog mats:
• timbers are to have a minimum width of 200mm and minimum thickness of 75mm
• timbers are to be laid together so that the timber pad width is wider than the
outrigger foot with no gaps between timbers
• pads are to have a minimum thickness of 75mm
• a competent person determines the dimensions of steel plates and bog mats
according to the mobile crane type.
3.3.6 Sloping ground

Many crane rollovers occur when pick-and-carry cranes travel with a load along a side
slope. Working on a slope affects the working radius of the crane which may affect the
crane’s stability and cause it 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 applies
particularly when:
• the boom has a high luff angle
• the boom is telescoped out
• the suspended load has a high centre of gravity.
A side slope of just two or three degrees can have a drastic effect on the stability of the
crane. Uneven ground, soft ground, pneumatic tyres and suspension movement also
increases the side angle of the crane and increases the risk of overturning.

Most pick-and-carry mobile crane manufacturers specify that these cranes are to be
operated on firm level ground. In practice, it can be very difficult to ensure the ground
surface for a pick-and-carry crane is firm and level. This is particularly the case at a
workplace where construction work is being performed where the ground condition and
slope may be constantly changing. A pothole has the same effect as a gradient if the
crane’s wheel enters the hole.
Note
It may be necessary to fill surface depressions and potholes or place mats
or other artificial surfaces to prevent pick and carry cranes from tilting
whilst travelling
Where possible avoid using pick-and-carry cranes on sloping ground. If working or

travelling on a slope is unavoidable the operator should consider carrying the load on
the uphill side of the crane, regardless of the direction of travel. Travel on a slope is to
be up or down the slope, not across the slope. Reference should be made to side de-
ration charts prior to carrying out this work.
Refer also to section 5.1 for more specific information on telehandlers and their
limitations.
3.3.7 Wind speed
Warning
If wind speed exceeds the maximum figure stated by the crane
manufacturer for a specific mobile crane, crane operations are to stop
immediately.
Mobile cranes are to be operated within their engineered design capacity. To ensure
the mobile crane stability in windy conditions, the following factors are to be addressed:
• if the manufacturer's wind speed limit is not known the operator must cease
operations if wind speed exceeds 36km/h (10m/s); in many situations, this speed
may need to be reduced, particularly where the load and boom have large surface
areas
• where the crane is lifting close to its rated capacity, the wind has a greater effect on
the crane stability and the potential application of a side load on the crane’s boom
• where the lift is non-standard, with a suspended load or large surface area to be
undertaken in windy conditions, the competent person in control of the lift is to
address wind speeds and control measures in the Mobile Crane Work Plan and/or
SWMS.
• consider attaching wind gauges to mobile cranes or providing another reliable
method of measuring wind speed (e.g. handheld wind gauge). Where wind gauges
are to be attached to the crane, they are to be mounted at the top of the main boom
and calibrated at predetermined intervals, to make sure they provide accurate
readings.
• mobile cranes with a maximum rated capacity of the crane of 100 tonnes or more
must have wind gauges fitted.

3.4 Erecting and dismantling mobile cranes

Operators are to make sure written instructions for erecting and dismantling the mobile
crane are available with the crane. The competent person controlling the lift must
supervise all erecting and dismantling activities. Only parts and components that meet
the specifications of either the crane manufacturer or the competent person are to be
used when erecting the mobile crane.
Erecting and dismantling activities are likely to produce falling objects. To minimise the
risk of persons being hit by falling objects during these activities, control measures are
to be included in either the Mobile Crane Work Plan or SWMS. Controls may include:
• erection and maintenance of effective barricades at an established distance around
the mobile crane
• allowing only persons directly involved in erecting and dismantling activities inside
barricaded area, and/or
• scheduling the erecting and dismantling of the crane when the movement of other
persons and mobile plant at the workplace is at a minimum.
4. Mobile crane operation

RailCorp Supervisors are to make sure that mobile cranes are operated in accordance
with the relevant part of AS2550. In particular, the following control measures are to be
implemented.
4.1 Lifting gear

