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Complex Lifting and Tandem Lifts Risk Assessment

Complex Lifting and Tandem Lifts Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
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Complex Lifting and Tandem Lifts Risk Assessment

Product Overview

Identify and control organisational risks associated with Complex Lifting and Tandem Lifts through a structured, management-level WHS Risk Management approach that focuses on planning, governance, competency and systems. This Risk Assessment supports compliance with the WHS Act, strengthens Due Diligence for Officers, and helps protect your business from operational and legal liability arising from high-risk lifting operations.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, WHS Duties & Lift Authorisation: Assessment of officer due diligence, PCBU responsibilities, formal lift authorisation processes and documentation of roles, responsibilities and accountabilities for complex and tandem lifts.
  • Complex Lift Planning & Engineering Assessment: Management of pre-lift engineering reviews, stability and load path analysis, centre-of-gravity calculations and verification of lift feasibility under worst-case conditions.
  • Lift Plan Documentation & Change Management: Protocols for developing, reviewing and approving complex lift plans, version control, change management, and ensuring field execution matches approved documentation.
  • Crane & Lifting Equipment Selection and Procurement: Assessment of crane capacity selection, configuration, derating for tandem lifts, rigging gear specification, procurement controls and alignment with manufacturer requirements.
  • Maintenance, Inspection & Certification Systems: Management of inspection schedules, pre-use checks, third-party certifications, record keeping and defect rectification for cranes, lifting gear and rigging equipment.
  • Competency, Licensing & Training: Evaluation of high-risk work licensing, verification of competency, supervision levels and targeted training for complex lifts, tandem lifts and specialised rigging operations.
  • Communication, Coordination & Lift Supervision: Controls for pre-lift briefings, communication protocols (including radios and hand signals), appointment of lift supervisors and coordination between multiple crane crews.
  • Work Environment, Site Layout & Exclusion Zones: Management of ground conditions, crane set-up locations, traffic interfaces, public protection, exclusion zone design and control of non-essential personnel.
  • Operation Near Overhead & Underground Services: Assessment of risks associated with power lines, underground services, service location verification, no-go zones and liaison with utility providers.
  • Synchronisation of Crane Movements & Tandem Lift Coordination: Protocols for coordinated movements, load sharing, speed control, sequencing, and contingency arrangements if synchronisation is lost.
  • Critical Lifting with Winches, Hoists & Specialised Rigging: Management of non-standard lifting configurations, specialised rigging assemblies, winch and hoist operations, and verification of engineered lift points.
  • Managing Mid-Lift Alterations & Abnormal Situations: Assessment of controls for pausing lifts, re-engineering during execution, dealing with stuck or swinging loads, and criteria for aborting lifts safely.
  • Fatigue, Work Scheduling & Human Factors: Controls for shift length, night work, environmental stressors, cognitive load on operators and doggers, and human error in high-consequence lifting tasks.
  • Emergency Preparedness & Incident Response: Planning for dropped loads, crane instability, power line contact, rescue procedures, emergency communications and post-incident investigation.
  • Contractor & Supplier Management for Lifting Operations: Systems for prequalification, verification of third-party procedures, interface management between principal contractor and crane provider, and performance monitoring.

Who is this for?

