Comprehensive SWMS for Vehicle-Mounted Loading Crane Operations

Crane Truck Mounted Safe Work Method Statement

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Truck-mounted cranes, also known as vehicle loading cranes or loader cranes, combine the mobility of a truck chassis with the lifting capability of a hydraulic crane, providing essential materials handling capacity across construction, transport, and maintenance industries. These versatile machines range from small 2-tonne capacity units mounted on light trucks to substantial 50-tonne capacity installations on heavy vehicle platforms. This SWMS addresses the comprehensive safety requirements for truck-mounted crane operations in accordance with Australian WHS legislation, AS 2550.5 standards, and high-risk work licensing requirements, providing detailed hazard controls, load chart compliance procedures, and operational safety protocols.

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Overview

What this SWMS covers

Truck-mounted cranes are hydraulic articulating boom cranes permanently mounted behind truck cabins on commercial vehicle chassis. These cranes provide self-contained lifting capability without requiring separate crane mobilisation, making them highly efficient for material delivery, equipment positioning, and site service tasks. The crane boom typically folds hydraulically when not in use, allowing the truck to travel normally on public roads before deploying for lifting operations at job sites. These cranes operate using hydraulic power derived from the truck's power take-off (PTO) system or auxiliary diesel engine. The operator controls crane functions including boom extension, slew rotation, and winch operation through a control console mounted on the crane pedestal or via remote control pendant. Modern truck-mounted cranes feature load moment indicators, automatic overload protection, and electronic stability monitoring systems that enhance operational safety by preventing operation beyond safe working limits. Truck-mounted crane applications span numerous industries. In construction, they deliver and position materials including steel beams, formwork panels, precast concrete elements, and packaged building supplies. In civil works, they install road barriers, position drainage structures, and deliver bulk materials to work zones. In utilities maintenance, they position poles, transformers, and equipment for electrical and telecommunications infrastructure. In landscaping, they deliver and position retaining wall blocks, large trees, and landscape materials. The crane's mobility allows rapid repositioning between multiple lift locations on large sites or travel between separate job sites within a single day. Safe operation requires crane operators to hold appropriate high-risk work licences for vehicle loading cranes issued under the WHS Regulations. The operator must interpret load charts specific to their crane model, accounting for boom configuration, extension length, operating radius, and outrigger deployment mode. Many lifts also require a trained dogman to direct operations, attach loads safely, and communicate with the crane operator using standardised hand signals or radio communication. The combination of crane operation expertise and coordinated lifting procedures ensures materials handling proceeds safely and efficiently.

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Why this SWMS matters

Truck-mounted crane operations present significant hazards that have caused numerous serious injuries and fatalities in Australian workplaces. Crane tip-overs resulting from inadequate outrigger deployment, soft ground conditions, or exceeding load chart capacities represent the most catastrophic failure mode, potentially crushing the operator, ground personnel, or nearby workers. Safe Work Australia incident data indicates crane stability failures account for a substantial proportion of crane-related fatalities, with many incidents involving truck-mounted cranes operating on construction sites, transport yards, or roadside locations. Contact with overhead powerlines during crane boom movement or while handling conductive loads presents severe electrocution risks to crane operators and ground personnel. Unlike mobile cranes with fixed jibs, truck-mounted cranes use articulating booms that can swing through wide arcs during slewing operations, potentially entering powerline clearance zones if operators lose awareness of boom position. Electrical arcing can occur even without direct contact when boom sections approach within minimum clearance distances. Powerline contact incidents frequently result in fatal electrocution or severe burns to operators who remain in contact with crane controls during arcing events. Load drops from rigging failure, boom overload, or insecure load attachment cause serious injuries to ground personnel working near crane operations. Suspended loads swinging during movement can strike workers, structures, or vehicles causing blunt force trauma. Inadequate load securing allows materials to shift or fall during lifting, particularly when handling multiple items, loose materials, or awkwardly shaped loads. The diverse range of materials handled by truck-mounted cranes, from palletised building supplies to individual steel beams, requires appropriate rigging knowledge and lifting accessory selection for each load type. Crushing injuries occur when workers position themselves between suspended loads and fixed structures, vehicles, or stacked materials. Ground personnel may enter danger zones beneath suspended loads to guide positioning or prematurely unhook loads before they are fully supported. The compact nature of many truck-mounted crane operations, particularly in confined site areas or busy transport yards, increases the risk of personnel working in proximity to crane swing paths and load trajectories. Comprehensive SWMS implementation establishes exclusion zones, communication protocols, and load handling procedures that protect all personnel in the crane operating area throughout lifting operations.

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

Hazard identification

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

Risk register

Crane Tip-Over from Outrigger Instability

High

Truck-mounted cranes rely on outriggers deployed to their full extension to provide stability during lifting operations. Inadequate outrigger extension, deployment on soft or sloping ground, or operation without outrigger deployment can cause the crane to become unstable and tip over. Ground subsidence beneath outrigger pads during lifting operations, particularly when using undersized pads on soft ground or after recent rain, progressively reduces stability. Operating the crane beyond the load chart capacity for the actual outrigger configuration deployed compounds instability risks. Underground voids, buried services, or inadequate ground bearing capacity may not be apparent until loaded outriggers begin to settle.

