High Risk Work Licence - Slewing Mobile Crane C0 (over 100t) cheat sheet

A high risk work licence for slewing mobile crane (C0) authorises operation of slewing mobile cranes with a rated capacity over 100 tonnes; the licence class is tied to the crane capacity, not the task.

Primary duty holders under WHS law: the person conducting a business or undertaking (PCBU) holds the primary duty of care; officers hold due diligence duties; workers must take reasonable care of themselves and others and follow reasonable instructions.

The hierarchy of control ranks elimination, substitution, isolation, engineering controls, administrative controls and PPE in descending effectiveness; PPE is the last line only.

A safe work method statement is required for high risk construction work; lifting operations involving cranes are declared high risk construction work in most jurisdictions.

Duty to consult: the PCBU must consult workers and their representatives on matters that affect health and safety, including lift planning and changes to plant or procedures.

Notifiable incidents include death, serious injury or illness, and dangerous incidents such as plant collapse, load drop, or uncontrolled crane movement; notification must be made to the regulator immediately.

Licences must be carried or made available for inspection; operating outside the class or with a suspended licence is an offence.

Design registration and plant registration obligations apply to certain cranes; mobile cranes above specified capacities may require design or item registration depending on jurisdiction.

Records that must be kept include lift studies, maintenance and inspection records, competency evidence, and incident reports; retention periods are set by regulation.

Risk score = likelihood × consequence; controls are applied in hierarchy order and residual risk is re-assessed after each control.

Common crane hazards: contact with powerlines, crane overturning, structural failure, load drop, crush zones, wind, poor ground, blind lifts, and personnel in the slew radius.

Exclusion zones are defined by the greater of the swing radius, the fall zone of a dropped load, or the calculated drop radius from the boom tip.

Wind limits are set by the manufacturer in the load chart; capacity reductions apply above the charted wind speed, and the load's sail area increases wind loading.

Powerline hazards: identify voltage and approach limits, use spotter, and where possible de-energise or isolate; the safe approach distance increases with voltage.

Environmental hazards include heat, cold, lightning, poor visibility and glare; each requires a specific control in the lift plan.

Hazard identification must consider the full lift cycle: set-up, rigging, lift, travel, placement, and pack-up, not only the lift itself.

A hazard and risk register should be reviewed whenever site conditions, personnel, plant, or the load change.

Load charts are configuration-specific: boom length, boom angle or radius, counterweight, outrigger spread, jib configuration and counterweight all change capacity.

Rated capacity = the chart value for the given radius and configuration; the actual capacity is the chart value minus deductions for hook block, slings, and any attached jib or fly.

Radius is measured from the slewing centre to the centre of gravity of the load, not to the hook or the boom tip.

Structural limits and stability limits both apply; the chart reflects the lesser of the two, and the operator must know which governs at the current radius.

Boom deflection increases radius under load; for long booms, chart values account for deflection, but the operator must still verify actual radius.

Deductions from the chart include the mass of the hook block, slings, spreader beams, and any jib or fly section; these are subtracted before the net load is lifted.

Cranes over 100t typically use multiple boom sections, luffing jibs and variable counterweight; each configuration has a separate chart section and must be verified before use.

The load chart in the cab must match the crane's serial number and current configuration; charts for other configurations are not valid.

Area of operation and slew restrictions may be charted; the chart may limit capacity in specific quadrants or over the front or side.

Sling tension = load / (number of legs × cos of the angle from vertical); the included angle between legs increases tension as the angle widens.

Working load limit (WLL) is the maximum mass a sling or fitting may lift in a specified configuration; the WLL must be at least equal to the calculated tension.

Sling angle factor: at 0° from vertical the factor is 1.0; at 30° it is 1.15; at 45° it is 1.41; at 60° it is 2.0.

Load estimation: mass = volume × density; steel is about 7,850 kg/m³, concrete about 2,400 kg/m³, water 1,000 kg/m³, and timber varies by species.

Centre of gravity must be identified and the load rigged so the hook is directly above it; an off-centre lift causes load shift and unequal sling tension.

Tag lines control rotation and swing but must not be used to restrain a load that is beyond the crane's capacity.

Shackles, hooks, and master links must be rated, inspected, and matched to the sling; the assembly's WLL is the lowest-rated component.

Synthetic slings must be protected from sharp edges and heat; wire rope slings must be inspected for broken wires, kinks, and corrosion before use.

