Product Overview

Summary: This Crane Use and Safety in Metal Fabrication SOP sets out clear, practical steps for planning, operating and supervising crane activities in workshops and fabrication yards. It supports compliance with Australian WHS laws, reduces the risk of dropped loads, crush injuries and collisions, and provides a defensible framework for safe lifting operations in metal fabrication environments.

Cranes are central to metal fabrication operations, from moving plate and structural steel to positioning heavy jigs, fixtures and assemblies. At the same time, they are a leading source of serious incidents, including crush injuries, struck‑by events, structural failures and uncontrolled load movements. This Safe Operating Procedure provides a clear, workshop-focused framework for planning and carrying out crane operations safely in metal fabrication settings, whether you are using overhead travelling cranes, jib cranes, portal cranes or mobile cranes working in or around the workshop.

The document translates Australian WHS requirements and industry best practice into step‑by‑step instructions that can be followed by supervisors, operators and doggers on the floor. It covers pre‑use inspections, communication protocols, load assessment and rigging, exclusion zones, coordination with other workshop activities (such as welding, cutting and forklift use), and emergency response. By implementing this SOP, metal fabrication businesses can demonstrate due diligence, standardise lifting practices across shifts and sites, and significantly reduce the likelihood of serious injuries, property damage, and costly downtime caused by crane-related incidents.

Key Benefits

• Ensure consistent, safe crane operations across all metal fabrication workshops and shifts.
• Reduce the risk of dropped loads, crush injuries and collisions with plant, structures and people.
• Demonstrate compliance with Australian WHS legislation and relevant crane and rigging standards.
• Improve communication and coordination between crane operators, doggers, welders and other workshop personnel.
• Streamline induction and refresher training for crane operators and fabrication staff using a clear, documented process.

Who is this for?

• Workshop Managers
• Fabrication Supervisors
• Crane Operators
• Doggers and Riggers
• Boilermakers and Fabricators
• WHS Managers and Advisors
• Maintenance Supervisors
• Project Engineers (Fabrication and Installations)
• HSEQ Managers
• Small Metal Fabrication Business Owners

Hazards Addressed

• Dropped or swinging loads striking workers or plant
• Crush injuries between loads, cranes, structures and fixed equipment
• Overloading of cranes, hoists, slings and lifting attachments
• Failure of lifting equipment due to poor inspection or maintenance
• Collisions between cranes, forklifts and other mobile plant
• Contact with overhead power lines or energised equipment (for mobile cranes near the workshop)
• Entanglement with chains, slings, hooks and rotating components
• Slips, trips and falls in crane operating areas and along gantry access paths
• Noise and communication failures leading to unsafe movements
• Poor visibility and blind lifts in congested fabrication areas
• Exposure to welding fumes, sparks or hot work near lifting operations
• Manual handling injuries from incorrect attachment or adjustment of rigging gear

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Crane Operators, Doggers, Workers)
• 4.0 Competency, Licensing and Training Requirements
• 5.0 Crane Types and Applications in Metal Fabrication (Overhead, Jib, Portal, Mobile)
• 6.0 Hazard Identification and Risk Assessment for Crane Operations
• 7.0 Pre-Start Checks and Inspection of Cranes, Hoists and Lifting Gear
• 8.0 Planning Lifts in Metal Fabrication Workshops and Yards
• 9.0 Load Assessment, Rigging Selection and Use of Lifting Devices
• 10.0 Establishing and Managing Exclusion Zones and Traffic Management
• 11.0 Communication Protocols, Signals and Use of Spotters
• 12.0 Safe Operating Procedure – Step-by-Step Crane Use
• 13.0 Coordination with Other Activities (Welding, Cutting, Forklifts and Mobile Plant)
• 14.0 Working Near Overhead Services and Other Critical Infrastructure
• 15.0 Housekeeping, Visibility and Line-of-Sight Controls
• 16.0 Emergency Procedures (Equipment Failure, Dropped Load, Injury, Power Loss)
• 17.0 Inspection, Maintenance and Tagging Requirements
• 18.0 Incident Reporting, Investigation and Corrective Actions
• 19.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and harmonised state and territory Acts)
• Work Health and Safety Regulations 2011 – Part 4.5 and 4.7 (Plant and High Risk Work)
• Safe Work Australia – Model Code of Practice: Managing the risks of plant in the workplace
• Safe Work Australia – Model Code of Practice: Managing risks of hazardous chemicals in the workplace (for lifts near hot work and chemicals)
• AS 2550 series: Cranes, hoists and winches – Safe use
• AS 1418 series: Cranes, hoists and winches – Design and construction
• AS 4991: Lifting devices
• AS 1353: Flat synthetic‑webbing slings
• AS 3775: Chain slings for lifting purposes
• AS/NZS ISO 31000: Risk management – Guidelines