Consequence: Catastrophic crane tip-over causing operator death or serious injury, crushing of ground personnel beneath falling crane or vehicle, property damage to structures or equipment, and potential entrapment requiring emergency rescue services. Load drop causing secondary injuries or damage.

Contact with Overhead Powerlines During Boom Operation

High

Articulating boom movement during slewing, extension, or raising operations can bring boom sections or suspended loads into contact with overhead powerlines. Operators may lose awareness of boom position relative to powerlines when focusing on load positioning or ground personnel signals. Energised powerlines conducting high voltage electricity cause electrical arcing even when crane booms approach within minimum clearance distances without direct contact. This hazard increases when operating in unfamiliar locations, when powerlines are not clearly visible against sky backgrounds, or when crane work occurs near power infrastructure including substations, transmission towers, or service entrances to buildings.

Consequence: Fatal electrocution of crane operator or ground personnel in contact with crane, load, or rigging. Severe electrical burns requiring long-term treatment. Electrical flash causing arc blast injuries. Power network damage causing widespread electricity supply disruption. Prosecution for breaching electrical safety clearance requirements.

Load Drop from Rigging Failure or Overload

High

Suspended loads can fall if lifting gear fails, loads exceed crane capacity, or attachments are insecure. Rigging components including hooks, slings, shackles, and chains subject to dynamic loading during lifting may fail if damaged, worn, or incorrectly rated for the load. Exceeding the crane's rated capacity for the operating radius and boom configuration causes structural failure of boom components or hydraulic system overload. Loads can slide from slings if the centre of gravity is misjudged or if packaging fails during lifting. Multiple lifts using single hook attachments can separate during movement if not adequately secured.

Consequence: Crushing injuries or death to ground personnel struck by falling loads. Serious injuries from loads swinging uncontrolled after partial failure. Property damage to materials, equipment, or structures. Regulatory prosecution for operating cranes beyond safe working limits. Potential crane structural damage requiring costly repairs and lost productivity.

Personnel Struck by Slewing Boom or Counterweight

High

Truck-mounted crane booms rotate 360 degrees around the crane pedestal during slewing operations to position loads. Workers standing in the slew path of the boom or crane counterweight can be struck as the crane rotates, particularly if they are focused on other tasks or unaware the crane is about to move. The boom tail swing extends beyond the truck body perimeter, creating additional strike zones. Limited visibility from the crane operator's position, particularly when using cab-mounted controls with restricted sightlines, prevents operators from seeing all personnel in the crane's working area. Communication failures between operators and ground crew compound strike risks.

Consequence: Serious blunt force trauma including head injuries, fractures, crush injuries, and potential fatalities from being struck by moving crane components. Workers may be pinned between boom sections and fixed structures. Secondary injuries from workers falling or being pushed into other hazards when struck by crane components.

Inadequate Ground Bearing Capacity Beneath Outrigger Pads

High

Truck-mounted crane outriggers concentrate vehicle and load weight onto relatively small outrigger pad contact areas. On soft ground, unprepared surfaces, or areas with underground voids, the ground may not provide adequate bearing capacity to support concentrated loads. Outriggers can punch through surface layers into soft substrata, causing progressive settling during lifting operations. Ground conditions may deteriorate during extended operations due to rain, sub-surface water flow, or vibration from nearby equipment. Asphalt surfaces soften in hot weather reducing bearing capacity. Underground services including pipes and conduits create voids that collapse under outrigger loading.

Consequence: Crane instability from uneven outrigger settlement leading to tip-over events. Damage to underground services causing utility disruptions, environmental contamination from broken pipes, or explosion risks from damaged gas mains. Uncontrolled load movement as crane settles causing load drops or swing hazards. Damage to road surfaces, pavements, or landscaped areas requiring costly repairs.

Exceeding Load Chart Capacity Limits

High

Every truck-mounted crane has a load chart specifying maximum safe working loads for different boom configurations, extension lengths, and operating radii. Operating the crane beyond these specified limits overloads structural components and hydraulic systems. Load charts vary significantly depending on outrigger deployment mode - intermediate outrigger extension provides substantially lower capacity than full extension. Operators may misinterpret load charts, misjudge load weights, or fail to account for rigging weight in capacity calculations. Dynamic loading during rapid boom movements or when arresting load swing increases actual loading beyond static load weight.

Consequence: Structural failure of boom sections causing complete boom collapse. Hydraulic system failure causing uncontrolled load lowering. Crane tip-over from overload exceeding stability limits. Load drop from hook or attachment failure under excessive loading. Serious injury or death to personnel beneath or near falling loads or collapsing crane components. Significant crane damage requiring major repairs or complete crane replacement.

Manual Handling Injuries During Rigging Operations

Medium

Dogmen and ground crew manually handle lifting slings, chains, shackles, and spreader bars when rigging loads for crane lifting. Larger lifting accessories including heavy-duty slings, chains rated for multi-tonne loads, and steel spreader bars can weigh 20-50kg or more. Repeatedly lifting these items from ground level, positioning them under loads, and attaching to crane hooks throughout a work shift creates cumulative manual handling strain. Working in awkward postures when rigging loads stacked on ground level or accessing loads in confined spaces compounds musculoskeletal loading.