Make sure that lifting gear is safe for use in crane lifting operations. Basic items to be
checked include:
• the lifting gear is tagged and all relevant information listed, e.g. relevant information
for a chain sling includes grade of chain, SWL, manufacturer, chain size and
Australian Standard marking
• lifting hooks are provided with operable safety latches
• shackles used as terminal fittings are prevented from unscrewing, e.g. mousing or
similar
• lifting eyes and inserts are compatible and the same proprietary brand
• lifting slings are not damaged, i.e not showing 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.
Where synthetic slings are used, protective sleeves and corner pieces are to be used
for all loads because although the edges of the load may not appear to be sharp, the
sling may become damaged when it is placed under tension.
A qualified dogger must inspect all lifting gear, including slings, hooks and material
boxes before each use; a competent person (eg dogger, rigger or specialist) must
inspect all lifting gear periodically for damage and wear. The period between
inspections depends on the severity of use, but must not exceed 12 months for steel
lifting gear and 3 months for nylon or fibre slings/ropes.
In addition to the above, Supervisors are to make sure that:

• all lifting gear is tagged to identify the date of the lifting gear’s last inspection
• all lifting equipment owned by RailCorp is included on the Plant and Equipment
Register
• inspection and test records are maintained at the workplace.
Refer to SMS-16-SR-0057 Inspection and Testing for more information.
4.2 Crane overload

A mobile crane must not be subjected to a manner of loading or a greater load than is
marked on the load chart. Where the load mass is cause for concern, the dogger must
verify if the stamped load mass is correct.
Before starting to hoist a load, the crane operator or dogger must make sure that the
hoist rope hangs vertically over the load. Care should be taken to make sure that load
swing is avoided when the lift is taken. The crane operator is to make sure the load is
always under control when lowering loads, or when the load is suspended.
When handling maximum or near maximum loads, the crane operator is to take the
following precautions after the load has been lifted a few centimetres:
• test the hoist brakes, and
• check the weight recorded on the load weight indicator, and
• recheck the load chart.
Except in an emergency, the crane operator must not leave the cabin while a load is
suspended from the crane.
4.3 Unsecured and dropped loads

Crane operators must exercise extreme care when lifting loads in the vicinity of other
persons, including other workers and members of the public. Where possible, avoid
handling loads over public access areas such as footpaths, roads, highways, railways,
waterways and buildings. If lifting over these areas cannot be avoided, put appropriate
control measures in place (e.g. exclusion zones, suitably designed gantries) to prevent
or minimise exposure to the risk of being hit by falling objects during the lifting
operation.
Warning
Loads must not under any circumstance be lifted above people.
Loads must not be lifted above occupied building or critical rail infrastructure, such as
signal boxes and substation, without a risk assessment being conducted in consultation
with the Asset Owner and relevant Infrastructure Division Regional Manager. Measures
to control the risk from unsecured or dropped loads are to be included in Mobile Crane
Work Plan and/or SWMS.
4.4 Lifting materials

Crane-lifted loads are to be slung and secured so that the load, or any part of it, cannot
fall. To ensure the safe lifting of loads the following general controls are to be
implemented:

• formwork frames are to be either tied together or lifting slings should be wrapped
around the load
• loads of joists or bearers are to be strapped together before lifting
• timber sheeting is to 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 is to:
− be certified by an engineer
− specify the minimum and maximum number of sheets
− specify the number and locations of lifting slings, and
− specify the capacity of lifting slings.
• tag lines are to be used to control loads and are to be non-conductive.
• all loads are to be supported where possible with dunnage (ie small bits of timber),
with the load uniformly distributed over the supporting surface.
4.4.1 Material boxes

Material boxes must not be top heavy, or have materials stacked higher than the side of
the material box unless they are adequately secured. The boxes must:
• be clearly marked with the tare mass and SWL
• be appropriate for the material being lifted, and be engineer-designed and certified
• have four chains (one in each corner) during lifting
• have enclosed sides or robust mesh, with openings less than the minimum size of
materials being lifted
• have loads within the box secured against movement
• be inspected and maintained, and inspection records kept.
Specifically designed material boxes are to be used to lift smaller components.
Note
Containers such as milk crates and oil drums must not be used or
modified for use as a material box.
4.5 Exclusion zones

Exclusion zones are to be established around mobile cranes and adjoining areas to
prevent persons from entering the area. The size of the exclusion zone depends on the
risks, and is to be clearly documented in the Mobile Crane Work Plan and/or SWMS.
The exclusion zone is to be marked out clearly and enforced.
Where the exclusion zone requires closure of a public footpath or roadway, Line
Managers are to:
• obtain approval from the relevant authority, and
• make sure persons are to be directed safely to an alternative footpath.