This Risk Assessment is designed for Business Owners, Project Directors, Construction Managers, Crane Company Managers and Safety Professionals responsible for planning, authorising and overseeing complex lifting and tandem lift operations.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Lift Authorisation
  • • Lack of clear allocation of WHS duties between PCBU, principal contractor, crane company and dogging/rigging subcontractors
  • • Inadequate organisational policy defining what constitutes a complex, critical or tandem lift
  • • Complex lifting activities proceeding without formal written authorisation from competent management
  • • Failure to consult, cooperate and coordinate activities between multiple PCBUs as required under WHS Act 2011
  • • Inadequate oversight by officers to exercise due diligence in relation to complex lifting risks
  • • Commercial pressures overriding safety decisions (e.g. proceeding despite incomplete documentation or controls)
2. Complex Lift Planning and Engineering Assessment
  • • Complex lifts being treated as routine lifts without appropriate planning depth
  • • Lack of formal engineering assessment for unusual loads, off‑centre of gravity items or non‑standard lifting points
  • • Inaccurate or incomplete information about load weight, geometry, centre of gravity and lifting parameters
  • • Failure to consider dynamic loading, load sharing and potential shock loading in planning phase
  • • Inadequate review of environmental factors such as ground conditions, wind, obstructions and proximity to structures
  • • Complex lifts undertaken without a formal documented Complex Lifting Plan or Lift Study
3. Complex Lifting Plan Documentation and Change Management
  • • Complex lifting activities proceeding based on verbal instructions without written plans
  • • Use of outdated or superseded versions of the Complex Lifting Plan on site
  • • Uncontrolled alterations to lifting configuration, crane models or rigging gear without formal review
  • • Failure to document and manage mid‑lift variations when site conditions differ from the plan
  • • Inadequate distribution and briefing of the Complex Lifting Plan to key personnel
  • • Poor traceability of approvals and changes for auditing and incident investigation
4. Crane and Lifting Equipment Selection and Procurement
  • • Selection of cranes or lifting equipment that are unsuitable for complex or tandem lift requirements
  • • Use of cranes without appropriate load moment indicators, rated capacity limiters or anti‑collision systems
  • • Insufficient capacity margins for cranes operating near their working load limits during complex lifts
  • • Incompatibility between cranes used in multiple crane or tandem lifts (e.g. differing performance curves or response characteristics)
  • • Procurement decisions based on cost rather than technical suitability and WHS risk
  • • Inadequate verification of third‑party crane and equipment certification prior to mobilisation
5. Maintenance, Inspection and Certification Systems
  • • Inadequate maintenance regimes leading to failure of cranes, winches, hoists or rigging during complex lifts
  • • Expired or missing inspection certificates for cranes, lifting gear, spreader beams and specialised attachments
  • • Reliance on informal or undocumented pre‑operational checks by operators only
  • • Failure to remove damaged or non‑conforming lifting equipment from service
  • • Poor management of inspection intervals for high‑duty or critical lifting components
  • • Lack of traceability for equipment defect reporting and rectification
6. Competency, Licensing and Training for Complex and Tandem Lifts
  • • Crane operators, doggers and riggers holding licences but lacking specific experience in complex or tandem lifts
  • • Inadequate training in synchronisation of crane movements and load sharing principles
  • • Supervisors and engineers not fully understanding the practical limitations of lifting equipment and personnel
  • • Lack of formal verification of competency for high‑risk work such as crane operation near power lines and critical lifting with winches and hoists
  • • Reliance on informal on‑the‑job training without structured assessment
  • • Insufficient training in emergency response during complex lifts, including mid‑lift failures
7. Communication, Coordination and Lift Supervision
  • • Poor communication between multiple crane operators, riggers, doggers and spotters during complex and tandem lifts
  • • Absence of a dedicated lift supervisor or lift director for critical operations
  • • Inconsistent use of radio channels, hand signals and terminology, leading to misinterpretation
  • • Simultaneous operations in the vicinity of the lift causing distraction or conflicting priorities
  • • No structured pre‑lift coordination meetings or toolbox talks for complex lifts
  • • Lack of escalation pathways when disagreements about safety arise
8. Work Environment, Site Layout and Exclusion Zones
  • • Inadequate planning of crane locations leading to encroachment on unstable ground, services or structures
  • • Insufficient exclusion zones around cranes, suspended loads and swing paths
  • • Uncontrolled public or worker access into high‑risk lifting areas
  • • Overhead hazards such as structures, scaffolding, lighting or trees not considered in layout planning
  • • Congested work areas causing interference between multiple cranes, plant and vehicles
  • • Poor lighting or visibility during early morning, night or adverse weather lifts
9. Operation Near Overhead and Underground Services (Including Power Lines)
  • • Unidentified or poorly mapped overhead power lines and underground services in or near crane operating envelope
  • • Failure to maintain statutory approach distances to energised electrical assets during crane operation
  • • Inadequate control of load drift or boom deflection causing unplanned encroachment into exclusion zones