Consequence: Lower back strain and injury from repetitive lifting of heavy rigging equipment. Shoulder injuries from overhead reaching when attaching slings to crane hooks. Soft tissue injuries from pinch points when handling chains and shackles. Cumulative musculoskeletal disorders from sustained manual handling throughout work shifts. Reduced workforce capacity from long-term injury requiring modified duties or time off work.

Adverse Weather Affecting Crane Stability and Operation

Medium

Strong winds affect crane stability and load control, particularly when lifting loads with large surface areas that catch wind. Wind loading on extended booms creates additional bending moments that reduce effective crane capacity. Suspended loads swing uncontrollably in gusty conditions creating strike hazards and making precise positioning difficult. Rain reduces ground bearing capacity, makes control surfaces slippery, and reduces operator visibility. Lightning during thunderstorms creates electrocution risks to operators in contact with crane structures. Extreme heat affects hydraulic fluid viscosity and operator fatigue levels.

Consequence: Loss of load control in high winds causing loads to swing into structures, personnel, or other equipment. Crane instability from combined wind loading and lift load exceeding stability limits. Operator injuries from slips on wet control platforms or access steps. Reduced operational efficiency from weather-related work stoppages. Electrocution risks during thunderstorms if operations continue inappropriately.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Mandatory Ground Assessment and Outrigger Pad Sizing

Engineering Control

Eliminate ground instability hazards through systematic ground bearing capacity assessment before outrigger deployment. Use engineered outrigger pads sized to distribute outrigger loads based on ground type and crane loading. Larger pads reduce ground pressure beneath outrigger feet, preventing punch-through on soft surfaces. Purpose-designed crane mats provide maximum load distribution for challenging ground conditions including soft soil, recently disturbed ground, or asphalt surfaces in hot weather. This engineering control prevents the most common cause of crane tip-over incidents by ensuring adequate ground support before lifting operations commence.

Implementation

1. Inspect proposed outrigger positions visually for obvious soft ground, recent excavation, underground service covers, or slope 2. Check ground using probe rod or hand tools to verify compacted surface extends at least 500mm depth beneath planned pad positions 3. Calculate required outrigger pad area based on crane capacity, maximum intended lift load, and ground bearing capacity (typically 100kPa for firm ground, 50kPa for soft ground) 4. Use outrigger pads minimum 600mm x 600mm x 50mm for firm ground; increase to 1200mm x 1200mm timber mats for soft or uncertain ground 5. Position pads on level surface, removing any debris, stones, or irregularities that could cause pad movement 6. Deploy outriggers fully to manufacturer's specified extension before commencing lifting operations 7. Monitor outrigger pad positions during lifting operations for any signs of ground settlement or pad movement 8. If any settling observed, lower load immediately and cease operations until ground is improved with additional matting or crane relocated

Overhead Powerline Identification and Clearance Maintenance

Elimination

Eliminate powerline contact hazards by identifying all overhead electrical conductors before crane operations commence and maintaining minimum regulatory clearance distances throughout work. Where adequate clearances cannot be maintained, arrange powerline de-energisation and isolation through the electricity supply authority. This represents the highest level of control in the hierarchy by completely removing the electrical hazard. Physical barriers or exclusion zones prevent boom encroachment into powerline clearance areas where de-energisation is not practicable.

Implementation

1. Identify all overhead powerlines in and around the work area during pre-start site inspection 2. Contact electricity supply authority to confirm voltage levels of identified powerlines and required clearance distances (minimum 3 metres for lines up to 132kV, 6 metres for higher voltages) 3. Mark powerline locations on lift plan site diagram with clearance zones extending the required distance in all directions 4. For work where crane boom may approach within clearance distances, request powerline de-energisation and isolation from electricity authority at least 5 working days before work commencement 5. Verify isolation with permit to work issued by authorised electricity authority representative before crane operations begin 6. Where de-energisation is not possible, establish physical barriers or marker systems preventing crane operation in directions that would bring boom within clearance distances 7. Brief crane operator and all ground personnel on powerline locations, clearance requirements, and work restrictions during toolbox meeting 8. Appoint dedicated spotter with sole responsibility of monitoring boom position relative to powerlines throughout operations 9. Cease operations immediately if weather conditions reduce powerline visibility or if any uncertainty exists about clearance distances

Load Weight Verification and Load Chart Compliance

Administrative Control

Implement systematic procedures requiring verification of load weight before lifting and confirmation that intended lift remains within crane load chart capacity for the actual boom configuration and operating radius. This administrative control prevents operation beyond crane design limits through documented planning and checking processes. Pre-lift planning using load charts appropriate to the specific crane model and configuration ensures structural capacity and stability limits are not exceeded. Load moment indicators on modern cranes provide real-time capacity monitoring as additional verification.