Lane closures and other operations that require the erection of barricades and signs are
to comply with Roads and Traffic Authority (RTA) requirements. Refer to the Working
On or Near Public Roads guide for more details.
4.6 Multiple crane lifts

Lifting a load with two or more cranes requires greater attention to planning and
supervision, because the effects of the relative motion between the cranes may create
additional loadings on the cranes, the load and the lifting gear in place.
Only use multiple cranes to lift a load if it is not reasonably practicable to use a single
crane.
Where a multiple crane lift is necessary, the following steps must be implemented:
• a qualified intermediate rigger is to be in overall control of the lift
• the competent person in control of the lift makes an accurate assessment of:
− the share of the load which is to be carried by each crane, and
− how the load sharing is to be proportioned, and
− how the proportioning is to be maintained
• the instructions to each crane operator and other persons are clear
• rehearsals are carried out before the start of the dual lift where possible
• cranes of equal capacity and similar characteristics are to be used where possible
• when using non-slewing type cranes in the pick-and-carry mode both cranes are to
be aligned in the same axis
• only motions in the same direction should be made simultaneously, otherwise the
lifting operation are to be carried out in a stepped sequence, undertaking only one
motion at a time.
• except where approved by the crane manufacturer or an engineer, the following
minimum capacity requirements for each crane apply for:
− two cranes – 20% greater than the calculated share of the load
− three cranes – 33% greater than the calculated share of the load
− four cranes – 50% greater than the calculated share of the load
For example, if two cranes are to lift a load of 20 tonnes, and they will each be
required to take a load of 10 tonnes, therefore their rated capacity must be
increased by 20% more than would normally be required to lift 10 tonnes.
Consequently if a 20 tonne crane is normally required to lift a load weighing
10 tonnes, for a two crane lift, each crane must have a capacity of 24 tonnes. For
a three crane lift, each crane must have a capacity of 27 tonnes and for a four
crane lift each crane must have a capacity of 30 tonnes.
Dual lifts are not to be undertaken unless each crane is fitted with a load indicator.
AS1418.5 requires load indicators to be fitted to all mobile cranes with rated capacity of
more than 3 tonnes; this includes excavators used as cranes.

4.7 Leaving the crane unattended

Mobile cranes must not be left unattended unless the following actions have been
taken:
• all loads are removed from the hook
• the hook has been raised to a position where it is safely clear of other operations
• all powered motions have been disabled
• the keys have been removed from the crane
• if being left unattended for a longer period of time, the crane’s boom is folded up
and retracted as far as possible.
4.8 Workboxes and first aid boxes

Workers use crane-lifted workboxes to gain access to elevated work areas that are
otherwise difficult to reach to perform minor work of short duration. Generally,
crane-lifted workboxes 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 workboxes provides a higher level of safety than a
fall-arrest system used on its own.
Before selecting workboxes as a means of access, the RailCorp Supervisor is to
undertake an assessment to determine that other means of access such as scaffolding
or elevating work platforms is impractical.
First aid boxes must be used only to retrieve injured persons.
4.8.1 Crane requirements when using workboxes and first aid boxes
When using crane-lifted workboxes or first aid boxes, the crane must:
• have a minimum SWL of 1000 kg at the maximum radius for the task to be
performed
• have a minimum SWL of at least twice the total load of the workbox and its
contents, at the maximum radius for the task to be performed
• 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
• have levers and foot pedals fitted with a constant pressure system that stops the
crane’s motions when the operator removes pressure from the controls
• if fitted with a free fall facility, the free fall function must be locked out with a keyed
lock out.
All crane workboxes are to be design registered with WorkCover. In addition they are to
have the features described in Section 4.8.2.
4.8.2 Features of workboxes and first aid boxes

First aid boxes must be identified clearly as such. Crane-lifted workboxes and first aid
boxes must:
• be supplied with correctly tagged lifting slings that are attached to the lifting points
by hammerlocks or moused shackles

• have a factor of safety for each suspension sling of at least eight for chains and ten
for wire rope
• be marked with the SWL, tare mass and design registration number
• have sides at least 1m high
• if provided with a door, the door must be self-closing and provided with a latch to
prevent accidental opening. A workbox door must be inward opening only; first aid
boxes may be provided with an outward opening door.
4.8.3 Safety of persons in crane-lifted workboxes

