Comprehensive SWMS for overhead bridge and gantry crane operations including load handling, maintenance, and operator safety protocols

Crane Overhead Bridge Gantry Safe Work Method Statement

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Overhead bridge and gantry cranes are essential material handling equipment in Australian manufacturing, construction, and industrial facilities, operating along fixed runways to lift, lower, and transport heavy loads across designated work areas. These cranes feature horizontal bridge structures supported by end trucks that travel along elevated runways, with hoisting mechanisms traversing the bridge span to position loads precisely within the operating envelope. Bridge cranes have runways supported by building columns or standalone structures, while gantry cranes utilize ground-level runway beams supported by legs creating a portal frame that can span outdoor yards or areas where building-mounted runways are impractical. This Safe Work Method Statement addresses all aspects of overhead bridge and gantry crane safety including operational procedures, load handling protocols, maintenance requirements, and emergency response in accordance with Australian WHS legislation, AS 1418 crane standards, and AS 2550 safe use requirements.

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Overview

What this SWMS covers

Overhead bridge and gantry cranes represent fixed-installation material handling systems operating within defined work envelopes in manufacturing plants, warehouses, steel fabrication shops, precast concrete facilities, and heavy equipment maintenance workshops across Australia. These cranes feature capacities ranging from 500 kilograms for light-duty applications to 500 tonnes for heavy industrial operations, with bridge spans extending from 5 metres in small workshops to 50 metres in large manufacturing facilities. The fundamental design incorporates a horizontal bridge beam supported by end trucks that travel along elevated runway beams, with a trolley-mounted hoist mechanism that traverses the bridge span providing precise three-dimensional load positioning within the rectangular operating envelope defined by runway length and bridge span. Bridge cranes mount to building structure with runway beams attached to columns at elevations typically 4-10 metres above floor level, creating clear operating space beneath the crane for manufacturing processes, material storage, and vehicular traffic. This configuration maximizes facility space utilization by positioning the crane overhead rather than consuming valuable floor area with material handling equipment. Gantry cranes utilize similar bridge and trolley configurations but support the bridge on leg structures creating a portal frame that travels along ground-level or slightly elevated runway beams. This arrangement suits outdoor applications such as steel yards, precast concrete casting yards, shipping container handling facilities, and construction sites where building-mounted runways are impractical or temporary lifting operations require relocatable systems. Operational configurations vary significantly depending on application requirements and facility design. Single-girder bridge cranes feature the trolley and hoist traveling on the bottom flange of a single main beam, offering economical solutions for lighter capacities up to approximately 20 tonnes with spans to 30 metres. Double-girder configurations position the trolley on rails mounted atop two parallel main beams providing increased capacity, greater hook height beneath the bridge, and improved load control for precise positioning requirements. Under-running or under-hung cranes suspend from the bottom flange of runway beams allowing installation in facilities with limited headroom or where runway beams must mount to existing building structure without major modifications. Top-running cranes position bridge end trucks on rails mounted atop runway beams providing maximum hook height and capacity capabilities for heavy industrial applications. Hoisting mechanisms employ wire rope or chain systems with electric motors driving drum or geared mechanisms through reduction systems providing controlled lifting and lowering at speeds typically ranging from 1-20 metres per minute depending on capacity and precision requirements. Modern hoists incorporate multiple safety features including upper and lower limit switches preventing over-travel, overload protection systems monitoring load weight and preventing lifts exceeding rated capacity, slack rope detection preventing drum over-spooling, and emergency stop systems enabling immediate cessation of all crane movements. Load positioning capabilities include bridge travel along the runway (referred to as long travel or cross travel), trolley traverse along the bridge span (referred to as short travel or cross travel), and hoist lift providing vertical movement, with all three motion axes typically controlled independently enabling diagonal load trajectories and precise final positioning. Control systems range from pendant push-button stations suspended from the trolley for operator positioning beneath the load, to radio remote control systems enabling operators to position themselves optimally for load visibility and personal safety away from suspended loads and pinch points. Cabin-controlled cranes position operators in enclosed cabs mounted on the bridge or trolley structure providing superior visibility of the operating area and load positioning particularly for high-capacity applications with frequent lifting operations. Modern cranes increasingly incorporate variable frequency drive (VFD) systems providing infinitely-variable speed control for smooth acceleration and deceleration, reducing load swing and structural stress while improving positioning precision and operator fatigue. The operation of overhead bridge and gantry cranes requires more than just the crane equipment itself. Qualified crane operators must hold appropriate high-risk work licenses under Australian WHS Regulations, specifically the CB (Bridge and Gantry Crane) license demonstrating competency in crane operation, load assessment, rigging practices, and emergency procedures. Dogmen or riggers attach loads to crane hooks using appropriate lifting gear including slings, shackles, hooks, and spreader beams, ensuring secure load attachment and proper rigging configuration. Maintenance personnel conduct regular inspections, preventive maintenance, and repairs maintaining crane mechanical, electrical, and structural systems in safe operating condition. Supervisors coordinate lifting operations ensuring safe work planning, hazard management, and regulatory compliance throughout crane operations.

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Why this SWMS matters

Overhead bridge and gantry crane operations are specifically classified as high-risk construction work under WHS Regulation 2011 when operating in construction environments or when lifting loads exceeding prescribed limits, triggering mandatory Safe Work Method Statement requirements. Beyond regulatory compliance, these cranes handle heavy loads suspended above workers and valuable equipment, with load drops, crane failures, or operational errors creating catastrophic incident potential resulting in fatalities, serious injuries, and major property damage. Safe Work Australia incident data consistently identifies overhead crane operations as significant contributors to workplace fatalities and serious injuries, with load drops, struck-by incidents from crane movements, and maintenance-related accidents representing primary incident mechanisms. Load drop incidents occur from rigging failures, overloading, mechanical failures, or improper load attachment causing suspended loads to fall with devastating consequences to workers positioned below. A Queensland manufacturing facility incident involved a 2-tonne steel fabrication component falling from an overhead crane when a wire rope sling failed due to inadequate inspection identifying severe wear damage. The falling component struck two workers conducting welding operations beneath the crane path, resulting in one fatality and permanent spinal injuries to another worker. Investigation revealed the worn sling had not been inspected for over 12 months despite regulatory requirements for frequent inspection, maintenance records were inadequate demonstrating poor safety management systems, and workers were permitted to work beneath suspended loads contrary to safe work procedures. The manufacturing company received fines exceeding $300,000 plus prosecution for multiple WHS breaches demonstrating serious consequences for inadequate overhead crane safety management. Struck-by incidents from moving crane components including bridge end trucks, traversing trolleys, and suspended loads cause serious injuries when workers fail to maintain awareness of crane movements or enter crane operating paths without authorization. The substantial mass of crane bridge structures ranging from several hundred kilograms for light cranes to multiple tonnes for heavy-duty equipment creates enormous kinetic energy even at low travel speeds typically 20-60 metres per minute. A New South Wales precast concrete facility incident involved a worker being struck and killed by a moving gantry crane leg while attempting to retrieve tools from the crane runway area. Investigation found inadequate traffic management separating crane operating areas from personnel access routes, absence of physical barriers preventing unauthorized access to crane paths, and inadequate worker training regarding gantry crane hazards. The facility operator received combined fines and legal costs exceeding $400,000 plus extensive corrective action requirements implemented across all company facilities. Crane structural and mechanical failures cause catastrophic incidents particularly during lifting of near-capacity loads when overstressed components fail without warning. Runway beam failures, bridge structural collapse, wire rope breakage, and hoist mechanical failures have resulted in multiple Australian workplace fatalities over the past decade. Factors contributing to mechanical failures include inadequate preventive maintenance, deferred repairs of identified defects, operation beyond rated capacity, structural fatigue from repeated loading cycles, and corrosion degradation particularly in outdoor gantry crane installations. A Victorian steel fabrication facility experienced runway beam failure causing an overhead crane to fall 6 metres to the workshop floor while lifting a 12-tonne steel assembly. Fortunately, no workers were beneath the crane at failure moment, but extensive property damage occurred to the crane, building structure, and equipment below. Investigation identified inadequate structural inspection programs failing to detect fatigue cracks in runway beam welds, operation at loads exceeding original design capacity following facility production expansion, and absence of engineering assessment when production loads increased. Prosecution resulted in fines and requirements for comprehensive structural inspection programs across the manufacturing sector. Maintenance and inspection activities expose workers to multiple hazards including falls from height when accessing elevated crane components, crush injuries from moving crane parts during maintenance, electrical hazards from crane power systems, and caught-between hazards from pinch points in crane mechanisms. Maintenance personnel must work at elevation accessing bridge beams, trolleys, hoists, and runway structures often in challenging positions with limited fall protection anchor points. A South Australian incident involved a maintenance technician falling 8 metres from a crane bridge during hoist maintenance when temporary fall arrest anchor points failed. Serious injuries including spinal fractures resulted from the fall. Investigation found inadequate fall protection planning for crane maintenance activities, inappropriate anchor point selection and installation, and absence of rescue procedures for workers using fall arrest systems at height. Communication failures between crane operators, dogmen, and other facility personnel create coordination hazards particularly in busy manufacturing environments with multiple simultaneous activities. Crane operators often have limited visibility of the complete load path particularly with long bridge spans or when loads must travel through congested work areas with equipment, materials, and personnel creating obstructions. Hand signal systems require direct line-of-sight between operators and dogmen, with radio communication systems providing backup when visual contact is interrupted. Communication breakdown has contributed to incidents including loads striking structures during travel, personnel being struck by moving loads or crane components, and loads being placed on inadequate supports causing secondary collapse incidents. Overhead bridge and gantry cranes represent significant capital investments ranging from $50,000 for small capacity systems to several million dollars for heavy-duty industrial installations, with regulatory compliance, proper maintenance, and safe operation protecting this investment while ensuring worker safety. The Australian standards AS 1418.18 (Crane runways and monorails) and AS 2550.1 (Safe use of cranes - General requirements) provide comprehensive technical requirements for crane design, installation, maintenance, and operational procedures. A well-implemented Safe Work Method Statement integrates these technical requirements with site-specific operational conditions, creating practical safety documentation that crane operators, maintenance personnel, and supervisors can use daily to maintain safe overhead crane operations. The implementation of systematic hazard identification, comprehensive control measures, regular inspection programs, and ongoing operator training through documented SWMS procedures demonstrates organizational commitment to safety while satisfying regulatory requirements and protecting workers from preventable crane-related incidents.