A trial lift of a few centimetres verifies rigging, load balance, and brake performance before the main lift.

Ground bearing pressure under each outrigger = total load on that outrigger divided by the effective pad area; the pad must spread the load to below the ground's bearing capacity.

Outrigger loads are not equal; the maximum load occurs on the outrigger nearest the load and can be several times the average.

Pad size must be calculated from the crane's maximum outrigger load and the verified ground bearing capacity, not assumed from a standard pad.

Ground bearing capacity must be verified by geotechnical assessment or plate load testing for soft, filled, or previously excavated ground.

Set-up requires the crane level within the manufacturer's tolerance; outriggers fully extended and pinned, with pads on stable bearing.

Underground services, basements, drains, and voids must be identified before outrigger placement; a void under a pad can cause collapse.

The crane must be positioned so the load can be placed within the charted radius without exceeding capacity at any point in the slew.

Access and egress for the crane, delivery vehicles, and emergency services must be maintained and the set-up area barricaded.

A lift plan documents the load, its mass and centre of gravity, the crane configuration, the chart used, the radius, the rigging, the personnel, and the controls.

A critical lift is one with high consequence or complexity: loads near capacity, multi-crane lifts, lifts over live plant or personnel, or lifts of unusual or unstable loads.

Multi-crane lift load share is not automatically equal; the share depends on the geometry, the rigging, and the relative height of the hooks.

For a two-crane lift, the load on each crane must not exceed 75% of its charted capacity at the working radius, and the load must be kept level.

The lift director is the single authority for the lift; all signals and decisions pass through the lift director and the designated signal person.

The load must be kept within the charted radius throughout the lift; boom deflection, wind, and slew can change the actual radius.

Travel with a suspended load is prohibited unless the load chart and lift plan permit it and the path is controlled.

The lift must be stopped if wind exceeds the charted limit, if the load becomes unstable, or if any person enters the exclusion zone.

Standard hand signals are used when radio communication is unavailable or fails; the signal person must be clearly visible to the operator.

Only one signal person directs the operator at a time; a change of signal person must be communicated to the operator before control passes.

Radio communication uses a dedicated channel; the operator must confirm each command and stop the lift if communication is unclear.

The emergency stop signal is a single sharp movement of the hand or arm across the body, or the word 'stop' by radio, and must be obeyed immediately.

Pre-lift briefing covers roles, signals, exclusion zones, emergency procedures, and the sequence of the lift for all personnel.

The dogger/rigger and the operator confirm the load, radius, and rigging before the lift; the operator does not lift until the rigger signals ready.

Blind lifts require a signal person positioned to see both the load and the operator, or a documented alternative such as cameras or radio relays.

Team roles must be clear: lift director, operator, rigger, signal person, and spotter each have defined responsibilities.

Pre-start inspection covers tyres, outriggers, boom, wire rope, hook, brakes, limit switches, alarms, and load moment indicator function.

Wire rope must be inspected for broken wires, corrosion, kinks, bird-caging, and diameter reduction; discard criteria are set by the manufacturer and standards.

The load moment indicator and rated capacity limiter must be tested and functional before each lift; a faulty unit means the crane is out of service.

Maintenance is performed to the manufacturer's schedule; records must be kept and made available for inspection.

A defect that affects safe operation must be reported, the crane tagged out, and the defect rectified and verified before return to service.

Daily, periodic, and major inspections have different intervals and scope; the operator performs the pre-start check, while competent persons perform periodic inspections.

Hooks must have a functioning latch and be free of cracks, deformation, or excessive throat opening; hook wear limits are specified by the manufacturer.

Outrigger beams, pads, and hydraulic systems must be checked for leaks, cracks, and full extension before set-up.

If the load becomes uncontrollable, lower it to a safe location if possible; if not, clear the exclusion zone and stop the crane.

In a powerline contact, the operator stays in the cab and warns others to stay clear; if evacuation is necessary, jump clear and shuffle away without touching the crane and ground simultaneously.

If the crane becomes unstable or an outrigger sinks, stop the lift, lower the load if possible, and evacuate the area; do not attempt to slew or travel.

Fire response: isolate the fuel and electrical systems, use the appropriate extinguisher, and evacuate to the assembly point.

Incident response includes making the area safe, preserving the scene, notifying the regulator where required, and recording statements and evidence.