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
• energy absorbers must be provided on the lanyards.
To ensure correct communication with the crane operator, at least one person in the
workbox must hold a dogger certificate or equivalent (ie rigger).
Refer to Working at Heights guide, Fall Arrest Systems guide and associated working at
heights SWIs for more requirements.
5. 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 (i.e. the load is not pinned to the boom or on tines, but is hanging from the boom
by means of a chain or rope). Other mobile plant that may be considered for this use
includes:
• backhoes
• front-end loaders
• tractors
• excavators
• forklift trucks with jib attachment
• telehandlers.
These other items of plant can be used only where it is not reasonably practicable to
use a mobile crane. Before using another item of mobile plant as a crane, RailCorp
Supervisor must conduct a plant risk assessment in accordance with SMS-06-GD-0403
Plant Risk Assessment guide. As part of the risk assessment, it must be confirmed that
the item of plant complies with the applicable Australian Standards.
RailCorp Supervisors who permit other mobile plant to be used as a mobile crane must
make sure that the level of safety provided by the lifting set-up is at least equal to that
when a mobile crane is used.

5.1 Telehandlers
A telehandler is a versatile type of mobile lifting plant that incorporates a telescopic
boom fitted with a lifting attachment. Telehandlers are also known as multi-purpose
handlers/cranes/tool carriers, telescopic forklifts and by proprietary names such as
Manitou.
Warning
A telehandler's stability is affected by the carried or lifted load, and terrain.
The usual means of lifting is by forks, but telehandlers can be fitted with a variety of
attachments for different types of loads. The range of attachments that can be used
depends upon the design of the particular machine, and often include a jib for lifting
freely suspended loads. See Figure 1 for examples.
Figure 1 Telehandler with five examples of associated attachments
5.1.1 Design
Where telehandlers are intended to lift freely suspended written confirmation is to be
provided by the supplier that the telehandler complies with AS 1418.19 Cranes, hoists
and winches Part 19: Telescopic Handlers.
All telehandlers must be fitted with:
• a boom angle indicator
• a lateral slope indicator
• a telescopic boom length indicator
• a longitudinal stability indicator
• a warning beeper (to provide nearby workers warning of the telehandler).
Where the telehandler's rated capacity is above 3 tonnes, it must also be fitted with:

• a rated capacity indicator that provides a visual and audible warning before the
load exceeds the rated capacity
• a longitudinal stability limiter
• a rated capacity limiter
• a maximum capacity limiter.
The above indicators and limiters must be specific to the type of attachment being used
on the telehandler. Where there are a range of possible attachments the limiters and
indicators must provide for use in all possible configurations.
5.1.2 Operation
Operators must have read and be familiar with the operator’s handbook before use. In
addition the following are to be supplied with the telehandler and be available on site:
• load configuration rating charts
• an operator’s handbook
• maintenance records
• inspection logbook.
Typically, telehandlers are used to move with their load (pick-and-carry). When
travelling with a fixed load, the operator must retract the boom and lower the load as
close to the ground as possible. The height above ground level should not exceed:
• 500mm above ground level for loads greater than 10 tonnes
• 300mm above ground level for loads10 tonnes or less.
If the load is freely suspended, the operator should travel with the load elevated high
enough to prevent it snagging on the ground or other obstacles.
Note
Operators and doggers must use tag lines to prevent freely suspended
loads swinging.
The following additional controls must be applied:

• before use, the operator must conduct an assessment on the gradient of the
ground on which the telehandler will operate, and identify if the gradient is more
than 1%, taking into account effects of potholes, etc
• telehandler operators must be qualified in the planned work/function; for example:
− when fitted with forks the operator is to hold a WorkCover certificate of
competency as a forklift operator (LF)
− when used as a pick-and-carry crane, the operator is to hold the correct class of
crane operator’s certificate of competency (CN, C2, C6, C1 or C0)
• operators accelerate and brake the telehandler gently to minimise load swing
• telehandlers carrying freely suspended loads must travel less than 2km/h
• persons slinging a load and in control of the load during movement must be
qualified as a dogger or rigger
• the dogger must not stand between the suspended load and the telehandler

• the dogger must be visible to the operator at all times

• travel on slopes should be up or down the slope – not across the slope; traversing
a slope is to be avoided at all times.
5.2 Rated capacity

The rated capacity of other mobile plant used as a mobile crane 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.
Unless the rated capacity chart allows otherwise, the operator must include the weight
of any attachments such as buckets or quick-hitches when determining the allowable
load to be lifted.
To ensure the stability of the mobile plant used as a mobile crane, 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 load for articulated wheel loaders and tool carriers.
5.2.1 Load chart