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Hazard identification

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

Risk register

Load Drop from Rigging Failure or Overloading

High

Suspended loads attached to overhead crane hooks through slings, chains, or other rigging equipment can fall if rigging components fail, loads exceed crane rated capacity, or attachment methods are inappropriate for load geometry and weight distribution. Rigging failures occur from worn or damaged slings showing broken wire strands, cut fibers, or chemical deterioration, overloaded rigging exceeding working load limits, incorrect rigging configurations creating excessive stress concentrations, or improper hook engagement where slings can slip off hooks during lifting. Overloading situations develop when load weights are estimated rather than measured, crane capacity charts are misinterpreted, or multiple cranes share loads without proper coordination. Load drops from significant heights ranging from 4-10 metres in typical facilities create catastrophic consequences for workers positioned below. Contributing factors include inadequate rigging inspection programs, absence of load weighing procedures, unclear capacity rating displays on cranes, and worker complacency from successful previous lifts creating false confidence. The instantaneous nature of rigging failures provides no warning enabling worker evacuation, making prevention through systematic rigging inspection and load weight verification absolutely critical.

Consequence: Fatalities or catastrophic injuries to workers struck by falling loads weighing hundreds to thousands of kilograms. Crush injuries causing permanent disability or death. Secondary injuries to workers attempting to avoid falling loads resulting in falls, struck-by incidents, or musculoskeletal damage. Major property damage to equipment, building structure, or products positioned beneath crane paths. Production shutdowns for incident investigation and regulatory compliance activities. Criminal prosecution and multi-million dollar fines following fatal load drop incidents. Permanent reputational damage affecting company safety standing and client relationships.

Struck by Moving Crane Bridge or Trolley Components

High

Workers positioned in crane operating areas face struck-by hazards from moving bridge end trucks traveling along runway beams at speeds typically 20-60 metres per minute, traversing trolleys moving along bridge spans, and suspended loads swinging during travel. The substantial mass of bridge structures ranging from several hundred kilograms for light cranes to multiple tonnes for heavy-duty equipment generates enormous kinetic energy even at relatively low travel speeds. Workers may enter crane operating paths to retrieve materials, perform maintenance on adjacent equipment, or take shortcuts across facilities without recognizing crane movement hazards. Crane operators often have limited visibility of the complete runway length particularly with long travel distances exceeding 30-50 metres or when building columns, equipment, or material storage creates visual obstructions. The relatively quiet operation of electric-powered cranes compared to diesel or hydraulic equipment reduces audible warnings that would alert workers to approaching cranes. Workers become complacent from frequent exposure to crane operations developing familiarity that reduces hazard perception. Gantry cranes present particular struck-by hazards from leg structures and horizontal cross-members creating multiple impact surfaces as the entire portal frame travels along ground-level runways. Communication failures between crane operators and facility personnel particularly in noisy industrial environments impair coordination regarding crane movements and worker positioning. The inability to stop moving crane bridges immediately due to momentum and brake system response times means avoiding struck-by incidents requires preventing workers entering crane paths rather than relying on operator reaction to stop cranes after workers are observed in dangerous positions.

Consequence: Severe crush injuries or fatalities from being struck by moving bridge structures, end trucks, or trolley components. Traumatic amputations from being caught between moving crane components and building structures, equipment, or materials. Head injuries and fractures from glancing contact with crane components even without full-force impacts. Falls from elevated work platforms if workers are struck while on ladders or platforms causing secondary fall injuries. Permanent disabilities requiring ongoing medical care and compensation. Production disruptions from incident investigations and regulatory actions. Prosecution and significant financial penalties following serious struck-by incidents.

Crane Structural or Mechanical Component Failure

High

Overhead bridge and gantry cranes operate under repeated loading cycles creating fatigue stress in structural members, mechanical components, and runway support systems that can lead to catastrophic failure without adequate inspection and maintenance programs. Structural failures include runway beam fractures particularly at welded connections where stress concentrations and welding defects create crack initiation points, bridge girder failures from fatigue or overloading, hoist drum shaft fractures, and wire rope strand breakage. Mechanical failures encompass gearbox component wear causing sudden mechanical seizure, brake system degradation preventing load control, trolley wheel bearing failures, and electrical system faults affecting crane control or safety systems. Contributing factors include inadequate preventive maintenance with deferred repairs of identified defects, operation beyond original design capacity particularly in facilities where production demands have increased, corrosion deterioration in outdoor gantry installations exposed to weather, and lack of engineering inspection for structural integrity assessment. Fatigue crack development in high-stress areas may progress undetected without comprehensive non-destructive testing programs including ultrasonic inspection, magnetic particle inspection, or dye penetrant testing. The catastrophic nature of structural failures provides no warning before collapse, with complete loss of load control causing loads to fall along with potential bridge structure collapse onto workers and equipment below. Older crane installations designed to earlier standards may not incorporate safety factors or redundancy features required by current AS 1418 standards.

Consequence: Multiple fatalities or serious injuries from bridge structure collapse onto workers below. Catastrophic property damage to crane equipment valued at hundreds of thousands to millions of dollars. Damage to building structure, production equipment, and materials positioned beneath failed cranes. Complete production shutdowns for extended periods during incident investigation, crane removal, and replacement installation. Regulatory enforcement actions including prohibition notices preventing similar equipment operation until comprehensive inspections completed. Criminal prosecution of duty holders following fatalities from mechanical failures. Massive financial penalties reaching millions of dollars. Permanent closure of facilities if structural damage is extensive or business interruption is prolonged.

Falls from Height During Crane Maintenance or Inspection

High

Maintenance personnel and inspectors access elevated crane components including bridge beams at heights typically 4-10 metres, trolley assemblies, hoisting mechanisms, and runway beam structures requiring work at height with fall risks if adequate fall protection systems are not provided and used correctly. Crane maintenance activities involve accessing confined spaces within bridge girders, working from ladders or elevated work platforms in awkward positions, and leaning outward to reach crane components creating fall hazards particularly when workers carry tools or parts affecting balance. Many older crane installations lack permanent fall protection anchor points designed specifically for maintenance access, requiring workers to install temporary anchor systems that may be inadequately designed or incorrectly positioned. The structural configuration of overhead cranes creates challenges for fall protection implementation with limited anchor point options on bridge beams, trolley frames, or runway structures. Workers may remove fall arrest equipment to improve access or movement efficiency particularly during prolonged maintenance tasks where tethering restricts work positioning. Maintenance on operating crane components while cranes remain energized creates additional hazards if fall arrest lanyards contact energized electrical systems. Rescue of fallen workers using fall arrest systems requires specialized rescue equipment and training that may not be available at industrial facilities. Outdoor gantry crane maintenance exposes workers to additional fall risks from weather conditions including high winds, rain-slicked surfaces, and reduced visibility. The complexity of crane mechanical and electrical systems requires extended maintenance duration with workers spending hours at elevation increasing fatigue and error risk. Emergency maintenance during production breakdowns creates time pressure that may cause workers to compromise fall protection procedures attempting to expedite crane return to service.

Consequence: Fatalities or catastrophic injuries from falls of 4-10 metres onto concrete factory floors or equipment below. Serious fractures, spinal injuries, and traumatic brain injuries causing permanent disability. Secondary injuries if fallen workers strike equipment, materials, or building structure during fall. Suspension trauma injuries if fall arrest systems activate but timely rescue is not performed. Criminal prosecution of duty holders following fall fatalities during maintenance activities. Significant financial penalties for inadequate fall protection systems. Workers compensation claims for permanent injury requiring ongoing medical care and income replacement.

