Product Overview

Summary: This Crane and Hoist Operations Safe Operating Procedure sets out clear, step-by-step requirements for planning, conducting, and supervising lifting operations in Australian workplaces. It helps your business control high-risk lifting activities, protect workers and plant, and demonstrate compliance with WHS laws and relevant Australian Standards.

Crane and hoist operations are classified as high-risk work under Australian WHS legislation, with the potential for catastrophic incidents if not carefully controlled. This Safe Operating Procedure provides a practical, field-ready framework for safely planning and executing lifting activities using mobile cranes, overhead gantry cranes, vehicle loading cranes, and powered hoists across construction, manufacturing, warehousing, utilities and maintenance environments. It translates legislative and technical requirements into clear, usable instructions that workers and supervisors can follow on site.

The SOP guides your team through the full lifecycle of a lift: from pre-start inspections, lift planning and communication protocols, through to safe operation, load handling, exclusion zones, and shutdown. It addresses common failure points such as inadequate rigging, poor signalling, overloading, unstable ground conditions, and uncontrolled loads. By implementing this procedure, organisations can reduce the likelihood of dropped loads, equipment damage, and serious injuries, while also providing evidence of due diligence to regulators, clients and principal contractors.

Developed for the Australian context, this document aligns with WHS Act and Regulation requirements, relevant Australian Standards, and Safe Work Australia guidance on cranes and high-risk work licensing. It supports consistent training, onboarding of new operators and doggers, and ongoing supervision, helping you embed a strong lifting safety culture across your sites and facilities.

Key Benefits

• Ensure crane and hoist operations are planned, authorised and executed in line with Australian WHS legislation and standards.
• Reduce the risk of dropped loads, collisions, tip-overs and crush injuries through defined controls and exclusion zone management.
• Standardise lifting practices across projects, shifts and locations, improving consistency and worker competence.
• Demonstrate due diligence to regulators, clients and auditors with a documented, systematic approach to crane and hoist safety.
• Streamline training and inductions for crane operators, doggers and spotters with clear, role-specific responsibilities and checklists.

Who is this for?

• Crane Operators
• Doggers and Riggers
• Site Supervisors
• Construction Project Managers
• WHS Managers and Advisors
• Manufacturing and Warehouse Managers
• Maintenance Supervisors
• Principal Contractors
• Engineering Managers
• Facilities Managers

Hazards Addressed

• Dropped or swinging loads causing impact or crush injuries
• Crane overturning or structural failure due to overloading or poor ground conditions
• Collision with structures, plant, vehicles or overhead services (including powerlines)
• Entanglement, pinch and crush points around hoists, hooks, slings and moving parts
• Electrical contact and arcing from operating near overhead or underground powerlines
• Failure of lifting gear such as slings, chains, shackles and lifting points
• Uncontrolled loads due to wind, poor rigging or inadequate tag lines
• Falls from height during access to cranes, hooks or loads
• Manual handling strains during rigging, attaching and detaching loads
• Noise and vibration exposure from crane and hoist operation

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Applicable Equipment (Cranes, Hoists, Lifting Gear)
• 3.0 Roles, Responsibilities and High Risk Work Licensing Requirements
• 4.0 Competency, Training and Verification of Competency (VOC)
• 5.0 Planning Lifting Operations and Lift Risk Assessment
• 6.0 Pre-Start Checks and Inspection of Cranes, Hoists and Lifting Gear
• 7.0 Set-Up Requirements (Ground Conditions, Outriggers, Supports and Environmental Factors)
• 8.0 Load Assessment, Rigging Selection and Inspection of Slings and Attachments
• 9.0 Establishing and Controlling Exclusion Zones
• 10.0 Communication Methods, Signalling and Use of Doggers/Spotters
• 11.0 Safe Operating Procedure – Crane and Hoist Operation Step-by-Step
• 12.0 Working Near Overhead and Underground Services (Including No-Go Zones)
• 13.0 Managing Adverse Weather, Wind and Environmental Conditions
• 14.0 Parking, Shutdown and Isolation of Cranes and Hoists
• 15.0 Emergency Procedures and Incident Response (Dropped Load, Contact with Powerlines, Equipment Failure)
• 16.0 Inspection, Maintenance and Tagging Requirements
• 17.0 Documentation, Lift Plans, Permits and Record Keeping
• 18.0 Review, Audit and Continuous Improvement of Lifting Operations

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (including high risk work and plant provisions)
• Safe Work Australia – General Guide for Cranes
• Safe Work Australia – Code of Practice: Managing the Risk of Plant in the Workplace
• AS 2550 series: Cranes, hoists and winches – Safe use (e.g. AS 2550.1, AS 2550.3, AS 2550.10)
• AS 1418 series: Cranes, hoists and winches – Design, construction and testing
• AS 4991: Lifting devices
• AS 1353: Flat synthetic-webbing slings
• AS 3775: Chain slings for lifting purposes
• AS/NZS 4801 or ISO 45001: Occupational health and safety management systems
• State/Territory WHS Codes of Practice and guidance on high risk work licensing and cranes