The load chart for the mobile plant used as a mobile crane should identify each lift
attachment location, and the corresponding rated capacity for the crane at that location.
The appropriate load chart should be fixed inside the operator's cab and include the
following information:
• manufacturer's 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
• either the rated load at the least stable position, or where variable load rating is
provided for, the means to clearly determine the load position in accordance with
the rated capacity chart.
5.2.2 Lifting points on earthmoving plant

The plant manufacturer sometimes supplies lifting attachments on earthmoving plant. If
lifting attachments are supplied with the plant, they are to be designed by an engineer
with written certification provided.
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 must
form a closed eye to which a load rated shackle may be attached.
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
occur even when the hook is fitted with a latch, because the latch may be damaged
(e.g. with a mobile crane, the hook hangs vertical, with an excavator, the lifting point
rotates).

5.2.3 Quick-hitches
A quick-hitch is a latching device that enables rapid connection of earthmoving plant
attachments to the plant’s dipper arm. Whilst this device saves time and effort, a
number of fatalities have occurred when excavator attachments have fallen off due to
loss of hydraulic pressure. Locking pins are used to ensure the attachment is engaged
correctly and remains locked in position on the dipper arm.
All quick-hitch devices are to be:
• fitted with a locking pin and be operated with the locking pin always in place, or
• designed with an automatic secondary locking system, such as an Essex
Auto-Latch, that negates the need to insert a locking pin manually.
5.2.4 Controlled lowering devices

Burst protection is to be fitted to the boom and dipper arm hydraulics (where attached)
of any mobile plant used as a crane. This protection prevents the boom or dipper arm
falling in an uncontrolled manner, due to failure of a hydraulic hose or other part of the
hydraulics system. Burst protection may consist of:
• controlled lowering devices
• pilot-operated check valves that sense a differential in hydraulic pressure, and lock
the boom in position.
5.2.5 Operator competency

Since 1996 the 'LE' type national excavator certificate for excavator operators has
included basic competencies for operating earthmoving equipment used as a mobile
crane. If an excavator operator holds an older type of earthmoving equipment
certificate, the operator must also hold a Slewing Mobile Crane Certificate.
6. Use of mobile cranes for tree-lopping

The use of mobile cranes for tree-lopping is to be treated as a very high risk activity due
to the potential for the crane to overturn or boom structural failure.
It is difficult to determine both the mass of the part of the tree being cut and the
direction in which the timber will fall during tree-lopping. In addition, it is extremely
difficult to eliminate shock loading that will be applied to the crane. Both issues will
either cause the load radius to increase or apply a side loading to the boom.
Safe crane operation requires that only vertical loads be applied to the hoist rope and
the loads be applied gradually. This requirement is generally stated in the crane
manufacturer's instructions.
RailCorp Managers and Supervisors are to make sure that mobile cranes are used for
tree lopping only if:
• the crane operator does not perform the role of a dogger
• a dogger is present during all lifting activities
• the arborist, crane operator and dogger consult with each other in the planning of
the work, the development of the Mobile Crane Work Plan and/or SWMS and
during the tree lopping
• side loading will not be applied to the crane boom

• any loading to the crane is well within the crane's SWL

• the crane will not be shock loaded
• wind will not adversely affect the safe use of the crane
• only vertical loads will be applied to the hoist rope and crane hook
• at completion of the saw cut, the radius of the load will not increase.
7. Vehicle-loading cranes
Vehicle loading cranes must:
• comply with AS 1418.11: Cranes, hoists and winches – Vehicle-loading cranes
• be operated in accordance with AS2550.11 Cranes Hoists and Winches – Safe
Use – Vehicle-loading cranes.
7.1 Mounting of vehicle-loading crane

Vehicle-loading cranes are to be mounted only on vehicle types and models specified
by the crane manufacturer.The method of mounting must comply with the crane
manufacturer’s specifications. Welding the crane to the vehicle chassis is not
acceptable because it can damage the chassis and lead to fatigue failure of the
connection.
7.2 Rated capacity indicators and limiters