Caught-Between or Crush Injuries from Pinch Points

High

Overhead bridge and gantry cranes create numerous pinch point hazards where moving components can trap workers causing crush injuries or amputations. Trolley movement along bridge spans creates pinch points between trolley assemblies and bridge end connections where workers accessing trolley maintenance points may be caught if cranes operate during maintenance. Bridge end truck travel along runway beams creates pinch points between end trucks and runway end stops, building columns, or adjacent equipment positioned near crane runways. Wire rope spooling onto hoist drums creates crush hazards between rope layers if workers position hands near drums during hoisting operations. Load positioning operations create pinch points between suspended loads and building structures, equipment, or materials particularly in congested facilities where clearances are minimal. Gantry crane legs traveling on ground-level runways create moving pinch points between legs and any fixed objects in the crane path including building structures, equipment, material storage, or vehicle parking areas. Workers may position themselves in pinch point areas during crane operations to observe load positioning, attach or detach rigging, or perform other tasks requiring proximity to moving loads and crane components. Inadequate clearance specifications during crane design or facility layout changes reducing clearances through equipment installation near crane paths creates pinch point risks. The relatively slow crane travel speeds provide false security suggesting workers can exit pinch point areas before being caught, but human reaction time combined with crane momentum prevents safe withdrawal once crane movement commences. Emergency stop systems may not prevent pinch point injuries if worker entrapment occurs before operators recognize the hazard and activate emergency stops. Lock-out tag-out procedures during maintenance prevent unexpected crane movements but are often inadequately implemented particularly for brief maintenance tasks or adjustments.

Consequence: Severe crush injuries causing traumatic amputations of fingers, hands, arms, or legs requiring immediate surgical intervention and permanent disability. Crush syndrome from sustained compression of limbs causing tissue death, kidney failure, and potential fatality if medical treatment is delayed. Long-term disability from crushed limbs even if amputation is avoided, limiting career options and quality of life. Workers compensation claims for permanent partial disability. Psychological trauma for injured workers and witnesses to crush incidents. Regulatory prosecution following serious crush injuries. Significant financial penalties and corrective action requirements. Lost production time during incident investigation and safety system upgrades.

Electrical Hazards from Crane Power Systems

High

Overhead bridge and gantry cranes utilize electrical power systems including conductor rails or cables supplying 415V three-phase power to crane motors and controls, with electrical hazards from direct contact with energized components, equipment faults causing electrification of crane structures, and electrical arcing during maintenance activities. Conductor rail systems mounted along runway beams provide continuous power supply to moving cranes with spring-loaded collector shoes maintaining electrical contact, creating exposed energized conductors at voltages capable of causing electrocution. Cable festoon systems use suspended cables and trolley assemblies supporting cables during crane travel, with potential for cable damage from abrasion, mechanical impact, or environmental deterioration causing electrical faults. Maintenance personnel access electrical control panels, motor terminal boxes, and limit switch assemblies requiring work on energized equipment if lock-out tag-out procedures are inadequately implemented. Electrical faults in crane motor systems or control circuits can energize crane structural members creating shock hazards for operators using crane controls or workers contacting crane structures. Outdoor gantry cranes face additional electrical hazards from weather exposure with rain or humidity causing insulation breakdown and electrical tracking. Emergency maintenance during production breakdowns may cause workers to shortcut electrical isolation procedures attempting to expedite repairs. Lack of electrical trade qualifications among maintenance personnel leads to inappropriate intervention on electrical systems without proper training or test equipment. Combination of fall protection systems and electrical work creates additional complexity if fall arrest anchor points or equipment contact energized components during maintenance positioning.

Consequence: Electrocution fatalities from contact with 415V crane power systems particularly if workers are positioned on conductive structures providing ground paths. Severe electrical burns requiring extensive medical treatment and causing permanent scarring and disfigurement. Cardiac arrest from electrical shock requiring immediate CPR and defibrillation to prevent fatality. Secondary injuries from falls if electrical shock occurs while workers are at elevation. Arc flash burns from short-circuit incidents during maintenance activities. Prosecution and significant penalties following electrical fatalities. Permanent electrical safety system upgrades required across all similar equipment. Loss of electrical trade workers reluctant to work on inadequately managed electrical systems.

Load Swing and Uncontrolled Load Movement

Medium

Suspended loads traveling beneath overhead cranes develop pendulum swinging motion particularly during bridge or trolley acceleration and deceleration, creating hazards from loads striking workers, equipment, or building structures during travel. Load swing is influenced by suspension cable length with longer cables creating larger swing amplitudes, crane acceleration rates with rapid starting causing increased swing, and external forces such as residual motion from previous load positioning. Workers attempting to stabilize swinging loads by hand contact risk being struck by loads weighing hundreds or thousands of kilograms generating substantial momentum. Swinging loads traveling through congested work areas can strike equipment, material storage, or building columns causing property damage and potentially dislodging loads from rigging. Operators may increase travel speeds attempting to improve productivity without recognizing the relationship between speed and load swing amplitude. Variable frequency drive systems on modern cranes provide soft-start capabilities reducing load swing, but older crane installations with across-the-line motor starting create harsh acceleration and increased swing. Load geometry affects swing characteristics with long or asymmetric loads more prone to swinging and twisting during travel. Wind effects on outdoor gantry cranes can induce load swing particularly with large surface area loads such as steel panels or formwork assemblies. Operators may attempt to compensate for load swing by counter-steering crane movements, but this technique requires substantial skill and can worsen swing if applied incorrectly. Tag lines attached to loads enabling workers to control swing create additional hazards if workers maintain grip on lines rather than releasing when loads move unexpectedly.

Consequence: Serious injuries from workers struck by swinging loads causing fractures, lacerations, and blunt force trauma. Property damage from loads striking expensive manufacturing equipment or building structure. Load dislodgement from rigging if swing causes dynamic loading exceeding rigging working load limits. Production delays from load positioning difficulties and incident investigations. Minor injuries from workers attempting manual load stabilization. Increased crane maintenance costs from structural stress caused by repeated load swing impacts. Reduced operational efficiency from prolonged load positioning time.

Inadequate Communication Between Crane Operators and Ground Personnel

Medium

Effective overhead crane operations require continuous communication between crane operators and dogmen or ground personnel directing load positioning, with communication breakdown creating coordination failures and incident risk. Operators in enclosed cabs or using pendant controls have limited visibility of the complete operating area particularly with long bridge spans exceeding 30 metres or when loads travel behind building structures or equipment obstructing operator sightlines. Dogmen direct load travel paths using hand signals or radio communications, but noisy industrial environments with machinery operation, compressed air tools, and production activities create communication difficulties. Standardized hand signal systems require direct line-of-sight between operators and dogmen, with communication interruption when visual contact is lost. Radio communication systems experience interference from electrical equipment, structural shielding, or multiple simultaneous radio users. Workers unfamiliar with crane operations may enter crane operating areas without understanding coordination protocols or recognizing the need to communicate position to crane operators. Language barriers in multicultural workplaces create communication challenges particularly with standardized safety terminology and emergency commands. Operators and dogmen may develop informal communication shortcuts that work effectively during normal operations but fail during non-routine situations or emergency scenarios. Communication protocols may be inadequately documented or trained particularly when new personnel commence work or temporary workers are engaged during production peaks. Emergency stop communication is critical but may be unclear regarding which personnel have authority to direct crane cessation and what constitutes emergency versus normal operational adjustments.

Consequence: Loads placed on inadequate supports causing secondary collapse incidents and worker injuries. Loads striking equipment or structures during travel causing property damage and potential injury. Workers struck by loads moving without adequate warning. Delays in emergency response if operators do not recognize hazardous situations. Production inefficiency from repeated load positioning adjustments. Near-miss incidents creating worker stress and reduced confidence in crane operations. Regulatory improvement notices requiring enhanced communication systems. Training costs for improved communication protocols and equipment upgrades.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Comprehensive Crane Inspection and Maintenance Programme

Elimination

Systematic inspection and maintenance programs identify and eliminate mechanical and structural defects before they cause crane failures, removing hazards through proactive equipment management. This control addresses the root cause of mechanical and structural failure hazards by maintaining crane equipment in safe operating condition through regular inspection intervals, documented maintenance procedures, and immediate rectification of identified defects. By eliminating equipment defects before they progress to failure state, this control provides fundamental hazard elimination following the hierarchy of control principles.