Implementation

1. Obtain load weight from delivery documentation, manufacturer specifications, or by calculation for assembled loads; never estimate weights for loads exceeding 500kg 2. Retrieve load chart specific to the crane model and serial number (charts vary between crane models and capacity ratings) 3. Confirm outrigger deployment mode that will be used (full extension, intermediate extension, or on tyres) and locate corresponding load chart section 4. Measure or calculate operating radius from crane centreline to load centre of gravity position at pickup and placement locations 5. Verify load weight plus rigging weight is less than rated capacity at maximum operating radius, applying 25% reduction factor for critical lifts, unfamiliar loads, or novice operators 6. Brief crane operator on load weight, planned lift radius, and load chart capacity limits before commencing lift 7. Monitor load moment indicator (LMI) during lifting operations; cease immediately if LMI approaches or reaches maximum capacity setting 8. If load weight cannot be verified accurately or exceeds apparent capacity margins, arrange alternative lifting method or bring larger capacity crane to site 9. Document all lifts exceeding 75% crane rated capacity in lift plan register including operator name, load details, and outcomes

Exclusion Zones and Personnel Segregation During Operations

Engineering Control

Establish physical exclusion zones using barriers, fencing, or marked lines preventing unauthorised personnel entering areas where crane boom, counterweight, or suspended loads can travel. Exclusion zones create physical separation between hazards and workers, representing an engineering control that does not rely on worker behaviour or procedural compliance. Minimum exclusion zone dimensions extend beyond maximum boom reach plus load dimensions, accounting for potential load swing during adverse conditions. Additional clearance accommodates potential load drops or crane component failure scenarios.

Implementation

1. Calculate maximum exclusion zone required encompassing full boom slew radius plus suspended load dimensions plus 3-metre clearance buffer 2. Establish exclusion zone using physical barriers appropriate to site conditions (temporary fencing, witches hats and bunting, safety barriers) 3. Position signage at exclusion zone entry points stating "Crane Operations - Authorised Personnel Only - Hard Hats and High-Vis Mandatory" 4. Brief all site personnel during toolbox meeting that exclusion zones are active and entry is prohibited except for authorised crane crew 5. Appoint dedicated safety observer (spotter) to monitor exclusion zones and prevent unauthorised entry during operations 6. Modify exclusion zone boundaries as crane relocates or boom reach changes for different lifts throughout the workday 7. Communicate to crane operator that lifting must cease if any unauthorised personnel enter exclusion zones until they exit 8. For operations near public areas or active traffic, use additional traffic controllers and physical barriers to prevent public entering hazard zones 9. Maintain exclusion zones throughout operations including during meal breaks if loads remain suspended or crane is left in operational configuration

Pre-Operational Crane Inspection and Serviceability Verification

Administrative Control

Require documented pre-operational inspection of crane systems, structures, and safety devices before each work period. Inspections verify critical components are serviceable, safety systems function correctly, and no damage or defects exist that could cause operational failure. This administrative control detects developing problems before they progress to catastrophic failures. Inspection checklists prompt systematic examination of structural, mechanical, hydraulic, and electrical systems. Failed inspections prevent unsafe equipment entering service until repairs restore serviceability.

Implementation

1. Complete pre-start inspection checklist covering boom sections, hydraulic hoses, outrigger rams, wire rope condition, hook assembly, load moment indicator, and all control functions 2. Test load moment indicator by attempting boom movement with outriggers retracted; LMI must prevent operation when not in safe configuration 3. Inspect wire rope across entire length for broken wires, kinks, crushing, or diameter reduction exceeding manufacturer retirement criteria (typically 10% diameter reduction or 6 broken wires in one lay) 4. Verify hook safety latch operates freely and fully closes; replace hooks with damaged or absent safety latches immediately 5. Check hydraulic hoses for leaks, abrasion, or exposed reinforcement; replace any damaged hoses before operation 6. Verify all outriggers extend fully and retract normally; check for hydraulic leaks at ram glands and connections 7. Test all crane control functions including boom extend/retract, slew left/right, winch up/down, and emergency stop systems 8. Document inspection completion including date, inspector name, crane identification, and any defects identified with rectification actions 9. Tag defective cranes with "DO NOT OPERATE" signage and remove keys until repairs completed and verification inspection passed 10. Maintain inspection records with crane documentation for WorkSafe inspector review during audits

Standard Communication Protocols Between Operator and Dogman

Administrative Control

Establish standardised communication methods between crane operators and dogmen directing ground operations using recognised hand signals per AS 2550.5 or two-way radio with clear verbal commands. Effective communication ensures operators understand load positioning requirements, hazards develop, or emergency situations require immediate response. This administrative control coordinates activities between operator and ground crew preventing miscommunication that could result in unsafe boom movement, load positioning errors, or personnel injuries. Communication protocols include pre-lift briefings, continuous operation communication, and emergency stop signals.

