Professional Documents
Culture Documents
Mobile Cranes
Title: Mobile Cranes Issue date: 12/11/08
Number: SMS-06-GD-1292 Review date: 12/11/11
Version control
Version Change from previous Date Comment
1.0 First version 1/11/08
1.1 Minor amendments to definitions 14/11/08 Introduced the requirement for crane
of High Risk crane activity use in rail corridor to be classified as
high risk only where the lift exceeds
50% of the crane’s lifting capacity.
Also amended definition of use in rail
corridor to only apply when electrical
infrastructure has not been isolated.
Removed reference to specific
inspection checklists for recording
pre-start inspections.
Contents
2. Background........................................................................................................................... 5
7. Vehicle-loading cranes....................................................................................................... 24
7.1 Mounting of vehicle-loading crane .............................................................................................. 24
2. Background
Competent and trained personnel must oversee and undertake all mobile crane
operations. All lifts must be planned, prepared and conducted to ensure the safety of
people, environment and property.
Examples of hazards specific to mobile cranes and their use that may need controlling
include:
• mechanical or structural failure of the crane, or a component
• supporting structure collapsing
• crane tipping over
• ground giving way
• overloading
• contact or collision with other plant or structures, particularly rollingstock and track
infrastructure
• contact with overhead powerlines or other electrical equipment
• persons being struck or crushed by operating crane or movement of suspended
load
• falls associated with access for cranes or for erecting or dismantling activities
• falling objects
• noise
• ergonomic hazards associated with manual handling of loads and lifting gear.
High risk crane lifts require a greater level of assessment, planning and control and the
completion of a crane siting and lift plan. The Mobile Crane Work Plan template is to be
used when a RailCorp employee is to control a crane lift.
A ‘high risk lift’ is any mobile crane lifting operation involving one of the following:
• the load exceeds 75% of the rated capacity of the crane during the course of the lift
• the load exceeds 50 tonnes
• multiple crane lifts, where more than one crane is used to lift a load at any one time
• any crane operation within the Rail Corridor where 50% of the crane’s rated
capacity is exceeded
• lifting over the Rail Corridor
• lifting over a public space
• lifting and erection of tilt-up concrete panels
• lifting large pressure vessels or tanks
• lifting in the vicinity of live overhead powerlines or other live exposed electrical
equipment
• lifting persons in workboxes
• lifting likely to be carried out in conditions where wind speed is 36km/h (10m/s) or
more
• using a crane on suspended ground or floor
• using a mobile crane for tree lopping
• using a mobile crane on a barge
• using a crane above buried services
• installing bridge beams during bridge installation work
• where pick and carry cranes are required to travel over sloping or uneven ground
• the crane is standing on soft or previously disturbed (excavated) ground or fill.
Warning
Failure to comply with these procedures could result in serious injury,
electrocution, damage to property, or the failure of RailCorp services,
power, and signalling or communication systems. The loss of any rail
infrastructure service could have major consequences to rail safety.
A range of competent persons may be required to assess, plan and carry out crane
lifting operations including:
• licensed crane operators, riggers and doggers trained and instructed in the safe
operation, maintenance and inspection of cranes and associated equipment
• qualified engineers to calculate loads, centre of gravity and ground bearing
capacity
• qualified mechanical assessors to undertake periodic inspections in accordance
with codes and Australian Standards.
3.1.1 Design
Supervisors are to make sure that all mobile cranes used by RailCorp are certified by
the supplier that the crane is compliant with the applicable part of AS1418 Cranes,
hoists and winches.
Warning
Wherever practicable, work in the vicinity of overhead power lines or other
exposed electrical equipment is to be carried out after the electrical supply
has been isolated and all permit requirements fulfilled.
• situations that require electrical permits are specified in Section 7.1 of SMS-06-GD-
0268 Working around Electrical Equipment document. For isolation to be achieved,
the SMS-06-FM-0484 Request for Electrical to Work form must be completed and
submitted to the respective regional nominated electrical representative
• compliance with the provisions of SMS-06-SW-0267 Working in Accordance with
an Electrical Permit and SMS-06-EN-0598 Electrical Permit to Work
• persons holding or receiving electrical permits must be Accredited Electrical Permit
Holders as stipulated in SMS-11-GD-0244 Personnel Certifications – Electrical
Authorisations guide.
Generally, it will harder to obtain isolation of 1500vDC overhead traction system than it
will be to obtain isolation for the high voltage network. If short term crane operation is
required in the vicinity of the 1500v DC overhead traction system and isolation will not
be granted due to the impacts on train movements, then the person planning the crane
operation must consider rescheduling the lifting operation until a time when isolation will
be granted, e.g. during a possession.