Implementation

1. Establish comprehensive pre-operational daily inspection procedures performed by crane operators before first use each day, checking hoist operation including lifting and lowering functionality, trolley travel smoothness without binding, bridge travel along full runway length, brake effectiveness for all motion axes, limit switch functionality preventing over-travel, emergency stop button operation, wire rope condition observing for broken wires or kinking, hook inspection for cracks or deformation, and control pendant or radio remote functionality 2. Implement monthly documented inspections by competent persons examining structural components including bridge girders checking for cracks particularly at welded connections, runway beams inspecting for deflection or damage, trolley frame integrity, hoist mounting bolts and connections, end truck wheels and axles for wear, electrical conductor rails or festoon cables for damage, and lubrication levels in gearboxes and bearings 3. Conduct annual major inspections by qualified engineers including load testing at 125% of rated capacity verifying structural integrity, non-destructive testing of high-stress areas using ultrasonic or magnetic particle inspection methods, detailed electrical system testing, brake system performance testing, and comprehensive mechanical system examination with disassembly of critical components 4. Engage professional crane service contractors for major inspections and specialized maintenance tasks requiring specific expertise, tooling, or testing equipment beyond facility capabilities 5. Maintain detailed maintenance records documenting all inspections, maintenance performed, defects identified, repairs completed, and parts replaced using computerized maintenance management systems enabling trending analysis and predictive maintenance scheduling 6. Implement defect reporting procedures requiring immediate notification of supervisors when defects affecting safety or operation are identified, with cranes tagged out of service until repairs are completed 7. Establish preventive maintenance schedules based on manufacturer recommendations and operating hours, performing tasks including lubrication of mechanical components, brake adjustment and testing, electrical connection inspection and tightening, wire rope lubrication, and replacement of wearing components before reaching service limits 8. Replace wire ropes before reaching discard criteria specified in AS 1418.1 including broken wire thresholds (10 broken wires in one lay length or 5 broken wires in one strand in one lay length), rope diameter reduction exceeding 7%, visible core protrusion, severe corrosion, or kinking damage 9. Calibrate load limiters and overload protection devices annually ensuring accurate load measurement and crane shutdown if rated capacity is exceeded 10. Implement runway beam inspection programs examining structural integrity, checking for deflection or settlement, verifying anchor bolt condition, and conducting engineering assessment if capacity increases are proposed 11. Document crane operating hours using hour meters enabling maintenance scheduling based on actual utilization rather than calendar intervals alone 12. Establish spare parts inventory for critical wear components including brake pads, limit switches, conductor shoes, wire rope, hooks, and electrical contactors enabling rapid repair without extended downtime 13. Train maintenance personnel in crane-specific maintenance procedures, manufacturer service bulletins, and safe maintenance practices including lock-out tag-out, fall protection during crane access, and proper torque specifications for critical fasteners 14. Conduct periodic structural engineering assessments particularly for older crane installations or facilities where production demands have increased since original crane design, verifying structural adequacy for current loading conditions 15. Implement condition monitoring for critical components such as gearboxes using oil analysis detecting wear particles indicating impending failures, vibration monitoring identifying bearing deterioration, and thermal imaging locating electrical connection overheating

Rated Capacity and Load Weight Verification Systems

Engineering

Engineering controls prevent overloading through load weighing systems, clearly marked capacity ratings, and overload protection devices that automatically prevent lifts exceeding crane design capacity. These systems provide objective load measurement and automatic crane lockout if capacity is exceeded, removing reliance on operator judgment and load weight estimation that creates overloading risk.

Implementation

1. Install load moment indicator (LMI) systems or load cell devices on crane hoists measuring actual load weight and displaying values to operators in real-time, with visual and audible alarms activating if loads approach rated capacity 2. Configure overload protection systems to automatically prevent hoist operation if loads exceed 100% of rated capacity for the specific crane configuration and radius, with protection settings verified during annual inspections 3. Display clear capacity rating plates on crane bridges visible to operators specifying maximum rated capacity, load rating charts if capacity varies with trolley position, and warning statements regarding overload consequences 4. Implement load weighing procedures for loads without known weights using either crane-mounted load cells during initial lift, portable floor scales before attachment, or engineering calculations based on material density and dimensions 5. Establish load verification documentation requirements where dogmen or riggers confirm load weights and rigging configurations on lift plans before commencing lifts particularly for heavy or critical loads approaching crane capacity 6. Mark crane hooks with rated capacity plates identifying maximum safe working load, and ensure rigging equipment attached to hooks does not exceed hook capacity 7. Install capacity warning systems providing progressive alerts as loads increase such as amber warning at 80% capacity and red warning at 95% capacity, enabling operators to monitor load levels during gradual load application 8. Calibrate load weighing systems annually using certified test weights ensuring measurement accuracy within ±2% of actual load weight across the full capacity range 9. Provide load capacity training to crane operators, dogmen, and supervisors covering interpretation of capacity rating plates, use of load charts, effects of load radius on capacity for specific crane types, and procedures when load weights are uncertain 10. Implement engineering assessment protocols if operational requirements demand lifts exceeding current crane rated capacity, requiring structural analysis by qualified engineers and potential crane modifications or capacity upgrades 11. Document load capacity verification for critical lifts in permit-to-lift systems requiring supervisor approval before commencing lifts exceeding predetermined weight thresholds typically 50% of rated capacity 12. Install warning systems preventing simultaneous multi-crane lifts unless specific procedures and load sharing calculations are documented and approved by engineering personnel 13. Prohibit estimating load weights for lifts exceeding 25% of crane rated capacity, requiring documented weight verification through measurement or calculation 14. Mark load capacity derating locations where specific positions or configurations reduce crane capacity below maximum rated values, ensuring operators recognize capacity limitations 15. Conduct load testing during annual inspections lifting test loads to 125% of rated capacity verifying crane structural and mechanical systems operate safely at overload conditions without permanent deformation or component damage

Physical Barriers and Exclusion Zones Preventing Personnel Access to Crane Operating Areas

Engineering

Physical barriers, fencing, and designated exclusion zones prevent workers entering areas beneath crane travel paths or adjacent to moving crane components, providing engineering control against struck-by hazards. These physical controls create reliable protection independent of worker behavior or awareness, representing superior control effectiveness compared to administrative procedures alone.

Implementation

1. Install physical barriers along crane runway perimeters using permanent fencing, safety mesh panels, or solid barriers preventing unauthorized access to areas beneath crane travel paths and adjacent to runway beams 2. Establish clear floor marking using high-visibility paint (typically yellow or red) delineating crane operating envelopes and exclusion zones on factory floors beneath overhead cranes 3. Install warning signage at exclusion zone boundaries displaying 'DANGER - OVERHEAD CRANE OPERATIONS - AUTHORIZED PERSONNEL ONLY' with pictorial symbols for multilingual workforce understanding 4. Create designated access gates in crane operating area barriers controlled by supervisors or crane operators, ensuring personnel entry is coordinated with crane operations 5. Implement interlock systems on access gates triggering audible and visual alarms alerting crane operators when gates open indicating potential personnel entry to crane operating areas 6. Position material storage zones outside crane exclusion areas or within specifically designated safe zones that are permanently marked and communicated to crane operators as no-travel areas 7. Establish physical barriers preventing workers approaching within 1 metre of gantry crane runway tracks, using bollards, permanent fencing, or raised kerbs creating clear separation between crane paths and pedestrian areas 8. Install overhead protection canopies or gantries above walkways that must cross beneath crane paths providing physical protection against falling object hazards if load drops occur 9. Utilize safety light curtains or laser-based detection systems around crane operating areas that automatically stop crane movements if personnel enter protected zones during crane travel 10. Establish designated load landing zones with physical boundaries marked on floors where loads are positioned for placement or removal, preventing loads being placed in areas where workers operate 11. Install physical stops on runway beams preventing crane bridge travel beyond designated limits and ensuring clearance from building end walls or adjacent structures 12. Implement traffic management systems separating vehicle movements from crane operating areas particularly in facilities where forklifts or service vehicles operate near gantry crane paths 13. Create elevated walkways or underpasses enabling personnel circulation through facilities without entering crane operating areas, providing alternative routes maintaining workflow efficiency 14. Position machinery and equipment outside crane exclusion zones during facility layout planning, ensuring adequate clearances and preventing workers accessing areas beneath crane paths during equipment operation 15. Maintain exclusion zone barriers in serviceable condition with regular inspection of fencing integrity, signage visibility, and floor marking clarity, replacing damaged or faded components immediately

Comprehensive Rigging Inspection and Certification Programme

Engineering/Administrative

Systematic inspection and testing of lifting gear including slings, shackles, hooks, and spreader beams identifies damaged or worn equipment before failure, combined with administrative procedures ensuring only certified rigging equipment is used. This control combines engineering verification through physical inspection and testing with administrative procedures governing equipment use and retirement.

Implementation

1. Implement pre-use visual inspection procedures requiring dogmen or riggers to examine all rigging components before each lift, checking wire rope slings for broken wires, distortion or kinking, cable diameter reduction, or visible corrosion, synthetic slings for cuts, tears, abrasions, or UV degradation, chain slings for elongation, twisted links, or cracking, and shackles for deformation, thread damage, or missing pins 2. Establish documented periodic inspection programs conducted by competent persons at maximum 6-month intervals for frequently-used rigging, examining equipment in detail and recording inspection findings, defects identified, and disposition decisions 3. Implement unique identification systems for all rigging equipment using stamped serial numbers, color coding, or RFID tags enabling tracking of inspection history, usage, and retirement dates 4. Conduct proof load testing for new rigging equipment before first use at loads specified in AS 1418.4, typically 2.5 times working load limit, verifying equipment integrity and documenting test results 5. Maintain rigging equipment registers documenting each item's identification number, type and capacity, date of manufacture or purchase, inspection history, and retirement date, using computerized asset management systems 6. Establish clear discard criteria based on AS 1418.4 requirements such as wire rope slings exceeding 10% broken wires in one lay length, synthetic slings with cuts or tears exposing core yarns, chains with elongation exceeding 5% of original length, or any component showing deformation, heat damage, or chemical attack 7. Retire damaged rigging immediately using physical destruction such as cutting wire ropes or chains preventing inadvertent reuse of defective equipment 8. Provide secure storage areas for rigging equipment protected from weather exposure, chemical contamination, and mechanical damage, with organized racks enabling easy equipment selection and inspection 9. Attach durable identification tags to rigging components displaying safe working load limits, inspection dates, and unique identification numbers ensuring information remains legible throughout equipment service life 10. Implement color-coding systems for rigging equipment grouping items by capacity ranges enabling rapid visual verification that selected rigging matches load requirements 11. Train dogmen and riggers in rigging inspection procedures, discard criteria, documentation requirements, and reporting processes for defective equipment 12. Establish minimum factors of safety for rigging selection typically 5:1 for wire rope and chain slings and 7:1 for synthetic slings, ensuring adequate capacity margins accounting for dynamic loading and degradation during service life 13. Prohibit field repairs or modifications of rigging equipment including welding on hooks or shackles, splicing wire ropes, or extending chains, requiring manufacturer-authorized repairs or equipment replacement 14. Conduct periodic audits of rigging equipment inventory verifying all items are properly identified, inspection dates are current, damaged equipment has been retired, and adequate quantities of serviceable equipment are available for operational needs 15. Provide documentation to crane operators and supervisors summarizing current rigging inventory, capacity ratings, and inspection status enabling verification that rigging used for specific lifts is certified and within capacity limits