Implementation

1. Conduct pre-lift briefing between crane operator, dogman, and all ground crew covering lift sequence, load weight, placement location, and emergency procedures 2. Confirm communication method will be used (hand signals or two-way radio) and verify all personnel understand signals or radio procedures 3. Test radio communication before commencing operations to verify clear reception and confirm all parties can communicate effectively 4. Use only standard hand signals as illustrated in AS 2550.5 Cranes - Safe Use Part 5: Vehicle Loading Cranes - never invent non-standard signals 5. Require crane operator to follow only the assigned dogman's directions; operator must refuse signals from other personnel to prevent conflicting instructions 6. Implement "emergency stop" protocol where any person observing danger can signal stop by raising both arms above head or shouting "STOP" on radio 7. Cease all boom movement immediately when stop signal received until situation assessed and safe recommencement confirmed 8. For complex lifts, assign specific radio channel exclusively for crane operations preventing interference from other site communications 9. If radio communication fails or becomes unclear, stop operations and revert to hand signals or resolve radio issues before continuing 10. Document any communication failures or near-misses resulting from communication breakdown in daily safety log with corrective actions

Personal Protective Equipment for Crane Operations

Personal Protective Equipment

Provide and mandate use of appropriate personal protective equipment for all personnel involved in crane operations including operators, dogmen, and ground crew. PPE represents the final control level in the hierarchy, protecting workers when exposure to hazards cannot be completely eliminated through higher-level controls. Task-specific PPE accounts for crane operation hazards including falling objects, pinch points during rigging, high visibility requirements near mobile plant, and hearing protection during hydraulic system operation.

Implementation

1. Issue Class D hard hats (AS/NZS 1801) to all personnel in crane exclusion zones protecting against falling objects and suspended load hazards 2. Provide high-visibility vests or shirts (Day/Night Class D/N per AS/NZS 4602.1) ensuring crane operators and vehicle drivers can see ground personnel 3. Require steel-capped safety boots (AS/NZS 2210.3) with minimum 200 joule impact protection for all personnel handling loads or rigging 4. Supply leather work gloves for rigging operations providing hand protection from wire rope burrs, chain edges, and pinch points 5. Provide Class 3 hearing protection (AS/NZS 1270) for ground crew working within 3 metres of operating hydraulic pump units 6. Ensure all PPE is correctly fitted, maintained in serviceable condition, and replaced when damaged or at end of service life 7. Brief all personnel that PPE must be worn at all times in crane operating areas; non-compliance results in removal from exclusion zones

Download complete control procedures

Personal protective equipment

Requirement: Type 1 impact protection per AS/NZS 1801

When: Mandatory for all personnel within crane exclusion zones during operations, protecting against falling objects and suspended load hazards

Requirement: Day/Night Class D/N per AS/NZS 4602.1

When: Required for crane operators when outside vehicle cab and all ground personnel in operating areas to ensure visibility to mobile plant and vehicle operators

Requirement: 200 joule impact protection per AS/NZS 2210.3

When: Throughout all crane operations and rigging activities to protect feet from dropped loads, tools, or rigging components

Requirement: Industrial grade leather providing abrasion resistance

When: During all rigging operations when handling wire ropes, chains, slings, or shackles to protect hands from burrs, sharp edges, and pinch points

Requirement: Class 3 protection per AS/NZS 1270 reducing noise to below 85dB(A)

When: For ground crew working within 3 metres of hydraulic power units or during extended crane operations exceeding 2 hours continuous operation

Requirement: Medium impact rated per AS/NZS 1337

When: When working in areas where hydraulic fluid spray, flying debris, or dust may affect eyes during maintenance or in dusty environments

Inspections & checks

Before work starts

  • ✓Verify crane operator holds current high-risk work licence for vehicle loading cranes issued by relevant state/territory authority
  • ✓Confirm crane registration is current and annual inspection certification is valid and displayed on crane
  • ✓Complete pre-operational inspection checklist covering structural, mechanical, hydraulic, and safety systems
  • ✓Test load moment indicator (LMI) functionality and verify audible/visual alarms operate when crane approaches capacity limits
  • ✓Inspect wire rope across full length documenting any broken wires, wear, kinks, or damage; compare to retirement criteria
  • ✓Check hook assembly including safety latch operation, swivel bearing movement, and visual condition of hook throat
  • ✓Verify all lifting accessories required for planned lifts are available, in date for certification, and visually serviceable
  • ✓Assess ground conditions at proposed outrigger positions and determine appropriate outrigger pad sizes required
  • ✓Identify overhead powerlines and confirm clearance distances or arrange isolation if required for planned work
  • ✓Review load weights and lifting requirements against crane load chart to verify lifts are within capacity
  • ✓Establish exclusion zones using physical barriers and signage appropriate to maximum crane operating radius
  • ✓Conduct toolbox meeting briefing all personnel on lift plans, communication methods, and emergency procedures

During work

  • ✓Monitor outrigger pad positions continuously during operations for any signs of ground settlement or movement
  • ✓Verify crane operator refers to load chart when boom configuration or operating radius changes between lifts
  • ✓Check that crane operator deploys outriggers to full extension before lifting operations and keeps tyres clear of ground
  • ✓Observe communication between operator and dogman to verify clear signals and immediate response to directions
  • ✓Monitor exclusion zone boundaries and prevent unauthorised personnel entering areas where boom or loads can travel
  • ✓Watch for load swing during movement and cease operations if loads swing excessively indicating wind conditions exceed safe limits
  • ✓Verify suspended loads remain secured in rigging and maintain stable orientation throughout lifting and placement
  • ✓Check that crane operator maintains awareness of boom position relative to overhead powerlines throughout operations
  • ✓Monitor for hydraulic fluid leaks, unusual noises, or changes in crane operation indicating developing problems
  • ✓Ensure ground personnel maintain safe distances from crane counterweight and boom slew paths during rotation
  • ✓Verify crane operator responds to emergency stop signals immediately by ceasing all boom movement
  • ✓Monitor weather conditions including wind speed, rain affecting visibility, or approaching thunderstorms requiring work cessation