Emergency lowering procedures must be known before the lift; the operator must know how to lower a load with a failed power source.

Shutdown procedure: land the load, retract the boom, stow the jib, set the park brake, lower outriggers, and isolate the crane.

Post-incident, the crane must not be returned to service until inspected and cleared by a competent person.

Operating rules: never exceed the charted capacity, never bypass the load moment indicator, and never lift personnel unless the crane and procedure are approved for it.

Smooth control inputs reduce load swing and dynamic amplification; sudden starts and stops increase the effective load on the crane and rigging.

The load must be kept within the charted radius and clear of obstructions; the operator monitors the load moment indicator throughout the lift.

At the end of the lift, land the load, release the rigging, and confirm the load is stable and supported before removing slings.

Shutdown: park on stable ground, apply the park brake, retract and stow the boom, secure the jib, and lower the outriggers or fit the travel configuration.

Post-operational checks include fuel, hydraulic leaks, tyre condition, and reporting of any defects found during the shift.

The crane is isolated and keys secured where required; the next operator receives a handover of any defects or restrictions.

Records of the shift, defects, and any incidents are completed and filed before leaving site.

A high risk work licence for slewing mobile crane (C0) authorises operation of slewing mobile cranes with a rated capacity over 100 tonnes; the licence class is tied to the crane capacity, not the task.

Primary duty holders under WHS law: the person conducting a business or undertaking (PCBU) holds the primary duty of care; officers hold due diligence duties; workers must take reasonable care of themselves and others and follow reasonable instructions.

The hierarchy of control ranks elimination, substitution, isolation, engineering controls, administrative controls and PPE in descending effectiveness; PPE is the last line only.

A safe work method statement is required for high risk construction work; lifting operations involving cranes are declared high risk construction work in most jurisdictions.

Duty to consult: the PCBU must consult workers and their representatives on matters that affect health and safety, including lift planning and changes to plant or procedures.

Notifiable incidents include death, serious injury or illness, and dangerous incidents such as plant collapse, load drop, or uncontrolled crane movement; notification must be made to the regulator immediately.

Licences must be carried or made available for inspection; operating outside the class or with a suspended licence is an offence.

Design registration and plant registration obligations apply to certain cranes; mobile cranes above specified capacities may require design or item registration depending on jurisdiction.

Records that must be kept include lift studies, maintenance and inspection records, competency evidence, and incident reports; retention periods are set by regulation.

Risk score = likelihood × consequence; controls are applied in hierarchy order and residual risk is re-assessed after each control.

Common crane hazards: contact with powerlines, crane overturning, structural failure, load drop, crush zones, wind, poor ground, blind lifts, and personnel in the slew radius.

Exclusion zones are defined by the greater of the swing radius, the fall zone of a dropped load, or the calculated drop radius from the boom tip.

Wind limits are set by the manufacturer in the load chart; capacity reductions apply above the charted wind speed, and the load's sail area increases wind loading.

Powerline hazards: identify voltage and approach limits, use spotter, and where possible de-energise or isolate; the safe approach distance increases with voltage.

Environmental hazards include heat, cold, lightning, poor visibility and glare; each requires a specific control in the lift plan.

Hazard identification must consider the full lift cycle: set-up, rigging, lift, travel, placement, and pack-up, not only the lift itself.

A hazard and risk register should be reviewed whenever site conditions, personnel, plant, or the load change.

Load charts are configuration-specific: boom length, boom angle or radius, counterweight, outrigger spread, jib configuration and counterweight all change capacity.

Rated capacity = the chart value for the given radius and configuration; the actual capacity is the chart value minus deductions for hook block, slings, and any attached jib or fly.

Radius is measured from the slewing centre to the centre of gravity of the load, not to the hook or the boom tip.

Structural limits and stability limits both apply; the chart reflects the lesser of the two, and the operator must know which governs at the current radius.

Boom deflection increases radius under load; for long booms, chart values account for deflection, but the operator must still verify actual radius.

Deductions from the chart include the mass of the hook block, slings, spreader beams, and any jib or fly section; these are subtracted before the net load is lifted.

Cranes over 100t typically use multiple boom sections, luffing jibs and variable counterweight; each configuration has a separate chart section and must be verified before use.

The load chart in the cab must match the crane's serial number and current configuration; charts for other configurations are not valid.

Area of operation and slew restrictions may be charted; the chart may limit capacity in specific quadrants or over the front or side.