Crane Operator Licensing and Competency Verification Programme

Administrative

Ensuring overhead crane operators hold current high-risk work licenses and demonstrated competency prevents operator error contributing to incidents through inadequate training, inexperience, or unfamiliarity with equipment. The CB (Bridge and Gantry Crane) high-risk work license mandates assessment of operator knowledge and practical skills in crane operation, load handling, and emergency procedures. This administrative control ensures only qualified persons operate overhead cranes with documented verification providing compliance evidence.

Implementation

1. Verify all overhead bridge and gantry crane operators hold current CB (Bridge and Gantry Crane) high-risk work license issued under WHS Regulations, checking photo identification matches license and recording license numbers and expiry dates 2. Maintain copies of operator licenses in personnel files with expiry date tracking systems flagging licenses requiring renewal minimum 60 days before expiry enabling renewal completion without lapses 3. Implement site access procedures preventing unlicensed persons operating overhead cranes through facility induction requirements and daily pre-start checks verifying operator qualifications 4. Verify operator licensing before permitting crane operation with shift supervisors responsible for license verification and documentation in daily attendance records 5. Establish company competency assessment programs supplementing statutory licensing, documenting operator training on facility-specific crane equipment, standard operating procedures, emergency response protocols, and communication systems 6. Conduct crane-specific operator induction for personnel operating overhead cranes at new facilities covering crane capacity ratings, operating envelope limits, known hazards, exclusion zones, communication protocols, and maintenance reporting procedures 7. Implement operator mentoring systems pairing newly-licensed operators with experienced operators for supervised operation periods minimum 40 hours before authorizing independent operation on critical production cranes 8. Provide ongoing refresher training annually covering incident learnings from industry, procedural updates, regulatory changes, and reinforcement of safe operating practices 9. Conduct operator performance evaluations annually assessing operational technique, safety compliance, communication effectiveness, and equipment care, with documented feedback and improvement plans 10. Establish minimum experience requirements for operators on high-capacity cranes exceeding 20-tonne capacity, requiring documented operating hours on similar equipment before authorization 11. Train operators in load dynamics including load swing causes and mitigation, effects of acceleration rates on load behavior, appropriate travel speeds for varying load characteristics, and soft-landing techniques for precise load positioning 12. Provide operators with crane-specific operating manuals covering control functions, capacity ratings, maintenance requirements, emergency procedures, and manufacturer safety bulletins 13. Brief operators on facility changes affecting crane operations including new equipment installations reducing clearances, process changes affecting typical lift patterns, or procedural updates following incident investigations 14. Implement operator fatigue management particularly for facilities with extended operating hours or shift work, establishing maximum continuous operating periods and mandatory break schedules 15. Document operator qualifications, training completion, competency assessments, and authorization status in personnel records with regular review ensuring currency and identifying training needs

Standardized Communication Protocols and Hand Signal Systems

Administrative

Establishing clear communication protocols between crane operators and dogmen using standardized hand signals, radio systems, and coordination procedures prevents communication failures causing struck-by incidents, load positioning errors, or coordination breakdowns. Systematic communication procedures ensure all personnel understand crane movements and load positioning intentions throughout lifting operations.

Implementation

1. Adopt standardized crane hand signal systems defined in AS 2550.1 including signals for HOIST (arm extended vertically with forefinger pointing up, moving in small circles), LOWER (arm extended downward with forefinger pointing down, moving in small circles), STOP (arm extended with palm down, moved horizontally back and forth), EMERGENCY STOP (both arms extended with hands waving), TRAVEL (arm extended pointing in direction of travel), and other standard signals for bridge and trolley movements 2. Train all crane operators and dogmen in standardized hand signal systems with practical assessment demonstrating competency in signal execution and recognition before authorization for crane direction duties 3. Establish radio communication systems for facilities where visual communication is impractical due to long crane travel distances, visual obstructions, or enclosed operator cabins limiting signal visibility 4. Allocate dedicated radio channels for crane operations preventing interference from other facility radio users, with clear call signs identifying specific cranes in facilities with multiple overhead crane installations 5. Implement radio discipline procedures requiring confirmation of instructions using standard phraseology such as 'CRANE 2, TRAVEL NORTH 10 METRES' followed by operator confirmation 'CRANE 2, ROGER, TRAVELING NORTH 10 METRES' 6. Provide backup communication methods ensuring operations can continue if primary systems fail, such as radio systems with hand signals as backup or vice versa 7. Establish single-point-of-control protocols where only one designated person directs crane movements for each lift operation preventing conflicting instructions from multiple personnel 8. Implement emergency stop authority empowering any person observing hazardous conditions to direct immediate crane cessation using EMERGENCY STOP signals recognized by all operators 9. Brief new facility personnel during induction on crane communication protocols even if not directly involved in crane operations, enabling recognition of hand signals and understanding of crane coordination requirements 10. Position dogmen in locations providing clear visibility of both the load and the crane operator or with unobstructed radio communication, relocating as needed during load travel 11. Establish pre-lift communication procedures requiring discussion between operators and dogmen before commencing critical lifts covering load weight, rigging configuration, travel path, obstacles, placement location, and expected duration 12. Utilize visual aids including load travel path drawings or facility layout plans marked with travel routes for complex lifts involving multiple crane movements or congested areas 13. Install communication system test procedures in daily pre-start checks verifying radio functionality, battery charge levels, and signal clarity before commencing crane operations 14. Document communication failures in incident and near-miss reporting systems identifying root causes and implementing corrective actions such as additional training, equipment upgrades, or procedural improvements 15. Conduct periodic drills practicing emergency communication scenarios including emergency stops, load malfunctions, and evacuation procedures ensuring all personnel respond appropriately to emergency signals

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Personal protective equipment

Requirement: Type 1 hard hats to AS/NZS 1801 with secure chin straps mandatory for all personnel in crane operating areas

When: Required at all times when working beneath overhead cranes or in designated crane operating areas. Critical protection against falling object hazards from loads or rigging components. Essential during crane maintenance activities

Requirement: Class D day/night high-visibility vests or shirts with reflective tape

When: Mandatory for dogmen, crane operators exiting control stations, and all personnel working in crane operating areas. Enables crane operators to identify workers in operating envelope particularly in large facilities or outdoor gantry crane areas

Requirement: Lace-up boots with steel toe protection and slip-resistant soles

When: Required for all personnel in crane operating areas protecting against crush injuries from falling objects, dropped rigging, or rolling loads. Anti-slip soles prevent falls on smooth factory floors

Requirement: Clear impact-resistant safety glasses with side protection

When: Required during rigging operations, crane maintenance activities, and when working beneath suspended loads. Protection against dust, metal particles from wire rope handling, and debris from maintenance activities

Requirement: Leather palm gloves providing grip and abrasion protection

When: Mandatory when handling rigging equipment, wire rope slings, or chains. Protection against wire rope strand injuries, sharp edges on loads, and abrasion during load guiding operations

Requirement: Full-body harness with shock-absorbing lanyard and double locking karabiners

When: Required for all maintenance personnel accessing elevated crane components including bridge beams, trolley assemblies, or runway structures above 2 metres height. Must be attached to appropriate anchor points before accessing height

Requirement: Class 4-5 earplugs or earmuffs providing minimum 25dB noise reduction

When: Required in facilities where ambient noise from production equipment exceeds 85dB(A). Particularly important in metal fabrication, precast concrete, and heavy manufacturing facilities with continuous high noise levels

Requirement: Class 00 insulated gloves rated for 500V with leather protectors, insulated tools, voltage testers

When: Required for electrically-qualified maintenance personnel working on crane electrical systems. Must be used in conjunction with lock-out tag-out procedures and electrical isolation verification

