Product Overview

Summary: This Rig Setup and Installation Safe Operating Procedure provides a clear, step-by-step framework for safely assembling, positioning and commissioning rigs on Australian worksites. It helps organisations control high-risk activities such as lifting, working at height and energy isolation, while maintaining productivity and complying with WHS obligations.

Rig setup and installation is one of the most critical phases of any drilling or rig-based operation. Whether the rig is used for geotechnical investigations, mining and resources, civil construction, piling or exploration, the process of transporting, positioning, stabilising and commissioning the rig exposes workers to significant hazards. This SOP provides a structured, defensible method for planning and executing rig setup activities so they are carried out safely, consistently and in line with Australian WHS expectations.

The document walks your team through the entire lifecycle of rig installation, from pre-start planning and site assessment, to exclusion zone establishment, lifting and cranage, anchoring and stabilisation, connection of services, pre-operational checks and sign‑off. It clarifies roles and responsibilities between the principal contractor, rig owner, operator and support personnel, and embeds risk assessment, permit-to-work and isolation requirements into the process. By implementing this SOP, businesses can reduce the likelihood of rig tip-overs, struck-by incidents, equipment damage and unplanned downtime, while demonstrating due diligence to regulators, clients and auditors.

Designed specifically for Australian conditions and regulatory frameworks, this SOP supports organisations operating in remote, urban and brownfield sites alike. It is particularly valuable for companies scaling up operations, onboarding new crews or standardising practices across multiple projects or states, ensuring that every rig is set up and installed to a consistent, auditable standard before drilling or production begins.

Key Benefits

• Reduce the risk of rig tip-over, collapse and loss of control during setup and installation.
• Ensure compliance with Australian WHS legislation, site rules and client requirements for high-risk work.
• Standardise rig setup practices across crews, shifts and locations to improve consistency and quality.
• Minimise equipment damage, unplanned downtime and costly rework caused by poor initial installation.
• Improve onboarding and competency of new rig operators and offsiders through clear, step-by-step guidance.

Who is this for?

• Drilling Supervisors
• Rig Managers
• Site Supervisors
• WHS Advisors and HSE Managers
• Construction Project Managers
• Maintenance Supervisors
• Drillers and Offsiders
• Mechanical Fitters
• Geotechnical Engineers
• Mining and Resources Operations Managers

Hazards Addressed

• Rig instability, tipping or collapse due to inadequate ground conditions or incorrect stabilisation
• Crush and pinch injuries during mast raising, lowering and component assembly
• Struck-by incidents from swinging loads, moving rigs or falling tools and equipment
• Falls from height when accessing platforms, masts or elevated work areas
• Contact with overhead or underground services, including powerlines and buried utilities
• Uncontrolled movement of vehicles and plant in the rig setup exclusion zone
• Manual handling injuries from lifting and positioning heavy components or tooling
• Exposure to noise, dust, vibration and diesel emissions during installation activities
• Uncontrolled release of stored energy (hydraulic, pneumatic, mechanical or electrical) during commissioning
• Environmental incidents from fuel, oil or hydraulic fluid spills during setup

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Rig Types Covered
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Site Requirements
• 5.0 Pre-Planning and Risk Assessment (JSA/SWMS)
• 6.0 Site Assessment and Ground Condition Verification
• 7.0 Traffic Management and Exclusion Zone Setup
• 8.0 Pre-Start Inspections and Documentation Checks
• 9.0 Delivery, Positioning and Mobilisation of the Rig
• 10.0 Lifting, Assembly and Mast Raising Procedures
• 11.0 Stabilisation, Outriggers, Anchoring and Level Verification
• 12.0 Connection of Services (Power, Air, Water, Hydraulic, Fuel)
• 13.0 Working at Height Controls and Access Systems
• 14.0 Lockout/Tagout and Stored Energy Controls During Setup
• 15.0 Pre-Operational Functional Testing and Commissioning
• 16.0 Environmental Protection Measures (Spill Prevention and Response)
• 17.0 Emergency Procedures During Setup and Installation
• 18.0 Handover, Sign-Off and Documentation Requirements
• 19.0 Training, Induction and Competency Verification
• 20.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (Cth and relevant state/territory variants)
• Safe Work Australia – Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Falls at Workplaces
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Excavation Work (for underground services and ground conditions)
• AS 2550 series: Cranes, hoists and winches – Safe use (where cranage is used to position rig components)
• AS/NZS 3000: Electrical installations (Wiring Rules) – for electrical connection requirements
• AS 1891 series: Industrial fall-arrest systems and devices
• AS/NZS 45001: Occupational health and safety management systems – Requirements with guidance for use