  • • Lack of formal consultation with asset owners or network operators regarding nearby services
  • • Reliance on informal spotters without specific power line safety training
  • • No contingency planning for power line contact or service strikes
10. Synchronisation of Crane Movements and Tandem Lift Coordination
  • • Unequal load sharing between cranes in a tandem or multiple crane lift due to poor synchronisation
  • • Uncoordinated crane movements resulting in side loading, overload or instability
  • • Inadequate monitoring of individual crane loads in real time during the lift
  • • Differences in crane response times, configuration or control systems not accounted for
  • • Lack of rehearsals or dry‑runs for complex synchronised movements
  • • Insufficient procedures for controlled stopping, holding and restarting during multi‑crane operations
11. Critical Lifting Using Winches, Hoists and Specialised Rigging
  • • Overloading of winches, hoists or specialised rigging due to inaccurate capacity assessment
  • • Inadequate anchoring or support structures for winch bases and hoist systems
  • • Complex load paths introducing unexpected side loads or torsional forces on equipment
  • • Lack of redundancy in critical lifting arrangements where failure would have catastrophic consequences
  • • Inadequate monitoring of line tension and equipment condition during critical lifts
  • • Improvised rigging solutions not subject to engineering review
12. Managing Mid-Lift Alterations and Abnormal Situations
  • • Pressures to continue a lift when conditions change (e.g. wind increase, equipment fault, unexpected load behaviour)
  • • Ad‑hoc decisions to alter crane configuration, rigging or load path mid‑lift without engineering input
  • • Inadequate procedures for safely securing or lowering a load if a problem arises during the lift
  • • Confusion among workers about who has authority to stop, modify or abort a lift
  • • Lack of documented criteria for suspending operations when environmental or site conditions deteriorate
  • • Failure to capture and learn from near misses or abnormal events during complex lifts
13. Fatigue, Work Scheduling and Human Factors
  • • Complex lifts scheduled at times when workers are likely to be fatigued (e.g. night shift, extended overtime, consecutive long shifts)
  • • Inadequate consideration of cognitive load and stress on operators, riggers and supervisors during high‑consequence lifts
  • • Distraction, complacency or overload leading to communication errors or missed cues
  • • Pressure to accelerate lifts to meet program deadlines, reducing adherence to procedures
  • • Insufficient planning for crew rotation during lengthy or staged complex lifts
  • • Poor interface between shift handovers and ongoing lifting operations
14. Emergency Preparedness and Incident Response for Complex Lifts
  • • Lack of specific emergency response plans for scenarios such as crane failure, dropped load, power line contact or ground collapse
  • • Emergency equipment (e.g. rescue gear, spill kits, first aid) not readily available or suited to lifting‑related incidents
  • • Workers unaware of emergency roles, evacuation routes or communication procedures during a lifting emergency
  • • Delayed notification of regulators and asset owners following notifiable incidents
  • • No provision for technical support or engineering input during incident stabilisation
  • • Inadequate post‑incident review to prevent recurrence
15. Contractor and Supplier Management for Lifting Operations
  • • Engagement of crane companies or rigging contractors with inadequate WHS systems for complex lifts
  • • Misalignment between principal contractor and crane contractor procedures, resulting in gaps or conflicts
  • • Poor verification of contractor competencies, licences and equipment certifications
  • • Commercial contracting arrangements that incentivise risky behaviours (e.g. penalty clauses for delays)
  • • Insufficient monitoring of contractor performance during complex lift campaigns
  • • Lack of clarity on who controls the lifting work area and has authority over safety decisions
16. Monitoring, Audit and Continuous Improvement of Lifting Systems
  • • Static lifting procedures that are not updated in line with industry learnings, technology advancements or regulatory changes
  • • Inadequate monitoring of leading indicators such as near misses, deviations from plans and minor equipment failures
  • • Lack of systematic audits of complex lifting activities and associated management systems
  • • Data on lifting performance and incidents not analysed to identify systemic weaknesses
  • • Workers and contractors perceiving that reporting issues will lead to blame rather than improvement
  • • No structured mechanism to integrate learnings across multiple projects or sites

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Model Code of Practice – Managing the Risks of Plant in the Workplace: Guidance on controlling risks associated with cranes and lifting equipment.
  • Model Code of Practice – Construction Work: Requirements and guidance for high-risk construction work, including work involving cranes.
  • Model Code of Practice – Managing Electrical Risks in the Workplace: Controls for work near overhead and underground electrical services.
  • AS 2550 series – Cranes, Hoists and Winches – Safe Use: Operational requirements and inspection regimes for cranes and lifting equipment.
  • AS 1418 series – Cranes, Hoists and Winches – Design Requirements: Design and performance standards for cranes and associated lifting plant.
  • AS 4991 – Lifting Devices: Requirements for the design, verification and safe use of lifting devices.
  • AS 1891 series – Industrial Fall-Arrest Systems and Devices: Guidance where working at height is associated with complex lifting operations.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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