Inspections & checks

Before work starts

✓Verify crane operator holds current CB (Bridge and Gantry Crane) high-risk work license checking photo identification and recording license number and expiry date
✓Conduct visual inspection of crane bridge structure checking for visible cracks, deformation, or damage particularly at welded connections and high-stress areas
✓Test hoist operation lifting hook slightly off ground and lowering, checking for smooth operation without jerking or unusual sounds indicating mechanical issues
✓Verify trolley traverse operates smoothly along full bridge span without binding, excessive noise, or hesitation indicating wheel or track damage
✓Test bridge travel along complete runway length ensuring smooth operation, checking for any areas of resistance or unusual sounds
✓Verify all crane brakes are functioning effectively by testing holding capability under light load conditions for hoist, trolley, and bridge movements
✓Test upper and lower limit switches by approaching limits under controlled conditions verifying automatic crane shutdown before physical stops are contacted
✓Verify emergency stop buttons on control pendants, operator cabs, and remote controls immediately cease all crane movements when activated
✓Inspect wire rope condition on hoist drum checking for broken wires, kinking, corrosion, cable diameter reduction, or other damage requiring rope replacement
✓Examine crane hook for cracks particularly in the hook bowl and shank areas, check safety latch functionality, and verify capacity marking plate is legible
✓Test control pendant or radio remote control functionality verifying all motion commands operate correctly and control responses match operator inputs
✓Check electrical conductor rail or festoon cable system for damage, proper contact shoe positioning, and adequate cable support preventing dragging or sagging
✓Verify exclusion zone barriers and signage remain in place and serviceable condition with floor markings clearly visible
✓Check lighting levels in crane operating area ensuring adequate illumination for safe load handling and inspection activities
✓Review previous shift maintenance records or defect reports identifying any issues requiring attention before commencing operations

During work

✓Monitor crane sounds during operation listening for unusual noises indicating mechanical deterioration such as grinding from worn gears or bearings
✓Observe load behavior during travel watching for excessive swing indicating inappropriate acceleration rates or long suspension cables requiring technique adjustment
✓Verify workers maintain clear of crane operating areas and exclusion zones with spotters enforcing access controls
✓Monitor communication effectiveness between crane operators and dogmen ensuring clear signal transmission and confirmation of instructions
✓Check wire rope spooling onto hoist drum ensuring even layer winding without rope overlapping or gaps indicating alignment issues
✓Observe brake operation during load positioning verifying smooth deceleration and secure load holding without drift or creep
✓Monitor load weights being lifted ensuring crane is not operated above rated capacity and overload protection systems are respected
✓Verify rigging equipment being used appears serviceable without obvious damage, with dogmen confirming rigging inspection before load attachment
✓Watch for any unusual crane behavior including erratic movements, control response delays, or partial function failures requiring immediate investigation
✓Monitor facility environment including changes to work areas that might reduce clearances or create new hazards near crane operating paths
✓Verify loads are adequately secured before commencing travel preventing load shifting or component detachment during crane movement
✓Check that personnel do not position themselves beneath suspended loads maintaining safe positions during all lifting operations
✓Monitor weather conditions for outdoor gantry cranes watching for high winds, lightning, or heavy rain requiring operational restrictions or cessation
✓Ensure maintenance activities on other equipment near crane operating areas are coordinated with crane operations preventing conflicts or struck-by hazards

After work

✓Return crane hook to designated parking position typically centered in the operating envelope and lowered to near floor level
✓Secure crane controls by switching control stations to off position and removing pendant control keys or disabling radio remotes preventing unauthorized operation
✓Conduct post-operational visual inspection of crane components checking for any damage, loose fasteners, or leaks that occurred during the shift
✓Document crane operating hours in equipment log books recording shift duration and any unusual events or equipment behavior observed
✓Report any defects, unusual sounds, or operational issues to maintenance personnel and supervisors using formal defect reporting procedures
✓Tag crane out of service if defects affecting safety or operation are identified, positioning clear signage on control stations indicating equipment status
✓Store rigging equipment in designated locations protected from damage and weather exposure, with damaged rigging segregated for retirement
✓Complete crane operating logs recording loads lifted, significant lifts, incidents or near-misses, and general operational observations
✓Secure crane operating areas ensuring exclusion zone barriers remain in place and access gates are locked if required by facility procedures
✓Verify facility is left in safe condition with no suspended loads, materials positioned clear of crane paths, and access routes clear
✓Conduct brief handover communication with incoming shift operators if facility operates continuously, discussing any issues or planned activities
✓Clean crane control stations removing debris or contamination ensuring controls remain in serviceable condition for next operator

Step-by-step work procedure

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

Field ready

Pre-Operational Inspection and Start-Up Procedures

Comprehensive pre-operational inspection identifies equipment defects before commencing operations preventing incidents from mechanical failures or operational malfunctions. Begin inspection by verifying current operator license status and reviewing any defect reports or maintenance activities from previous shifts. Conduct visual inspection walking the full runway length checking runway beam condition, bridge structure integrity, and access area clearances. Examine bridge and trolley components checking for obvious damage, leaks, or unusual conditions requiring detailed investigation. Inspect hoist wire rope on the drum looking for broken wire strands, kinking, corrosion, or diameter reduction indicating rope deterioration. Check hook condition examining for cracks using visual inspection and dye penetrant methods if cracks are suspected, verify safety latch operates correctly, and ensure capacity markings are legible. Test crane electrical systems by energizing the crane and verifying indicator lights, warning systems, and control station displays function normally. Systematically test each crane motion including hoist lift and lower, trolley traverse in both directions, and bridge travel along full runway, checking for smooth operation without jerking or binding. Verify brake operation by loading the hoist with a light test load and checking secure holding in all positions. Test limit switches by approaching upper and lower hoist limits and runway end positions under controlled conditions verifying automatic shutdown before physical stops contact. Test emergency stop systems by activating emergency buttons during test movements confirming immediate cessation of all motions. Document inspection findings in daily pre-start inspection logs noting any defects and remedial actions required. Communicate with maintenance personnel and supervisors regarding any defects requiring attention before operational authorization. Only commence crane operations after completing inspection procedures and confirming crane is in safe operational condition.

Safety considerations

Inadequate pre-operational inspection allows defective equipment to operate creating mechanical failure risk. Operators who skip inspection procedures due to production pressure or complacency increase incident probability. Visual inspection alone may not identify internal mechanical deterioration requiring operational testing. Emergency stop testing is essential as non-functional emergency systems prevent incident mitigation. All defects must be documented providing maintenance prioritization and compliance evidence.

Load Assessment and Rigging Selection

Accurate load weight determination and appropriate rigging selection prevents overloading and rigging failure incidents. Before any lift commences, determine load weight through direct measurement using floor scales, calculation based on material specifications and dimensions, or reference to load data plates on manufactured items. Compare load weight to crane rated capacity ensuring adequate safety margin typically maintaining loads below 90% of rated capacity for routine lifts. Assess load geometry including dimensions, center of gravity location, and lifting point positions determining appropriate rigging configuration. Select rigging equipment including slings, shackles, and hardware based on load weight and rigging angle calculating sling loads using appropriate formulas accounting for multi-leg sling configurations where load distributes across multiple slings. Verify rigging equipment capacity markings ensure working load limits exceed calculated sling loads with appropriate safety factors typically 5:1 for wire rope and chain. Inspect rigging equipment before use checking wire rope slings for broken wires exceeding 10 in one lay length, synthetic slings for cuts or abrasion, chains for elongation or distortion, and shackles for deformation or thread damage. Reject defective rigging immediately removing from service and reporting for replacement. Plan load attachment points ensuring balanced rigging configuration with load center of gravity directly below the hook preventing load tilting or instability during lift. Consider load orientation during travel ensuring loads fit through required clearances and will not strike structures or equipment. Brief all personnel involved in the lift including crane operator, dogmen, and spotters regarding load characteristics, weight, travel path, and placement location. Document critical lift details on lift plan forms for heavy loads exceeding 50% of crane rated capacity including load weight verification, rigging configuration, and supervisor approval. Only commence lifting after completing load assessment and rigging selection ensuring all preparations support safe load handling.

Safety considerations

Load weight estimation rather than measurement creates overloading risk with catastrophic failure potential. Incorrect rigging selection exceeding working load limits causes rigging failure and load drops. Inadequate rigging inspection allows damaged equipment use risking sudden failure during lifts. Unbalanced rigging creates load instability causing loads to tip or shift unexpectedly. Heavy or critical lifts require documented planning and supervisor review ensuring appropriate controls.

Load Attachment and Initial Lift

Proper load attachment technique and controlled initial lifting prevents load instability, rigging failure, and struck-by incidents during the critical lift commencement phase. Position crane hook over load attachment points using precise trolley and bridge movements directed by dogman hand signals or radio commands. Lower hook slowly maintaining control until rigging can be attached, ensuring hook is not dropped onto load causing impact damage. Attach rigging to load using appropriate connection methods ensuring wire rope slings seat properly in load contact areas, synthetic slings position flat without twisting, chains engage properly without kinking, and shackles orient correctly with pins secured. Attach rigging to crane hook ensuring slings position within hook bowl not on hook tip, safety latch closes properly securing slings, and multiple sling legs balance appropriately. Verify load is balanced by visual inspection checking rigging angles are equal and load orientation appears stable. Instruct all personnel to stand clear of the load and potential fall paths before commencing lift. Communicate lift commencement to crane operator using standard hand signals or clear radio commands. Take up slack in rigging slowly removing wire rope or chain slack until rigging becomes taut without load lifting. Pause momentarily with rigging tight confirming load balance and rigging security. Commence initial lift slowly raising load only 100-200mm above supporting surface while maintaining close observation of load behavior, rigging alignment, and any unusual conditions. Stop immediately after initial lift observing load stability, checking rigging has not shifted or loosened, verifying load is balanced without tilting, and confirming crane operates smoothly under load. If any instability or concern is observed, lower load immediately and reassess rigging configuration. Only proceed with full lift after confirming initial lift demonstrates load control and rigging adequacy. For heavy loads near crane capacity, verify overload protection systems have not activated indicating load weight is within crane rating. Communicate successful initial lift test to all personnel before proceeding with load travel.