After work

  • ✓Inspect crane for any damage or defects that developed during operations including boom sections, hydraulic hoses, and rigging
  • ✓Document any unusual occurrences including near misses, communication failures, or equipment problems in daily log
  • ✓Return crane to transport configuration with boom folded, outriggers retracted, and stabiliser legs secured
  • ✓Store all lifting accessories in designated locations; inspect slings and chains for damage before storage
  • ✓Clean outrigger pads and load spreading mats; check for cracks or damage requiring replacement
  • ✓Complete post-operational checklist noting any maintenance requirements identified during use
  • ✓Report any defects or serviceability concerns to site supervisor and fleet management for rectification
  • ✓Review lift operations with crew discussing any improvements to procedures or controls for future similar work
  • ✓Verify exclusion zones are removed and work areas are returned to general site access
  • ✓Update crane service records with operating hours, lifts completed, and next scheduled maintenance requirements

Step-by-step work procedure

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

Field ready

Pre-Operational Crane Inspection and Documentation Verification

Begin by verifying the crane operator holds a current high-risk work licence for vehicle loading cranes. Check the crane registration and annual inspection certification are current; these documents must be displayed on the crane or available in vehicle documentation. Complete the comprehensive pre-start inspection checklist covering all critical crane systems. Inspect boom sections for cracks, distortion, or other damage. Check hydraulic hoses for leaks, abrasion, cuts, or exposed reinforcement. Test the load moment indicator by attempting boom operation with outriggers retracted - the LMI must prevent operation and activate audible/visual alarms. Inspect wire rope across its entire length documenting the number of broken wires in any section and comparing findings to manufacturer retirement criteria. Check the hook assembly including safety latch function, throat condition, and swivel bearing. Test all hydraulic control functions including boom extend/retract, slew rotation, winch operation, and emergency stop. Document inspection completion and findings. Tag any defective equipment with "DO NOT OPERATE" signage and remove from service until repairs are completed.

Safety considerations

Never operate cranes with expired certifications or without current operator licensing. Failed pre-start inspections must result in immediate removal from service. Do not rush inspection procedures - systematic checking prevents catastrophic failures during operation. Photograph any defects for maintenance records.

Site Assessment and Ground Preparation for Outrigger Deployment

Assess the proposed crane operating location for overhead powerlines, underground services, ground conditions, and spatial constraints. Use service location plans and underground service detection equipment to identify buried utilities beneath outrigger positions. Check for overhead powerlines within or approaching crane operating radius; measure clearance distances and contact electricity authority if isolation is required. Inspect ground conditions at each outrigger position using visual assessment and probe rods to verify firm, compacted ground. Avoid recently excavated areas, soft ground, underground service covers, and sloping surfaces. Check ground bearing capacity is adequate for concentrated outrigger loads; calculate required pad area based on maximum crane capacity and ground type. Prepare ground by removing debris, loose stones, or surface irregularities. Position appropriate outrigger pads at each outrigger location - use minimum 600mm x 600mm x 50mm timber pads on firm ground or larger 1200mm x 1200mm crane mats on soft or uncertain ground. Ensure pads are level and stable before outrigger deployment. Mark overhead powerline clearance zones if present using high-visibility markers.

Safety considerations

Never assume ground is adequate without assessment. Soft ground or underground voids cause most crane tip-over incidents. Larger outrigger pads provide insurance against unexpected ground conditions. Always verify powerline clearances before operations commence; contact with powerlines is immediately fatal.

Crane Positioning and Outrigger Deployment

Position the truck and crane to allow outrigger deployment on prepared pads while maintaining clear access for load pickup and placement. Consider boom reach requirements at both pickup and placement locations when selecting crane position. Engage the vehicle park brake and transmission park lock. Start the crane hydraulic system using the PTO or auxiliary engine per manufacturer procedures. Deploy outriggers to their full extension positions ensuring each outrigger foot centres on the prepared pad. Extend outriggers evenly to maintain vehicle level; uneven extension can twist chassis causing structural damage. Raise the truck wheels clear of the ground using outrigger lift capacity - tyres must be completely unweighted before lifting operations commence. Verify vehicle stability by attempting slight boom movement - any vehicle rocking indicates inadequate outrigger deployment requiring adjustment. Check outrigger jack rams are fully extended and not near fully extended position which reduces stability. Verify load moment indicator displays correct outrigger configuration mode. Position the operator control station or retrieve remote control pendant; test all control functions before proceeding to lifting operations.

Safety considerations

Full outrigger extension is mandatory before lifting operations. Intermediate extension substantially reduces crane capacity and stability. Ensure outrigger rams do not reach fully extended stroke during operations as this indicates ground settling. Never commence lifting with tyres still contacting ground surface.

