Product Overview

Summary: This Safe Operating Procedure provides a clear, step-by-step framework for developing, reviewing, and approving lift plans for crane and mechanical lifting operations. It helps Australian businesses manage high-risk lifting work in a consistent, defensible way that protects workers, plant, and surrounding assets while demonstrating compliance with WHS legislation.

Lift planning is a critical control for any high-risk lifting activity, from routine materials handling to complex multi-crane lifts. Poorly planned lifts can result in dropped loads, crane instability, structural damage, serious injury or fatality, as well as significant project delays and regulatory scrutiny. This Lift Plan Development and Approval SOP sets out a structured process for identifying lift requirements, assessing risks, selecting appropriate lifting equipment, and documenting every stage of the lifting operation before work begins.

Developed specifically for the Australian WHS environment, the procedure guides your team through pre-lift engineering checks, ground and structural assessments, exclusion zone design, communication protocols, and sign‑off requirements. It clarifies who is responsible for preparing, reviewing, and authorising lift plans, and how changes to a lift are controlled on the day. By standardising how lift plans are developed and approved, this SOP helps businesses demonstrate due diligence, improve coordination between contractors, and embed a safety-first culture across all lifting operations.

Whether you manage a single mobile crane on a small site or oversee complex lifting programs across multiple projects, this SOP provides a repeatable, auditable method for planning and approving lifts. It reduces reliance on individual experience alone and replaces ad-hoc practices with a documented system that stands up to client, auditor, and regulator expectations.

Key Benefits

• Ensure all lifting operations are planned, risk-assessed, and documented in line with Australian WHS requirements.
• Reduce the likelihood of dropped loads, crane overturns, and collision incidents through structured lift planning and review.
• Clarify roles, responsibilities, and approval authority for lift plans, reducing confusion and delays on site.
• Standardise lift planning across projects and contractors, improving consistency, communication, and coordination.
• Provide an auditable record of planning and approvals to support incident investigations, client requirements, and regulator enquiries.

Who is this for?

• Construction Project Managers
• Site Supervisors
• Crane Coordinators
• Doggers and Riggers
• Crane Operators
• WHS Managers
• Engineering Managers
• Operations Managers
• Facilities and Maintenance Managers
• Principal Contractors

Hazards Addressed

• Crane overturning or structural failure due to inadequate ground or load assessment
• Dropped loads from incorrect rigging, sling selection, or load estimation
• Collision with structures, services, or plant during slewing or load travel
• Contact with overhead or underground electrical services
• Personnel struck by moving loads or crane components
• Uncontrolled lifts in high winds or adverse weather conditions
• Equipment failure from overloading or using unsuitable lifting accessories
• Traffic and pedestrian interface risks around lifting exclusion zones
• Communication failures between crane operators, doggers, riggers, and spotters

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (Lift Types, Critical Lifts, High-Risk Work)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Pre-Lift Planning Requirements and Triggers for a Formal Lift Plan
• 5.0 Site and Ground Condition Assessment
• 6.0 Load Assessment, Centre of Gravity and Rigging Selection
• 7.0 Crane Selection, Configuration and Capacity Verification
• 8.0 Development of the Lift Plan (Diagrams, Lift Path and Exclusion Zones)
• 9.0 Risk Assessment and Control Measures for Lifting Operations
• 10.0 Communication Protocols, Signalling and Lift Coordination
• 11.0 Lift Plan Review, Approval and Authorisation Process
• 12.0 Management of Change for Variations to Approved Lift Plans
• 13.0 Pre-Lift Briefing and Toolbox Talk Requirements
• 14.0 Monitoring, Supervision and Documentation During the Lift
• 15.0 Post-Lift Review, Sign-Off and Record Keeping
• 16.0 Training, Competency and Verification of Qualifications
• 17.0 Emergency Response and Incident Management for Lift Failures
• 18.0 Audit, Review and Continuous Improvement of Lift Planning Process

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (particularly provisions for high risk work and plant)
• Safe Work Australia – Managing the Risk of Plant in the Workplace: Code of Practice
• Safe Work Australia – Construction Work: Code of Practice
• Safe Work Australia – Managing Risks of Cranes in the Workplace: Code of Practice
• AS 2550 series: Cranes, hoists and winches – Safe use
• AS 1418 series: Cranes, hoists and winches – Design, testing and commissioning
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)
• ISO 45001: Occupational health and safety management systems (where adopted by the organisation)