Safety considerations

Rushed load attachment without proper positioning creates rigging misalignment risking load drops. Failure to clear personnel before initial lift exposes workers to load fall hazards. Initial lift test is critical for detecting rigging problems before loads are elevated to dangerous heights. Load instability during initial lift indicates rigging problems requiring immediate correction. Personnel must never position beneath loads during attachment and initial lift phases.

Load Travel and Positioning

Controlled load travel and precise positioning prevents struck-by incidents, load swing hazards, and damage to loads or facility structures. After successful initial lift test, communicate intended travel path to crane operator and any spotters positioned along the route. Raise load to appropriate travel height providing clearance over obstacles typically 500mm minimum clearance above highest obstruction in travel path. Commence bridge or trolley travel using smooth acceleration preventing sudden load swing from jerky crane movements. Maintain controlled travel speeds appropriate for load characteristics typically 20-40 metres per minute for standard loads, slower for long or unstable loads prone to swinging. Monitor load constantly during travel observing for any swing development, load rotation, or rigging shifting indicating problems requiring immediate stopping. Use spotters positioned along travel path particularly when operator visibility is limited by building structures, equipment, or when loads travel behind crane bridge. Communicate continuously with crane operator providing directional commands and alerting to any hazards or personnel in proximity to load path. Slow crane movements well before reaching destination allowing load swing to dampen before final positioning. Position load over final placement location using small precise movements guided by dogman signals. Lower load slowly maintaining control throughout descent, watching for any obstacles or misalignment. Guide load into final position manually only when load is within 300mm of landing and moving slowly, using push sticks or tag lines rather than hand contact for heavy loads. Land load onto supports ensuring supports are adequate for load weight and stable preventing load rolling or tipping. Verify load is stable on supports before releasing rigging tension. Lower hook completely removing load support from crane. Inspect load stability before detaching rigging ensuring load will not shift or fall when rigging is removed. Detach rigging systematically preventing rigging from falling or swinging into personnel or equipment. Recover rigging to safe storage location for inspection and reuse.

Safety considerations

Excessive travel speed causes load swing creating struck-by hazards and loss of load control. Insufficient clearance height results in loads striking obstacles causing property damage and potential load drops. Operators with inadequate visibility require spotters preventing blind crane movements. Manual load guidance during movement creates crush injury risks if loads swing unexpectedly. Inadequate landing supports cause secondary incidents from load collapse after placement. Never position personnel beneath loads during travel or positioning operations.

Emergency Response and Incident Management

Effective emergency response to crane malfunctions, load control loss, or other incidents minimizes injury severity and property damage while enabling safe incident recovery. Crane operators and facility personnel must understand emergency procedures before incidents occur through training and periodic drills. Common emergency scenarios requiring immediate response include loss of crane power causing inability to control suspended loads, brake failure causing uncontrolled lowering or drift, mechanical failure such as wire rope or mechanical component breakage, overload situations where crane capacity is exceeded, load swing or instability creating struck-by hazards, and personnel in danger from crane movements or suspended loads. For power loss scenarios with loads suspended, secure the area beneath the load preventing personnel access, establish exclusion zones using barriers and warning signage, assess load and rigging stability determining immediate fall risk, implement temporary load support using jacks, lifting equipment, or structural shoring if load stability is questionable, coordinate with electrical contractors and maintenance personnel to restore power or implement manual load lowering procedures, and monitor load continuously until power restoration or controlled lowering completion. For brake failure scenarios causing uncontrolled load movement, activate emergency stop systems immediately attempting to stop all crane movements, communicate emergency to all facility personnel using emergency alarms or radio announcements, evacuate personnel from crane operating area particularly anyone in the path of drifting loads or crane components, attempt to control load using alternative braking methods if available such as mechanical brakes or motor dynamic braking, and if load cannot be controlled safely cease all operation and secure area until mechanical repairs restore braking capability. For mechanical failures such as wire rope breakage or structural component failure, stop all crane movements immediately if safe to do so, assess structural stability determining if continued operation creates additional collapse risk, evacuate area beneath affected crane sections establishing large exclusion zones accounting for potential crane collapse envelope, isolate crane electrical power using lock-out tag-out procedures, engage structural engineers to assess damage and recommend safe recovery procedures, and implement engineered recovery plan potentially using other cranes or lifting equipment to stabilize damaged crane before repairs. For overload situations identified by load moment indicators or overload protection activation, lower load immediately if possible before structural damage occurs, stop lift if load cannot be lowered safely maintaining load suspended, verify actual load weight to confirm overload condition, reduce load weight through partial unloading or load splitting into multiple lighter lifts, reassess crane capacity and rigging adequacy, and only resume operation after confirming load is within crane rating. Document all emergency incidents including circumstances, actions taken, injuries or damage, and causal factors in formal incident investigation reports. Conduct post-incident analysis identifying root causes and implementing corrective actions preventing recurrence across similar equipment and operations.

Safety considerations

Immediate response is critical in emergencies as delay increases injury severity and property damage. Unclear emergency procedures cause confusion delaying effective response. Personnel must be trained in emergency response before incidents occur rather than attempting to learn during crisis. Exclusion zones during emergencies must be larger than normal operations accounting for increased failure risks. Always engage engineering expertise for structural assessment after major mechanical failures. Emergency drills validate procedures and identify training needs before real emergencies occur.

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Frequently asked questions

What license is required to operate overhead bridge and gantry cranes in Australia?

Overhead bridge and gantry crane operators in Australia must hold a current CB (Bridge and Gantry Crane) high-risk work license issued under the Work Health and Safety Regulations 2011 by state or territory workplace health and safety regulators such as WorkSafe Victoria, SafeWork NSW, or equivalent authorities in other jurisdictions. This licensing requirement applies to cranes with lifting capacity exceeding 3 tonnes or bridge span exceeding 8 metres. The CB license requires completion of nationally recognized training delivered by registered training organizations, covering theoretical knowledge of crane mechanics, load calculations, rigging principles, operational safety, and emergency procedures, followed by practical assessment demonstrating competency in crane operation, load handling, and safety procedures. Training typically requires 3-5 days depending on prior experience, with assessment conducted by qualified assessors. License holders must be at least 18 years old, and licenses remain current for 5 years requiring renewal before expiry through refresher training or demonstration of continued competency. Operating overhead cranes without appropriate licensing constitutes a serious breach of WHS regulations attracting penalties up to $10,000 for individuals and $50,000 for companies, plus potential prosecution following incidents. Facilities must verify operator licensing before permitting crane operation and maintain license copies in project records providing compliance evidence during regulatory inspections or incident investigations.

How often must overhead cranes be inspected and what inspections are required?

Overhead bridge and gantry crane inspection requirements are specified in AS 2550.1 and WHS Regulations establishing multiple inspection tiers. Daily pre-operational inspections must be conducted by crane operators before first use each shift examining visual crane condition, testing operational functions including hoist, trolley and bridge movements, verifying brake effectiveness, checking limit switch operation, and inspecting wire ropes and hooks for obvious damage. Monthly documented inspections by competent persons examine crane components in detail including structural members for cracks or deformation, mechanical systems for wear or damage, electrical systems for connection integrity, wire rope condition using detailed criteria, hook integrity including crack inspection, brake systems for adjustment and wear, and limit switch calibration. Annual major inspections conducted by qualified engineers include comprehensive structural examination using non-destructive testing methods such as ultrasonic or magnetic particle inspection for crack detection, load testing at 125% of rated capacity verifying structural adequacy, detailed mechanical system inspection potentially including component disassembly, electrical system testing including insulation resistance and protection devices, runway beam inspection for structural condition and deflection, and preparation of detailed inspection reports documenting findings and recommendations. Special inspections are required after significant events such as overload incidents, structural impacts, modifications to crane systems, or whenever defects are suspected. All inspections must be documented in permanent crane records maintained for the equipment working life plus 5 years, with inspection findings and defect rectification records available for regulatory inspection. Cranes with identified safety-critical defects must be removed from service immediately using lock-out tag-out procedures and clear signage until repairs are completed and verified by competent persons. Failure to maintain adequate inspection programs contributes to mechanical failure incidents resulting in serious regulatory consequences including prohibition notices, prosecution, and significant financial penalties.

What are the requirements for rigging equipment inspection and retirement?