Where the work may infringe the relevant safe approach distance at any stage, and it is
not practicable to isolate the electrical supply, the person in control must use the
highest practicable control measure, or combination of measures as set out in the Safe
Use of Mobile Plant guide, to control the risks. These controls may include the use of
one or more of the following – limiting devices, physical barriers, bunting, signage and
trained safety observers.
• Where the ground is compact and non-friable (i.e. not crumbling), the distance of
any part of the crane support timbers from the excavation must be at least equal to
the depth of the excavation (1:1 rule).
For example, for a three metre deep trench in compact ground, the outrigger
timbers or pads should be a horizontal distance of at least three metres away from
the closest edge of the trench wall.
• Where the ground is loose or backfilled (i.e. crumbling), the distance of any part of
the crane support timbers from the excavation should be at least twice the depth of
the excavation (2:1 rule).
For example, for a three metre deep trench in backfilled ground, the outrigger
timbers or pads should be a horizontal distance of at least six metres away from
the closest face of the trench wall.
Where the above principles cannot be adhered to advice from a competent person such
as a geotechnical or civil engineer must be sought.
• bridge beams
• tilt-up panels
• other loads of 50 tonnes or more.
Outriggers are used on mobile cranes to help level the crane and provide greater
stability when lifting loads. Irrespective of the ground conditions, timbers or other means
of distributing the load must be placed under the outriggers. Outriggers are to be set
according to the manufacturer's operating instructions for the specific mobile crane
type.
Many cranes are not designed for lifting with partially extended outriggers. If one or
more outriggers are not fully extended, the crane may become unstable during lifting
operations.
In some instances, it may not be possible to fully extend all outriggers. Supervisors
must make sure that:
• only cranes that have the manufacturer's approval to lift with partially extended
outriggers are used this way
• if a lift is to be undertaken with partially extended outriggers, that the correct
outrigger configuration according to the appropriate load chart is used.
Generally, the following principles are to be applied to timbers, pads, steel plates and
bog mats:
• timbers are to have a minimum width of 200mm and minimum thickness of 75mm
• timbers are to be laid together so that the timber pad width is wider than the
outrigger foot with no gaps between timbers
• pads are to have a minimum thickness of 75mm
• a competent person determines the dimensions of steel plates and bog mats
according to the mobile crane type.
Most pick-and-carry mobile crane manufacturers specify that these cranes are to be
operated on firm level ground. In practice, it can be very difficult to ensure the ground
surface for a pick-and-carry crane is firm and level. This is particularly the case at a
workplace where construction work is being performed where the ground condition and
slope may be constantly changing. A pothole has the same effect as a gradient if the
crane’s wheel enters the hole.
Note
It may be necessary to fill surface depressions and potholes or place mats
or other artificial surfaces to prevent pick and carry cranes from tilting
whilst travelling
Warning
If wind speed exceeds the maximum figure stated by the crane
manufacturer for a specific mobile crane, crane operations are to stop
immediately.
Mobile cranes are to be operated within their engineered design capacity. To ensure
the mobile crane stability in windy conditions, the following factors are to be addressed:
• if the manufacturer's wind speed limit is not known the operator must cease
operations if wind speed exceeds 36km/h (10m/s); in many situations, this speed
may need to be reduced, particularly where the load and boom have large surface
areas
• where the crane is lifting close to its rated capacity, the wind has a greater effect on
the crane stability and the potential application of a side load on the crane’s boom
• where the lift is non-standard, with a suspended load or large surface area to be
undertaken in windy conditions, the competent person in control of the lift is to
address wind speeds and control measures in the Mobile Crane Work Plan and/or
SWMS.
• consider attaching wind gauges to mobile cranes or providing another reliable
method of measuring wind speed (e.g. handheld wind gauge). Where wind gauges
are to be attached to the crane, they are to be mounted at the top of the main boom
and calibrated at predetermined intervals, to make sure they provide accurate
readings.
• mobile cranes with a maximum rated capacity of the crane of 100 tonnes or more
must have wind gauges fitted.
• all lifting gear is tagged to identify the date of the lifting gear’s last inspection
• all lifting equipment owned by RailCorp is included on the Plant and Equipment
Register
• inspection and test records are maintained at the workplace.
Refer to SMS-16-SR-0057 Inspection and Testing for more information.
Warning
Loads must not under any circumstance be lifted above people.