Irrespective of capacity, vehicle-loading cranes manufactured after 2003 are to be fitted
with a rated capacity indicator to warn the operator when the load exceeds 90% of the
rated capacity. The rated capacity indicator must give a separate warning to the
operator and persons in the vicinity of the crane if the rated capacity is being exceeded.
All vehicle loading cranes with a capacity of 10 tonnes or more must be fitted with a
rated capacity limiter
7.3 Operation of vehicle-loading cranes
Warning
Vehicle-loading cranes must not be used in pick-and-carry mode or to lift
persons.
RailCorp Managers and Supervisors are to make sure that:

• vehicle-loading cranes are operated in accordance with the operator instructions
provided by the crane’s manufacturer
• the crane is used only with all stabilisers extended in accordance with the crane
manufacturer’s instructions. Where multiple positions can be used on stabiliser
legs, the legs must be set up in compliance with the manufacturer’s load chart
• the crane is used only so that it is level in accordance with the crane
manufacturer’s specifications (usually not exceeding 1o or less)
• timbers or other pads specified by the crane manufacturer are used under the
stabiliser feet

• hooks have spring-loaded safety latches, and are adequately maintained

• where it is possible to apply a side load to the crane hook, the hook has an
appropriate swivel
• where provided, vehicle spring lock-outs are activated during crane operation
• the crane is used only with a load suspended vertically from the hook. The crane is
not to be used to drag a load across a supporting surface.
8. Inspection of cranes
Mobile cranes require four types of inspection:
• pre-start inspection
• routine maintenance and inspection
• periodic inspection
• major inspection.
8.1 Pre-start inspection

The operator must carry out a pre-start inspection before using the mobile crane at
each work shift. The inspection is to include the following:
• operating and emergency controls
• brakes
• safety switches and interlocks
• structure
• wire ropes, to ensure they are on the drum and correctly reeved on the sheave.
Any personal protective equipment is to also be inspected for correct function.
Pre-start inspections are to be recorded in a pre-start inspection checklist or logbook.
8.2 Routine maintenance and inspection

A competent person is to undertake routine maintenance and inspections in accordance
with manufacturer’s recommendations, at no more than three-monthly intervals, unless
the crane is not in service.
The inspection is to include, but not be limited to checking:
• 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
• filter elements and fluid levels
• visual inspection and measurement 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 listed in the crane manufacturer’s instructions.
When parts and components are replaced, the replacements must be identical or
equivalent to the original parts or components.
The inspector must provide a written inspection report.
8.3 Periodic inspection

A competent person, ideally an independent 3rd party, must undertake a periodic
inspection.
The periodic inspection must be undertaken annually as a minimum and 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
• any additional items specified by the manufacturer.
A certificate may be issued as evidence the crane has undergone its annual inspection.
RailCorp staff undertaking periodic mobile crane inspections are record the results in
either the crane logbook or the Crane Periodic Inspection checklist.
8.4 Major inspection

A major inspection is required for cranes that:
• have reached the end of their design life, or where this is unknown, 25 years for the
structure and 10 years for the mechanical components
• are to be recommissioned and do not have previous operating records
• were designed and built to unknown standards
• are to be upgraded or modified.
The purpose of a major inspection is to ensure that the cranes are suitable for
continued safe operation. Major inspections must be carried out or supervised by a
competent person (refer to 9.3 below).
8.5 Records of inspections and maintenance

Mobile crane inspections and maintenance records are to be maintained locally and by
the owner of the crane for the life of the crane, in accordance with SMS-05-SR-0027
Records Management.
When RailCorp sells a crane, the person disposing of the crane must provide all
maintenance and inspection records to the purchaser.

9. Training and competency
9.1 General training and competency requirements

Managers are to make sure that mobile crane users are provided with information,
training and instruction that covers, as a minimum, the following:
• safe work practices (SWMS or SWIs) to be used in the set up and safe operation of
mobile crane activities
• the method for inspection and maintenance of mobile cranes
• knowledge of the crane manufacturer's operation and service manuals
• the correct use, care and storage of personal protective equipment
• the correct use, care and storage of tools and equipment to be used
• observance of electrical safety practices
• procedures to be adopted in the event of accident or injury.
Managers and Supervisors are to:
• make sure that only those workers who have received training and instruction
operate mobile cranes; and
• monitor all work periodically to ensure operators adhere to safe work practices.
Training requirements for mobile crane operation, dogging and rigging are to be
included in Safety Competency Profiles and Training Plans, in accordance with SMS-
SR-11-0123 Safety Training and Competency and SMS-PR-11-0747 Managing Safety
Training and Competence.
9.2 Scheduled work