Rigging equipment inspection and retirement requirements are specified in AS 1418.4 establishing both pre-use inspection and periodic documented inspection programs. Pre-use visual inspection must be conducted by dogmen or riggers before each use examining wire rope slings for broken wires (discard if 10 broken wires visible in one lay length or 5 broken wires in one strand), severe corrosion, kinking, wire rope diameter reduction exceeding 7%, or visible core protrusion indicating internal damage. Synthetic slings require inspection for cuts or tears exposing core yarns, abrasion reducing strap thickness, UV degradation indicated by discoloration or brittle fibers, chemical damage, heat damage, and stitching deterioration. Chain slings must be checked for elongation exceeding 5% of original length, twisted or bent links, cracks visible at link bends, and wear exceeding 10% of original chain diameter. Shackles require inspection for deformation, thread damage, missing or damaged pins, and capacity marking legibility. Periodic documented inspections by competent persons must occur at maximum 6-month intervals for frequently-used rigging or 12 months for occasional-use equipment, with detailed examination and documentation of findings. All rigging equipment must have unique identification enabling tracking of inspection history, typically using stamped numbers, color coding by capacity, or RFID tags. New rigging requires proof load testing before first use at loads typically 2.5 times working load limit for wire rope and chain, verifying manufacturing quality. Rigging registers must document each item's identification, type, capacity, acquisition date, inspection history, and retirement date. Damaged rigging must be retired immediately through physical destruction such as cutting wire ropes or chains preventing inadvertent reuse. Minimum factors of safety are 5:1 for wire rope and chain slings and 7:1 for synthetic slings calculated as breaking strength divided by working load limit. Field repairs including welding on hooks, splicing wire ropes, or extending chains are prohibited, requiring manufacturer-authorized repairs or equipment replacement. Adequate rigging inspection programs demonstrating systematic approach with documentary evidence are essential elements of WHS compliance and duty of care obligations.

What clearances are required between overhead cranes and building structures or equipment?

Clearance requirements between overhead cranes and building structures, stored materials, or equipment are specified in AS 1418.1 and AS 2550.1 ensuring safe crane operation and personnel protection. Minimum clearances between moving crane components and fixed structures must be 300mm in any direction for bridge end trucks traveling along runways, trolley frames traversing bridge spans, and load blocks moving through operating envelopes. This 300mm minimum applies to clearances between crane components and building columns, walls, mezzanine structures, services including piping and electrical conduits, and any fixed equipment positioned within the crane operating envelope. For suspended loads, minimum clearance from structures should be 500mm recognizing that loads may swing during travel and precise load positioning becomes difficult with smaller clearances. Runway beam placement must provide adequate clearance from building structure particularly end wall clearances where inadequate clearance creates impact risks if crane bridge over-travels. End stops on runways must be designed to arrest crane travel within available clearance distances accounting for crane mass, travel speed, and stopping distances. Clearances between adjacent crane operating envelopes in facilities with multiple overhead cranes must prevent crane-to-crane contact during simultaneous operations, typically requiring minimum 1000mm clearance between closest approach positions plus adequate coordination procedures. Vertical clearance beneath crane hooks when hoists are fully retracted must provide adequate hook height for typical loads plus minimum 2.5 metres clearance above floor level or highest work platform within the operating envelope enabling safe personnel access beneath crane paths. These clearances may be reduced in specific locations if comprehensive risk assessment demonstrates adequate controls including reduced crane speed in restricted clearance areas, physical barriers preventing access during crane operation in tight clearances, or specialized operating procedures. Documentation of clearance assessment and any non-standard clearance approvals must be maintained in crane design records and operational procedures. Periodic clearance verification is required particularly after facility modifications, equipment installations, or material storage pattern changes that might reduce clearances below minimum requirements. Warning signage should identify restricted clearance areas requiring special operational precautions or reduced crane speeds ensuring operators recognize hazards.

Can overhead cranes be used to lift or transport personnel?

Using overhead bridge or gantry cranes to lift or transport personnel is generally prohibited under Australian WHS regulations and AS 2550.1 requirements due to extreme fall and injury risks. The prohibition reflects that overhead cranes are designed for material handling not personnel lifting, lacking redundant safety systems required for personnel lifting applications. Specific hazards include absence of secondary load arrest systems meaning single point failures cause catastrophic falls, inadequate control precision for smooth personnel movement compared to purpose-designed personnel hoists, lack of enclosed personnel carriers providing fall protection, and operator training focused on material handling not personnel safety. Limited exceptions may apply where specifically designed and engineered personnel carriers (man baskets) are used in conjunction with comprehensive engineering assessments, documented safe work procedures, and regulatory approvals. Such applications require the personnel carrier to be specifically designed for overhead crane use meeting structural requirements, rated for personnel capacity, fitted with appropriate fall protection systems, and tested to verify structural adequacy. Crane systems must be inspected and certified suitable for personnel lifting including assessment of brake redundancy, load control precision, and emergency descent capabilities. Documented operational procedures must address emergency scenarios including power failure, brake failure, and personnel medical emergencies. Operator training specific to personnel lifting operations is mandatory covering smooth movements, emergency response, and communication with personnel in the carrier. Regulatory approval from state or territory WHS authorities may be required before commencing personnel lifting operations even with engineered systems. Purpose-designed personnel and materials hoists are strongly preferred over overhead crane adaptations as they incorporate appropriate safety systems including secondary brakes, overload protection, multiple load arrest systems, and operator training specific to personnel lifting. Facilities should carefully assess whether personnel access truly requires lifting operations or whether alternative access methods including scaffolding, elevated work platforms, or permanent access stairs provide safer solutions. Any proposal to use overhead cranes for personnel lifting requires thorough risk assessment, engagement of qualified engineers, and potentially external safety consultation ensuring adequate risk management before implementation.

What are the main causes of overhead crane load drops and how can they be prevented?

Load drops from overhead cranes result from multiple failure mechanisms that can be prevented through systematic risk management. Primary causes include rigging failure from worn, damaged, or overloaded slings, chains, or shackles; incorrect rigging configurations creating excessive stress concentrations; crane overloading exceeding rated capacity causing structural or mechanical failure; wire rope failure from broken strands, corrosion, or lack of maintenance; hook failures including cracks or safety latch malfunctions; mechanical component failures such as hoist drum shafts, gear systems, or brake mechanisms; and improper load attachment where loads slip from rigging during lifting. Prevention strategies address each failure mechanism systematically. Rigging failure prevention requires comprehensive inspection programs with pre-use visual inspection by competent dogmen examining all rigging for damage indicators, periodic documented inspection at 6-month maximum intervals by trained inspectors, immediate retirement of damaged rigging using physical destruction preventing reuse, application of appropriate safety factors (minimum 5:1 for wire rope and chain), and proper rigging storage in protected locations preventing environmental degradation. Overloading prevention demands accurate load weight determination through measurement or calculation never estimation, clear capacity rating displays visible to operators, overload protection systems providing automatic crane lockout if capacity is exceeded, and documented lift planning for heavy loads approaching capacity limits. Wire rope failure prevention requires regular inspection for broken wires, kinking, corrosion, or diameter reduction, replacement before reaching discard criteria, proper rope lubrication maintaining internal wire protection, and adherence to manufacturer specifications regarding rope construction and capacity. Mechanical failure prevention depends on comprehensive preventive maintenance per manufacturer schedules, annual major inspections by qualified engineers including non-destructive testing for crack detection, immediate defect rectification with equipment lockout until repairs are completed, and documentation of all maintenance activities enabling trending analysis. Proper load attachment requires training for dogmen in rigging principles and techniques, balanced rigging configurations with load center of gravity beneath the hook, adequate rigging contact area preventing point loading, and verification of secure attachment before lifting. Additional controls include initial lift tests raising loads only 100-200mm to verify rigging security and load balance before full lifts, prohibition on working beneath suspended loads eliminating personnel exposure, comprehensive operator training in safe load handling practices, and investigation of near-miss incidents identifying system improvements. Integration of multiple prevention layers following defense-in-depth principles ensures no single failure causes load drops, with comprehensive SWMS documentation guiding systematic implementation of prevention measures.

Crane Overhead Bridge Gantry SWMS Sample

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Risk Rating

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After ControlsLow

Key Controls

• Pre-start briefing covering hazards
• PPE: hard hats, eye protection, gloves
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Crane Overhead Bridge Gantry Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Load Drop from Rigging Failure or Overloading

Struck by Moving Crane Bridge or Trolley Components

Crane Structural or Mechanical Component Failure

Falls from Height During Crane Maintenance or Inspection

Caught-Between or Crush Injuries from Pinch Points

Electrical Hazards from Crane Power Systems

Load Swing and Uncontrolled Load Movement

Inadequate Communication Between Crane Operators and Ground Personnel

Control measures

Comprehensive Crane Inspection and Maintenance Programme

Rated Capacity and Load Weight Verification Systems

Physical Barriers and Exclusion Zones Preventing Personnel Access to Crane Operating Areas

Comprehensive Rigging Inspection and Certification Programme

Crane Operator Licensing and Competency Verification Programme

Standardized Communication Protocols and Hand Signal Systems

Personal protective equipment

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Pre-Operational Inspection and Start-Up Procedures

Load Assessment and Rigging Selection

Load Attachment and Initial Lift

Load Travel and Positioning

Emergency Response and Incident Management

Frequently asked questions

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Crane Overhead Bridge Gantry SWMS Sample

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