Loads must not be lifted above occupied building or critical rail infrastructure, such as
signal boxes and substation, without a risk assessment being conducted in consultation
with the Asset Owner and relevant Infrastructure Division Regional Manager. Measures
to control the risk from unsecured or dropped loads are to be included in Mobile Crane
Work Plan and/or SWMS.
• formwork frames are to be either tied together or lifting slings should be wrapped
around the load
• loads of joists or bearers are to be strapped together before lifting
• timber sheeting is to be strapped together and lifted in a flat position
• sheets of plasterboard may be lifted in a specifically designed material box. if a
material box is not used, then the lifting system is to:
− be certified by an engineer
− specify the minimum and maximum number of sheets
− specify the number and locations of lifting slings, and
− specify the capacity of lifting slings.
• tag lines are to be used to control loads and are to be non-conductive.
• all loads are to be supported where possible with dunnage (ie small bits of timber),
with the load uniformly distributed over the supporting surface.
Note
Containers such as milk crates and oil drums must not be used or
modified for use as a material box.
Lane closures and other operations that require the erection of barricades and signs are
to comply with Roads and Traffic Authority (RTA) requirements. Refer to the Working
On or Near Public Roads guide for more details.
4.8.1 Crane requirements when using workboxes and first aid boxes
When using crane-lifted workboxes or first aid boxes, the crane must:
• have a minimum SWL of 1000 kg at the maximum radius for the task to be
performed
• have a minimum SWL of at least twice the total load of the workbox and its
contents, at the maximum radius for the task to be performed
• be fitted with an upper hoist limit (anti-two block) that stops operation of the hoist,
luff and telescope functions of the crane, or be designed so that two-blocking
cannot damage any part of the crane or lifting gear
• have levers and foot pedals fitted with a constant pressure system that stops the
crane’s motions when the operator removes pressure from the controls
• if fitted with a free fall facility, the free fall function must be locked out with a keyed
lock out.
All crane workboxes are to be design registered with WorkCover. In addition they are to
have the features described in Section 4.8.2.
• have a factor of safety for each suspension sling of at least eight for chains and ten
for wire rope
• be marked with the SWL, tare mass and design registration number
• have sides at least 1m high
• if provided with a door, the door must be self-closing and provided with a latch to
prevent accidental opening. A workbox door must be inward opening only; first aid
boxes may be provided with an outward opening door.
5.1 Telehandlers
A telehandler is a versatile type of mobile lifting plant that incorporates a telescopic
boom fitted with a lifting attachment. Telehandlers are also known as multi-purpose
handlers/cranes/tool carriers, telescopic forklifts and by proprietary names such as
Manitou.
Warning
A telehandler's stability is affected by the carried or lifted load, and terrain.
The usual means of lifting is by forks, but telehandlers can be fitted with a variety of
attachments for different types of loads. The range of attachments that can be used
depends upon the design of the particular machine, and often include a jib for lifting
freely suspended loads. See Figure 1 for examples.
5.1.1 Design
Where telehandlers are intended to lift freely suspended written confirmation is to be
provided by the supplier that the telehandler complies with AS 1418.19 Cranes, hoists
and winches Part 19: Telescopic Handlers.
All telehandlers must be fitted with:
• a boom angle indicator
• a lateral slope indicator
• a telescopic boom length indicator
• a longitudinal stability indicator
• a warning beeper (to provide nearby workers warning of the telehandler).
Where the telehandler's rated capacity is above 3 tonnes, it must also be fitted with:
• a rated capacity indicator that provides a visual and audible warning before the
load exceeds the rated capacity
• a longitudinal stability limiter
• a rated capacity limiter
• a maximum capacity limiter.
The above indicators and limiters must be specific to the type of attachment being used
on the telehandler. Where there are a range of possible attachments the limiters and
indicators must provide for use in all possible configurations.
5.1.2 Operation
Operators must have read and be familiar with the operator’s handbook before use. In
addition the following are to be supplied with the telehandler and be available on site:
• load configuration rating charts
• an operator’s handbook
• maintenance records
• inspection logbook.
Typically, telehandlers are used to move with their load (pick-and-carry). When
travelling with a fixed load, the operator must retract the boom and lower the load as
close to the ground as possible. The height above ground level should not exceed:
• 500mm above ground level for loads greater than 10 tonnes
• 300mm above ground level for loads10 tonnes or less.
If the load is freely suspended, the operator should travel with the load elevated high
enough to prevent it snagging on the ground or other obstacles.
Note
Operators and doggers must use tag lines to prevent freely suspended
loads swinging.
