Product Overview

Summary: This SOP provides clear, step-by-step guidance for the safe assembly and disassembly of drill rigs across Australian construction, mining and civil works sites. It helps organisations control high-risk activities involving heavy components, suspended loads and stored energy, while supporting compliance with WHS legislation and manufacturer requirements.

Drill rig assembly and disassembly is a high-risk activity that often occurs under time pressure, in variable ground conditions and in congested work areas. Without a structured procedure, crews are exposed to serious hazards including crush injuries, falls from height, uncontrolled movement of heavy components and contact with pressurised hydraulic systems. This Safe Operating Procedure establishes a consistent, documented method for planning, assembling, commissioning, disassembling and transporting drill rigs in line with Australian WHS expectations and OEM specifications.

The SOP breaks the task into logical stages, from pre-start planning and exclusion zone setup through to lock-out/tag-out, lifting arrangements, connection of power packs, mast raising/lowering and final verification checks. It clearly defines roles and communication protocols between operators, doggers, riggers and spotters, and integrates risk controls such as isolation procedures, use of certified lifting gear, ground stability checks and emergency response planning. By adopting this SOP, businesses can demonstrate due diligence, improve workforce competence, reduce downtime from equipment damage and significantly lower the likelihood of serious incidents during rig mobilisation and demobilisation.

Key Benefits

• Reduce the risk of serious injury or fatality during drill rig mobilisation and demobilisation activities.
• Ensure consistent, manufacturer-aligned assembly and disassembly practices across all crews and sites.
• Demonstrate compliance with Australian WHS legislation, plant regulations and high-risk work requirements.
• Minimise equipment damage, unplanned downtime and costly repairs caused by incorrect handling or setup.
• Improve planning, communication and coordination between operators, riggers, doggers and site supervisors.

Who is this for?

• Drill Rig Operators
• Drilling Supervisors
• Site Supervisors
• Project Engineers
• WHS Managers and Advisors
• Maintenance Supervisors
• Construction and Civil Works Managers
• Mining Supervisors
• Principal Contractors
• Fleet and Asset Managers

Hazards Addressed

• Crush and pinch point injuries during positioning and bolting of mast and components
• Struck-by incidents from falling or swinging loads during lifting operations
• Uncontrolled movement or collapse of the rig due to unstable ground or inadequate support
• Contact with moving parts during testing, commissioning and mast raising/lowering
• Hydraulic fluid injection injuries and leaks from pressurised systems
• Falls from height when accessing platforms, masts or elevated components
• Manual handling strains and sprains from handling tooling, hoses and smaller components
• Electrical hazards when working near overhead or underground services
• Noise and vibration exposure during testing and function checks
• Traffic and mobile plant interaction in shared work areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (Operator, Supervisor, Rigger, Dogger, Spotter)
• 4.0 Required Competencies, Licences and Training
• 5.0 Required PPE, Tools and Equipment
• 6.0 Pre-Assembly Planning and Risk Assessment (JSA/SWMS)
• 7.0 Site Preparation, Ground Conditions and Exclusion Zones
• 8.0 Pre-Use Inspection of Drill Rig, Lifting Gear and Ancillary Equipment
• 9.0 Isolation, Lock-Out/Tag-Out and Energy Control Requirements
• 10.0 Drill Rig Assembly – Step-by-Step Procedure
• 11.0 Lifting, Positioning and Securing of Mast and Major Components
• 12.0 Connection of Hydraulics, Power Packs, Controls and Ancillary Systems
• 13.0 Commissioning, Functional Testing and Final Safety Checks
• 14.0 Drill Rig Disassembly – Step-by-Step Procedure
• 15.0 De-energisation, Depressurisation and Safe Disconnection of Systems
• 16.0 Lifting, Lowering and Packing of Components for Transport
• 17.0 Housekeeping, Waste Management and Environmental Considerations
• 18.0 Communication Protocols, Spotting and Hand Signals
• 19.0 Emergency Procedures and Incident Response
• 20.0 Documentation, Records and Review Requirements

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 – Part 4.5 Plant and structures
• Safe Work Australia – Code of Practice: Managing the risks of plant in the workplace
• Safe Work Australia – Code of Practice: Construction work
• AS 4024.1 Series: Safety of machinery
• AS 2550.1: Cranes, hoists and winches – Safe use – General requirements (for lifting operations interface)
• AS 1418 Series: Cranes, hoists and winches (as applicable to lifting equipment used in rig assembly)
• AS/NZS 1891 Series: Industrial fall-arrest systems and devices
• AS/NZS 3012: Electrical installations – Construction and demolition sites
• Manufacturer’s operating and maintenance manuals for specific drill rigs and associated equipment