Under the OHS Regulation 2001, operating a mobile crane and performing dogging or
rigging activities are classified as scheduled work.
This means that persons performing that work must:
• hold the applicable National certificate of competence (WorkCover issued), or
• be being trained, using a logbook to record the training, under the direct
supervision of a person that holds a certificate of competence.
Refer to SMS-GD-11-0243 Plant and Equipment Certificates of Competency for more
information.
9.2.1 Crane operator

Persons operating mobile cranes must hold the appropriate class of mobile crane
certificate for the specific mobile crane.
For vehicle loading cranes with a capacity of less than 10 tonnes, a WorkCover
Certificate of Competency is not required; however, operators must still be trained in
accordance with the requirements described in Section 8.1 above.

9.2.2 Dogger
A dogger is a person who:
• applies slinging techniques, including the selection or inspection of lifting gear, to
safely sling a load, or
• directs a crane or hoist operator in the movement of a load when the load is out of
the operator's view.
Managers and Supervisors are to make sure that only a person with a Dogger
Certificate (DG) or Rigger Certificate (RB, RI, RA) is permitted to perform dogging
activities.
An operator of a vehicle loading crane (of any capacity) may also be required to hold a
dogging certificate if they are required to exercise judgment in the slinging of the load
(including selection or inspection of the lifting gear).
If the load is out sight of the operator at any time a certificated dogger/rigger must
control the lift; the operator must not undertake the tasks of the dogger/rigger, even if
they hold a certificate of competence as a dogger or rigger.
9.2.3 Rigger
Rigging involves the use of mechanical load shifting equipment and associated gear to
move, place or secure a load, or to set up or dismantle a crane and hoists.
Managers and Supervisors are to make sure that rigging duties are performed only be
persons with a rigger certificate. There are three rigging certificate levels - basic (RB),
intermediate (RI), and advanced rigging (RA). A different set of competencies must be
obtained for each rigging level. Refer to Clause 266 of the OHS Regulation 2001 for
more specific details.
9.2.4 Familiarisation training

Mobile cranes can be fundamentally different in their design, mode of operation, control
layout and configuration. Before a person is allowed to work as a crane operator,
Managers and Supervisors are to make sure the crane operator is familiar with the
particular crane.
Crane operators should be provided familiarisation training before they start work or
operate a newly acquired crane to give them the opportunity to become familiar with the
design, layout and operating functions of a specific mobile crane. This training may be
provided by the mobile crane supplier or manufacturer.
9.2.5 Refresher training

Employers must ensure that persons who work as part of a crane crew (crane
operators, doggers and riggers) receive refresher training on an ongoing basis. It is
particularly relevant for persons who have not worked continuously in the prescribed
occupation.
Refresher training may be provided by the employer, an independent consultant or third
party such as a registered training authority. The person providing the refresher training
should be endorsed by the crane company as competent to provide this training.

The purpose of this training is to ensure that crane operators, doggers and riggers
maintain the competencies they achieved originally in the relevant certificates of
competency.
Refresher training should reflect issues such as:
• the application of new technology, particularly for those persons who obtained their
certificates while working on more basic cranes
• any relevant changes to occupational health and safety legislation and Australian
Standards which may impact on safe crane operations
• safe crane operation.
The interval between refresher training courses should not exceed three years. Crane
operators, doggers and riggers should undergo refresher training between two and a
half and three years after either being issued their initial certificate of competency, or
since attending their most recent refresher training, whichever is the shorter timeframe.
9.2.6 Training records

Records of the training are to be kept in accordance with SMS-05-SR-0027 Records
Management, SMS-11-SR-0123 Safety Training and Competence and RailCorp’s
Quality Training Management System (QTMS).
9.3 Competency for carrying out crane inspections

For the purpose of carrying out periodic and major inspections of cranes, a competent
person is someone who:
• has a sound knowledge of relevant Australian Standards, relevant codes of
practice and other relevant legislation, and
• has a sound knowledge and competence in the risk management process for the
erection, operation, maintenance, repair, alteration and dismantling of cranes, and
• has acquired through training, qualifications or experience, the skills to design
procedures for the inspection, maintenance and repair of the crane.
A competent person who has been engaged to inspect a specific part of a crane should
have suitable experience and knowledge in the inspection of that part of the crane. This
person may not necessarily need experience in inspecting the complete 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 AS/NZS 1554: Structural steel
welding.
• 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 electrician where the voltage of the electrical
system is greater than 50V alternating current, or 115V direct current.