5.2.3 Quick-hitches
A quick-hitch is a latching device that enables rapid connection of earthmoving plant
attachments to the plant’s dipper arm. Whilst this device saves time and effort, a
number of fatalities have occurred when excavator attachments have fallen off due to
loss of hydraulic pressure. Locking pins are used to ensure the attachment is engaged
correctly and remains locked in position on the dipper arm.
All quick-hitch devices are to be:
• fitted with a locking pin and be operated with the locking pin always in place, or
• designed with an automatic secondary locking system, such as an Essex
Auto-Latch, that negates the need to insert a locking pin manually.
7. Vehicle-loading cranes
Vehicle loading cranes must:
• comply with AS 1418.11: Cranes, hoists and winches – Vehicle-loading cranes
• be operated in accordance with AS2550.11 Cranes Hoists and Winches – Safe
Use – Vehicle-loading cranes.
Warning
Vehicle-loading cranes must not be used in pick-and-carry mode or to lift
persons.
8. Inspection of cranes
Mobile cranes require four types of inspection:
• pre-start inspection
• routine maintenance and inspection
• periodic inspection
• major inspection.
9.2.2 Dogger
A dogger is a person who:
• applies slinging techniques, including the selection or inspection of lifting gear, to
safely sling a load, or
• directs a crane or hoist operator in the movement of a load when the load is out of
the operator's view.
Managers and Supervisors are to make sure that only a person with a Dogger
Certificate (DG) or Rigger Certificate (RB, RI, RA) is permitted to perform dogging
activities.
An operator of a vehicle loading crane (of any capacity) may also be required to hold a
dogging certificate if they are required to exercise judgment in the slinging of the load
(including selection or inspection of the lifting gear).
If the load is out sight of the operator at any time a certificated dogger/rigger must
control the lift; the operator must not undertake the tasks of the dogger/rigger, even if
they hold a certificate of competence as a dogger or rigger.
9.2.3 Rigger
Rigging involves the use of mechanical load shifting equipment and associated gear to
move, place or secure a load, or to set up or dismantle a crane and hoists.
Managers and Supervisors are to make sure that rigging duties are performed only be
persons with a rigger certificate. There are three rigging certificate levels - basic (RB),
intermediate (RI), and advanced rigging (RA). A different set of competencies must be
obtained for each rigging level. Refer to Clause 266 of the OHS Regulation 2001 for
more specific details.
The purpose of this training is to ensure that crane operators, doggers and riggers
maintain the competencies they achieved originally in the relevant certificates of
competency.
Refresher training should reflect issues such as:
• the application of new technology, particularly for those persons who obtained their
certificates while working on more basic cranes
• any relevant changes to occupational health and safety legislation and Australian
Standards which may impact on safe crane operations
• safe crane operation.
The interval between refresher training courses should not exceed three years. Crane
operators, doggers and riggers should undergo refresher training between two and a
half and three years after either being issued their initial certificate of competency, or
since attending their most recent refresher training, whichever is the shorter timeframe.
10. References
• OHS Regulation 2001, Chapters 5 and 9, and Schedule 1
• AS1418.1 2002 Cranes (including hoists and winches) – general requirements
• AS1418.5 2002 Cranes (including hoists and winches) - mobile cranes and vehicle
loading cranes
• AS1418.8 2002 Cranes, hoists and winches – Special purpose appliances
• AS1418.11 2004 Cranes (including hoists and winches) - Vehicle loading cranes
• AS1418.17 1996 Cranes (including hoists and winches) – Design and construction
of workboxes
• AS1418.19 2007 Cranes, hoists and winches – telescopic handlers
• AS2550.1 2002 Cranes, hoists and winches – safe use – general
• AS2550.5 2002 Cranes, hoists and winches – safe use – mobile cranes
• AS2550.11 2004 Cranes, hoists and winches – safe use – vehicle loading cranes
• AS2550.19 2007 Cranes, hoists and winches - safe use - telescopic handlers
• QLD Division of Workplace H&S Mobile Crane Code of Practice 2006
• SMS-05-SR-0027 Records Management
• SMS-11-SR-0123 Safety Training and Competence
• SMS-16-SR-0057 Inspection and Testing
• SMS-11-PR-0747 Managing Safety Training and Competence
• SMS-06-GD-0268 Working Around Electrical Equipment
• SMS-06-GD-0403 Plant Risk Assessment
• SMS-11-GD-0243 Plant and Equipment Certificates of Competency
• SMS-11-GD-0244 Personnel Certifications – Electrical Authorisations
• SMS-06-SW-0267 Working in Accordance with an Electrical Permit
• SMS-06-EN-0598 Electrical Permit to Work