Product Overview

Summary: This Safety Operating Procedure sets out clear, practical steps for safely lifting, moving and landing hazardous loads with cranes in Australian workplaces. It helps your team control high‑risk activities, protect people and plant, and demonstrate due diligence under WHS legislation when dealing with awkward, unstable or dangerous loads.

Handling hazardous loads with cranes is a high‑risk activity that sits under intense regulatory and client scrutiny across construction, manufacturing, mining, logistics and infrastructure projects in Australia. Loads that are oversized, unstable, chemically hazardous, fragile, sharp-edged or with a high centre of gravity can quickly turn a routine lift into a critical incident if they are not planned and controlled correctly. This Safe Operating Procedure provides a clear, step‑by‑step framework for assessing loads, planning the lift, selecting the right lifting gear, coordinating communications and executing the lift safely from start to finish.

The document translates Australian WHS requirements, relevant crane standards and good industry practice into practical instructions that supervisors and crews can actually use on site. It tackles common pain points such as poorly defined roles between crane operator and dogger, inconsistent lift planning, ad‑hoc rigging decisions, and inadequate exclusion zones around suspended loads. By implementing this SOP, businesses can significantly reduce the likelihood of dropped loads, equipment damage, uncontrolled movements and serious injuries, while also providing a defensible system of work that supports training, toolbox talks and incident investigations.

Whether you are running tower cranes on a multi‑storey build, mobile cranes in a laydown yard, or bridge cranes inside a fabrication workshop, this SOP helps standardise how hazardous loads are identified, controlled and documented. It supports your organisation in meeting its duty of care, maintaining client confidence and keeping projects moving without unnecessary delays caused by unsafe lifting practices or regulatory non‑compliance.

Key Benefits

• Reduce the risk of dropped loads, crush injuries and structural damage by standardising safe lifting practices for hazardous loads.
• Ensure compliance with Australian WHS legislation and relevant crane and rigging standards through a documented system of work.
• Improve coordination between crane operators, doggers, riggers and spotters with clear role definitions and communication protocols.
• Streamline pre‑lift planning and risk assessment for complex or non‑routine lifts, reducing delays and rework on site.
• Enhance training, onboarding and competency assessment for lifting personnel using a consistent, documented procedure.

Who is this for?

• Crane Operators
• Doggers and Riggers
• Site Supervisors
• WHS Managers
• Construction Project Managers
• Manufacturing and Warehouse Managers
• Transport and Logistics Coordinators
• Maintenance Supervisors
• Principal Contractors
• Safety Advisors

Hazards Addressed

• Dropped or uncontrolled loads due to incorrect rigging or sling failure
• Crush and pinch injuries to workers in the vicinity of suspended loads
• Load swing, rotation or instability caused by wind, sudden movements or incorrect centre of gravity assessment
• Structural failure of lifting points, lifting beams or attachments
• Contact with overhead powerlines or other services during crane movements
• Collision of loads with structures, plant, scaffolding or other equipment
• Exposure to hazardous substances from damaged containers or process equipment being lifted
• Manual handling injuries during attachment, detachment and tag line use
• Slips, trips and falls in poorly controlled lifting and landing areas
• Noise, visibility and communication issues affecting safe signalling and coordination

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (Hazardous Loads, Critical Lifts, Exclusion Zones)
• 3.0 Roles and Responsibilities (PCBU, Crane Operator, Dogger/Rigger, Spotter, Supervisor)
• 4.0 Competency, Licensing and Training Requirements
• 5.0 Pre‑Lift Planning and Risk Assessment
• 6.0 Identification and Classification of Hazardous Loads
• 7.0 Selection and Inspection of Cranes, Lifting Gear and Accessories
• 8.0 Load Assessment (Weight, Centre of Gravity, Stability and Load Path)
• 9.0 Site Preparation and Establishing Exclusion Zones
• 10.0 Communication Methods, Signals and Two‑Way Radio Protocols
• 11.0 Step‑by‑Step Lifting Procedure for Hazardous Loads
• 12.0 Special Considerations (Fragile, Liquid, Chemical, Pressurised or Hot Loads)
• 13.0 Working Near Overhead Services and Other Critical Infrastructure
• 14.0 Securing, Landing and Unrigging Loads
• 15.0 Inspection, Maintenance and Storage of Lifting Equipment
• 16.0 Emergency Procedures and Incident Response (Dropped Load, Equipment Failure, Chemical Release)
• 17.0 Documentation, Permits and Lift Plans
• 18.0 Monitoring, Review and Continuous Improvement of the Procedure

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (particularly provisions relating to plant and high risk work)
• Safe Work Australia – Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Guide to Cranes
• AS 2550 series: Cranes, hoists and winches – Safe use (e.g. AS 2550.1, AS 2550.5, AS 2550.10 as applicable)
• 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 1891 series: Industrial fall-arrest systems and devices (where working at heights around loads is required)
• AS/NZS ISO 31000: Risk management – Guidelines