• A competent person carrying out non-destructive testing on mobile crane

components should have suitable knowledge and experience in non-destructive
testing methods. This person must be accredited by the National Association of
Testing Authorities (NATA).
In these instances, the competent person verifies that the welding, hydraulic system or
electrical system complies with the relevant technical standards. It is not be appropriate
for this person to verify that the complete crane complies with a relevant technical
standard or is in a safe condition.
9.4 Competency for certifying crane alterations

Where an alteration has been made to the design of a crane, the competent person
certifying the alteration must be an engineer with suitable knowledge and experience. It
is likely that the competent person will need to perform engineering calculations on the
crane design to determine that it complies with relevant technical standards.
10. References
• OHS Regulation 2001, Chapters 5 and 9, and Schedule 1
• AS1418.1 2002 Cranes (including hoists and winches) – general requirements
• AS1418.5 2002 Cranes (including hoists and winches) - mobile cranes and vehicle
loading cranes
• AS1418.8 2002 Cranes, hoists and winches – Special purpose appliances
• AS1418.11 2004 Cranes (including hoists and winches) - Vehicle loading cranes
• AS1418.17 1996 Cranes (including hoists and winches) – Design and construction
of workboxes
• AS1418.19 2007 Cranes, hoists and winches – telescopic handlers
• AS2550.1 2002 Cranes, hoists and winches – safe use – general
• AS2550.5 2002 Cranes, hoists and winches – safe use – mobile cranes
• AS2550.11 2004 Cranes, hoists and winches – safe use – vehicle loading cranes
• AS2550.19 2007 Cranes, hoists and winches - safe use - telescopic handlers
• QLD Division of Workplace H&S Mobile Crane Code of Practice 2006
• SMS-05-SR-0027 Records Management
• SMS-11-SR-0123 Safety Training and Competence
• SMS-16-SR-0057 Inspection and Testing
• SMS-11-PR-0747 Managing Safety Training and Competence
• SMS-06-GD-0268 Working Around Electrical Equipment
• SMS-06-GD-0403 Plant Risk Assessment
• SMS-11-GD-0243 Plant and Equipment Certificates of Competency
• SMS-11-GD-0244 Personnel Certifications – Electrical Authorisations
• SMS-06-SW-0267 Working in Accordance with an Electrical Permit
• SMS-06-EN-0598 Electrical Permit to Work


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System Guide

Custodian: Manager SMS Operations © RailCorp

1. Purpose and scope............................................................................................................... 5

3. Planning mobile crane use .................................................................................................. 6

5. Use of other mobile plant as a mobile crane ................................................................... 19

6. Use of mobile cranes for tree-lopping .............................................................................. 23

Custodian: Manager SMS Operations © RailCorp

7.2 Rated capacity indicators and limiters......................................................................................... 24

Custodian: Manager SMS Operations © RailCorp

1. Purpose and scope

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3. Planning mobile crane use

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3.1 Selecting the crane

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Registration and modification

Mobile cranes with a rated capacity over 10 tonnes must be:

3.2 Assess the site and lift

3.2.1 Ordinary lifts

3.2.2 High risk lifts and Mobile Crane Work Plans

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• location of underground services

3.3 Crane siting controls

3.3.1 Overhead powerlines and other exposed electrical equipment

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Elimination not practicable

3.3.2 Risk of collision

3.3.3 Proximity to excavations

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3.3.4 Proximity to underground services

3.3.5 Crane stability and outriggers

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3.3.6 Sloping ground

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Where possible avoid using pick-and-carry cranes on sloping ground. If working or

3.3.7 Wind speed

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3.4 Erecting and dismantling mobile cranes

4. Mobile crane operation

4.1 Lifting gear

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4.2 Crane overload

4.3 Unsecured and dropped loads

4.4 Lifting materials

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4.4.1 Material boxes

4.5 Exclusion zones

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4.6 Multiple crane lifts

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4.7 Leaving the crane unattended

4.8 Workboxes and first aid boxes

4.8.2 Features of workboxes and first aid boxes

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4.8.3 Safety of persons in crane-lifted workboxes

5. Use of other mobile plant as a mobile crane

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Figure 1 Telehandler with five examples of associated attachments

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The following additional controls must be applied:

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• the dogger must be visible to the operator at all times