Product Overview

Summary: This SOP sets out clear, practical fall prevention measures for crane operators working at height, in and around cranes, on Australian worksites. It gives your business a defensible, step-by-step system for eliminating or minimising fall risks, while supporting compliance with WHS legislation and industry best practice.

Falls from height remain one of the leading causes of serious injury and fatality on Australian worksites, and crane operations present a unique combination of access, egress and working-at-height risks. This Safe Operating Procedure provides a structured framework for planning, setting up, operating and shutting down cranes with a strong focus on eliminating or controlling fall hazards for crane operators and associated personnel. It covers safe access to cabs and walkways, use of fall-arrest systems, maintaining three points of contact, controls around slewing and wind conditions, and safe behaviour while working on or around crane structures.

By implementing this SOP, businesses can move beyond informal “common sense” approaches and embed a consistent, auditable process for fall prevention in crane operations. The procedure supports compliance with WHS regulations, crane and height safety standards, and principal contractor requirements, while also making it easier to induct new operators and contractors to site rules. The result is fewer incidents, clearer expectations, and a safer, more professional lifting operation that protects your people, your plant and your reputation.

Key Benefits

• Reduce the risk of falls from height during crane access, operation and maintenance activities.
• Ensure alignment with Australian WHS legislation and relevant height safety and crane standards.
• Standardise safe access, egress and fall prevention practices across all crane operators and shifts.
• Support more effective inductions, toolbox talks and refresher training for crane crews.
• Minimise downtime, incident-related costs and regulatory scrutiny arising from fall incidents.

Who is this for?

• Crane Operators
• Doggers and Riggers
• Site Supervisors
• Construction Project Managers
• WHS Managers and Advisors
• Plant and Equipment Coordinators
• Civil and Infrastructure Supervisors
• Manufacturing and Yard Managers

Hazards Addressed

• Falls while climbing ladders, stairs or access systems to crane cabs or walkways
• Slips and trips on crane platforms, walkways and around the slew ring
• Falls from unprotected edges during inspection, maintenance or setup
• Loss of balance due to wind, crane movement or unexpected slewing
• Incorrect or absent use of fall-arrest and restraint systems
• Struck-by hazards from dropped objects resulting from poor footing at height
• Fatigue-related missteps when accessing or exiting cranes
• Falls during emergency evacuation from crane cabs at height

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Crane Operators, Doggers/Riggers)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for Falls in Crane Operations
• 6.0 Hierarchy of Control for Fall Prevention (Elimination, Substitution, Engineering, Administrative, PPE)
• 7.0 Requirements for Crane Access Systems (Ladders, Stairs, Platforms and Walkways)
• 8.0 Pre-Operation Checks for Fall Prevention (Housekeeping, Guardrails, Access Ways)
• 9.0 Use of Fall-Arrest and Restraint Systems for Crane Operators
• 10.0 Safe Access and Egress to Crane Cabs and Upper Structures
• 11.0 Safe Work Practices While Operating and Slewing Cranes at Height
• 12.0 Controls for Environmental Conditions (Wind, Rain, Lighting) Affecting Fall Risk
• 13.0 Communication, Spotters and Exclusion Zones Around Crane Access Areas
• 14.0 Inspection, Maintenance and Tag-Out of Fall Prevention Equipment
• 15.0 Emergency Response and Rescue Procedures for Falls from Cranes
• 16.0 Training, Competency and Verification of Crane Operators in Fall Prevention
• 17.0 Documentation, Recordkeeping and Audit Requirements
• 18.0 Review, Consultation and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth) and harmonised state and territory WHS Acts
• Work Health and Safety Regulation 2011 (particularly provisions relating to falls and plant)
• Safe Work Australia - Managing the Risk of Falls at Workplaces Code of Practice
• Safe Work Australia - Managing the Risks of Plant in the Workplace Code of Practice
• AS 2550 Cranes, hoists and winches – Safe use (relevant parts)
• AS 1418 Cranes, hoists and winches (relevant design and operational requirements)
• AS/NZS 1891 Industrial fall-arrest systems and devices (relevant parts)
• AS 1657 Fixed platforms, walkways, stairways and ladders – Design, construction and installation