Load Weight Verification and Load Chart Confirmation

Obtain accurate load weight information from delivery documentation, manufacturer specifications, or by calculation for assembled materials. Never estimate load weights by visual appearance for lifts exceeding 500kg. Add rigging weight including slings, shackles, and lifting beams to load weight to determine total lifted weight. Retrieve the load chart specific to the crane model being used - charts vary significantly between crane makes and models. Locate the chart section corresponding to the outrigger deployment mode being used (full extension, intermediate extension, or on tyres). Measure or calculate the operating radius from crane centreline to the load centre of gravity at both pickup and placement positions - use the greater radius for capacity checking. Verify total weight is less than rated capacity at maximum operating radius; apply a 25% capacity reduction for critical lifts, unfamiliar loads, or when operating with less experienced operators. Consider dynamic loading from rapid boom movements or load swing which can exceed static weight by 10-30%. Brief the operator on confirmed load weight, operating radius, and applicable capacity limits before commencing the lift. Document capacity calculations for lifts exceeding 75% of rated capacity.

Safety considerations

Exceeding load chart capacity causes crane structural failure or tip-over. When load weight is uncertain, use greater capacity crane or verify weight accurately before proceeding. Operating radius increases substantially as boom extends or raises - check capacity at maximum intended radius, not just pickup position.

Rigging Selection and Load Attachment

Select appropriate lifting accessories based on load weight, configuration, and attachment points. Choose slings rated for at least four times the intended load weight when used in choke hitch, three times in basket configuration. Inspect slings, chains, and shackles for damage, wear, or defects before use. Verify current test certification tags are attached to each lifting accessory. Position slings to balance the load with centre of gravity beneath the crane hook. For long materials, use spreader bars or lifting beams to prevent sling angle from becoming too acute (maintain minimum 60-degree angle between sling legs). Ensure sling attachment points are secure and will not damage the load. Attach slings to crane hook ensuring safety latch closes fully. Apply taglines to control load rotation and swing during lifting and movement. Brief ground crew on hand signals or radio communications to be used during the lift. Conduct final inspection of rigging before signalling operator to take weight. Apply slight tension to rigging and verify load balance before lifting load clear of ground.

Safety considerations

Never use damaged or uncertified lifting accessories. Verify safety latch closes fully before loading hook. Ground crew must keep hands clear of pinch points as load weight comes onto rigging. Stand clear of potential load drop zones during initial lifting. Use taglines to maintain control - never grab suspended loads with hands.

Lifting Operation and Load Movement

Signal crane operator to take load weight slowly, lifting load just clear of ground or support surface. Pause lifting with load 100-200mm off ground and verify load balance, rigging security, and absence of obstructions. Check load moment indicator reading and verify operation remains well within capacity limits. If all checks are satisfactory, signal operator to continue lifting to required height for movement. Control load swing using taglines; never allow loads to swing freely. Move load using smooth boom extension, raising, and slewing movements - avoid rapid starts or stops that create dynamic loading. Maintain communication between dogman and operator throughout movement; operator must follow only assigned dogman's signals. Monitor load position relative to exclusion zone boundaries, overhead powerlines, and structures. Watch for ground personnel and ensure no one enters the area beneath suspended loads. If boom approaches overhead powerlines, cease operations immediately and reassess clearances. Position load over intended placement area and lower slowly to final position. Maintain tagline control until load contacts support surface. Signal operator to hold position while ground crew guides final placement and confirms load is stable.

Safety considerations

Never stand or allow others beneath suspended loads. Maintain constant awareness of boom position relative to powerlines. Control load swing - excessive swing indicates winds exceed safe operating limits. Monitor LMI continuously; cease operation if alarms activate. Clear exclusion zones of all non-essential personnel before lifting.

Load Placement and Rigging Removal

Guide load to final placement position ensuring it will settle on stable support. Verify placement area can support load weight before releasing crane support. Lower load slowly onto supports using controlled hydraulic descent. Maintain slight rigging tension and verify load is stable on supports before releasing full weight. Once load is confirmed stable and secure, signal operator to create slack in rigging. Remove rigging from load while maintaining awareness of potential pinch points. Never place hands between load and fixed structures during rigging removal. Extract slings by pulling from clear positions. Verify load is secure and will not shift after crane support is removed. Signal operator to raise hook clear of load. Return crane boom to safe position for next lift or to transport configuration if work is complete. Ground crew collects rigging and prepares for next lift or stores accessories in designated location. Brief operator on next lift requirements or confirm work completion. Document lift completion including any variations from planned procedures.

Safety considerations

Verify loads are stable before removing rigging - unstable loads can shift causing crushing injuries. Keep hands clear of pinch points during sling removal. Never walk beneath suspended crane boom during repositioning. Coil and store rigging properly to prevent trip hazards in work area.

