Product Overview

Summary: This Rigging and Mast Erection Safe Operating Procedure provides a clear, step-by-step framework for planning and executing mast erection tasks safely on Australian worksites. It helps businesses control the significant risks associated with lifting operations, suspended loads and working at height, while supporting compliance with WHS legislation and industry best practice.

Rigging and mast erection work involves high-risk activities such as lifting heavy components, working with cranes and hoists, and assembling structures at height. Without a structured procedure, businesses are exposed to serious incidents including dropped objects, structural collapse, equipment failure and falls from height. This Safe Operating Procedure sets out a practical, repeatable method for planning and carrying out rigging and mast erection tasks, from initial site assessment and lift planning through to installation, securing, inspection and demobilisation.

Developed for Australian conditions and WHS expectations, this SOP helps duty holders demonstrate due diligence when managing high-risk construction work. It supports safe coordination between riggers, doggers, crane operators and site supervisors, ensuring everyone understands their role, the communication protocols, exclusion zones, and emergency arrangements. By implementing this SOP, organisations can reduce the likelihood of serious injuries, protect critical assets and avoid costly delays, rework and regulatory action arising from non-compliant rigging and mast erection activities.

Key Benefits

• Ensure high-risk rigging and mast erection work is planned, authorised and executed in line with Australian WHS requirements.
• Reduce the risk of dropped objects, structural instability and equipment failure during lifting and erection activities.
• Standardise communication, signalling and coordination between riggers, doggers, crane operators and site management.
• Demonstrate due diligence to regulators, clients and principal contractors through documented safe work processes.
• Improve efficiency on site by providing clear, step-by-step instructions, checklists and pre-start requirements for each job.

Who is this for?

• Riggers
• Doggers
• Crane Operators
• Telecommunications Tower Technicians
• Construction Site Supervisors
• Project Engineers
• WHS Managers and Advisors
• Event and Staging Crew Leaders
• Maintenance Supervisors
• Principal Contractors

Hazards Addressed

• Falling objects from lifted or partially erected masts
• Structural collapse or instability of masts, guy wires and temporary supports
• Crush and pinch injuries from moving loads, rigging gear and crane slewing
• Falls from height during mast assembly, climbing or connection of components
• Failure or misuse of lifting gear, slings, shackles and attachment points
• Uncontrolled movement of loads due to wind, poor rigging configuration or inadequate tag lines
• Electrocution from contact or arcing with overhead powerlines
• Manual handling injuries from handling sections, braces and rigging equipment
• Environmental hazards such as high winds, lightning and poor ground conditions affecting stability
• Communication failures between riggers, doggers and crane operators leading to unsafe lifts

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Applicable Legislation, Standards and References
• 4.0 Roles, Responsibilities and Competency Requirements (including High Risk Work licences)
• 5.0 Pre-Planning and Risk Assessment (JSA/SWMS, lift studies, engineering requirements)
• 6.0 Site Assessment and Preparation (ground conditions, access, exclusion zones, utilities)
• 7.0 Equipment Selection, Inspection and Maintenance (cranes, lifting gear, mast components, fall protection)
• 8.0 Rigging Plan and Mast Erection Methodology
• 9.0 Step-by-Step Operating Procedure – Mast Erection and Securing
• 10.0 Working at Height and Fall Protection Requirements
• 11.0 Communication, Signalling and Permit-to-Work Requirements
• 12.0 Weather, Environmental and Ground Condition Controls
• 13.0 Hazard Identification and Control Measures (dropped objects, powerlines, structural stability)
• 14.0 Emergency Preparedness and Rescue Procedures (including working at height rescue)
• 15.0 Post-Erection Inspection, Testing and Handover
• 16.0 Demobilisation, De-rigging and Site Restoration
• 17.0 Training, Induction and Competency Verification
• 18.0 Recordkeeping, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and corresponding state and territory WHS Acts)
• Work Health and Safety Regulations 2011 – High Risk Work, Construction Work and Plant chapters
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Construction Work
• AS 2550 series: Cranes, hoists and winches – Safe use
• AS 4991: Lifting devices
• AS 1891 series: Industrial fall-arrest systems and devices
• AS/NZS 1891.4: Industrial fall-arrest systems and devices – Selection, use and maintenance
• AS/NZS 1576 series: Scaffolding (where temporary access is used for mast erection)
• AS 4100: Steel structures (where applicable to mast design and erection)
• AS/NZS ISO 31000: Risk management – Guidelines