Crane Shutdown and Transport Preparation

After completing all lifting operations, prepare crane for transport configuration. Ensure crane boom is empty and no loads remain suspended. Fold boom sections hydraulically following manufacturer sequence - typically retract extensions first, then fold primary boom sections. Secure boom in transport latches or storage cradles. Retract outriggers slowly and evenly; ensure outrigger feet clear the ground as rams retract fully. Secure outriggers in transport position using mechanical locks or pins. Return vehicle wheels to ground support. Release park brake and transmission park lock. Conduct post-operational inspection checking for damage, leaks, or defects that developed during operations. Clean outrigger pads and store securely on truck. Test vehicle movement before travelling - verify steering and braking systems were not affected by hydraulic system operation. Complete daily crane log recording operating hours, lifts performed, any defects noted, and maintenance requirements identified. Report any safety incidents, near misses, or equipment problems to supervisors. Secure all loose items before road travel. Ensure boom will not exceed height restrictions during travel to next location or return to depot.

Safety considerations

Verify boom is fully secured before road travel - unsecured booms can shift causing loss of vehicle control. Check height clearances for bridges and powerlines on travel route. Inspect hydraulic systems for leaks before travelling. Never travel with outriggers extended or partially extended.

Get risk assessment & procedures

Frequently asked questions

What high-risk work licence is required to operate a truck-mounted crane in Australia?

Operators of truck-mounted cranes must hold a vehicle loading crane (C2) high-risk work licence issued by their state or territory work health and safety regulator. This licence requires completion of nationally recognised training units and demonstration of competency in crane operation, load chart interpretation, and safety procedures. The licence must be carried during crane operations and be current (renewed every 5 years). Some jurisdictions also require a driving licence appropriate for the truck's gross vehicle mass. The crane operator's licence is separate from dogman licences - if the same person performs both roles, they must hold both licences. Licence verification is a critical pre-operational check that must be completed before any lifting operations commence.

How do I determine what size outrigger pads are required for safe crane operation?

Outrigger pad sizing depends on ground bearing capacity and maximum crane loading. Calculate required pad area by dividing maximum outrigger load (obtained from crane manufacturer data) by ground bearing capacity. Typical ground bearing capacities are: 100-150 kPa for firm, undisturbed ground; 50-75 kPa for ordinary soil; 25-50 kPa for soft ground. For example, if maximum outrigger load is 80 kN and ground capacity is 100 kPa, required pad area is 0.8 square metres (approximately 900mm x 900mm). As a practical minimum, use 600mm x 600mm x 50mm hardwood pads on firm ground, 900mm x 900mm on ordinary soil, and 1200mm x 1200mm timber mats or engineered crane mats on soft or uncertain ground. Larger pads provide safety margin against unexpected soft spots or ground condition changes. Never operate on undersized pads - this is the primary cause of crane tip-over incidents.

What are the minimum clearance distances required when operating near overhead powerlines?

Minimum clearance distances from overhead powerlines are specified in state/territory electrical safety regulations and typically follow Safe Work Australia guidelines. For powerlines up to 132,000 volts, maintain minimum 3 metres clearance between any part of the crane, boom, load, or rigging and the nearest powerline conductor. For powerlines between 132kV and 330kV, increase clearance to 6 metres. For any powerline where voltage cannot be confirmed, use 6 metre clearance. These distances apply in all directions accounting for potential load swing, boom deflection, and electrical arcing gaps. Where clearances cannot be maintained, contact the electricity supply authority to arrange powerline de-energisation and isolation with permit to work issued before operations commence. Never rely on visual judgment of clearances - use measuring devices and maintain substantial safety margins. Appoint dedicated spotters to monitor boom position relative to powerlines throughout operations.

How do I know if a lift exceeds the crane's safe working load capacity?

Verify lift capacity by comparing total lift weight (load plus rigging) against the crane's load chart for the specific boom configuration and operating radius. Load charts are displayed on the crane or in the operator's manual; ensure you reference the chart for the actual crane model being used. Measure operating radius from crane centreline to load centre of gravity - this increases as boom extends or raises. Find the operating radius on the load chart and verify total weight is less than the rated capacity at that radius for the outrigger extension mode being used. Apply a 25% reduction factor for critical lifts or unfamiliar loads. Dynamic loading from rapid movements can increase effective weight by 10-30% above static load. If load weight is unknown or uncertain, do not proceed - verify weight using documentation or calculation. Never estimate by visual appearance. Load moment indicators on modern cranes provide real-time capacity monitoring, but operators must still verify lifts remain within rated capacity before commencing. Operating beyond capacity causes structural failure, hydraulic system damage, or crane tip-over.

What should I do if I notice the ground settling beneath outrigger pads during lifting operations?

If any ground settlement is observed beneath outrigger pads during operations, immediately cease all crane movements and lower the suspended load slowly to a safe support surface if possible. Do not attempt to continue operations or reposition the crane while loaded. Once the load is safely supported, retract outriggers and relocate the crane to firmer ground or implement improved ground preparation. Ground settlement indicates inadequate bearing capacity which can progress to catastrophic crane tip-over if operations continue. To prevent recurrence, use larger outrigger pads or engineered crane mats to distribute loads over greater ground area. Consider using multiple layers of timber mats on soft ground. Have geotechnical engineer assess ground bearing capacity if ongoing operations are required in challenging ground conditions. On construction sites, coordinate with earthworks contractors to provide compacted working platforms at planned crane locations. Never operate cranes on recently placed fill, near edges of excavations, or over underground voids without specific engineering assessment. Report all ground settlement incidents in site safety documentation and review ground preparation procedures to prevent recurrence.

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