Sling tension = load / (number of legs × cos of the angle from vertical); the included angle between legs increases tension as the angle widens.

Working load limit (WLL) is the maximum mass a sling or fitting may lift in a specified configuration; the WLL must be at least equal to the calculated tension.

Sling angle factor: at 0° from vertical the factor is 1.0; at 30° it is 1.15; at 45° it is 1.41; at 60° it is 2.0.

Load estimation: mass = volume × density; steel is about 7,850 kg/m³, concrete about 2,400 kg/m³, water 1,000 kg/m³, and timber varies by species.

Centre of gravity must be identified and the load rigged so the hook is directly above it; an off-centre lift causes load shift and unequal sling tension.

Tag lines control rotation and swing but must not be used to restrain a load that is beyond the crane's capacity.

Shackles, hooks, and master links must be rated, inspected, and matched to the sling; the assembly's WLL is the lowest-rated component.

Synthetic slings must be protected from sharp edges and heat; wire rope slings must be inspected for broken wires, kinks, and corrosion before use.

A trial lift of a few centimetres verifies rigging, load balance, and brake performance before the main lift.

Ground bearing pressure under each outrigger = total load on that outrigger divided by the effective pad area; the pad must spread the load to below the ground's bearing capacity.

Outrigger loads are not equal; the maximum load occurs on the outrigger nearest the load and can be several times the average.

Pad size must be calculated from the crane's maximum outrigger load and the verified ground bearing capacity, not assumed from a standard pad.

Ground bearing capacity must be verified by geotechnical assessment or plate load testing for soft, filled, or previously excavated ground.

Set-up requires the crane level within the manufacturer's tolerance; outriggers fully extended and pinned, with pads on stable bearing.

Underground services, basements, drains, and voids must be identified before outrigger placement; a void under a pad can cause collapse.

The crane must be positioned so the load can be placed within the charted radius without exceeding capacity at any point in the slew.

Access and egress for the crane, delivery vehicles, and emergency services must be maintained and the set-up area barricaded.

A lift plan documents the load, its mass and centre of gravity, the crane configuration, the chart used, the radius, the rigging, the personnel, and the controls.

A critical lift is one with high consequence or complexity: loads near capacity, multi-crane lifts, lifts over live plant or personnel, or lifts of unusual or unstable loads.

Multi-crane lift load share is not automatically equal; the share depends on the geometry, the rigging, and the relative height of the hooks.

For a two-crane lift, the load on each crane must not exceed 75% of its charted capacity at the working radius, and the load must be kept level.

The lift director is the single authority for the lift; all signals and decisions pass through the lift director and the designated signal person.

The load must be kept within the charted radius throughout the lift; boom deflection, wind, and slew can change the actual radius.

Travel with a suspended load is prohibited unless the load chart and lift plan permit it and the path is controlled.

The lift must be stopped if wind exceeds the charted limit, if the load becomes unstable, or if any person enters the exclusion zone.

Standard hand signals are used when radio communication is unavailable or fails; the signal person must be clearly visible to the operator.

Only one signal person directs the operator at a time; a change of signal person must be communicated to the operator before control passes.

Radio communication uses a dedicated channel; the operator must confirm each command and stop the lift if communication is unclear.

The emergency stop signal is a single sharp movement of the hand or arm across the body, or the word 'stop' by radio, and must be obeyed immediately.

Pre-lift briefing covers roles, signals, exclusion zones, emergency procedures, and the sequence of the lift for all personnel.

The dogger/rigger and the operator confirm the load, radius, and rigging before the lift; the operator does not lift until the rigger signals ready.

Blind lifts require a signal person positioned to see both the load and the operator, or a documented alternative such as cameras or radio relays.

Team roles must be clear: lift director, operator, rigger, signal person, and spotter each have defined responsibilities.

Pre-start inspection covers tyres, outriggers, boom, wire rope, hook, brakes, limit switches, alarms, and load moment indicator function.

Wire rope must be inspected for broken wires, corrosion, kinks, bird-caging, and diameter reduction; discard criteria are set by the manufacturer and standards.

The load moment indicator and rated capacity limiter must be tested and functional before each lift; a faulty unit means the crane is out of service.

Maintenance is performed to the manufacturer's schedule; records must be kept and made available for inspection.

A defect that affects safe operation must be reported, the crane tagged out, and the defect rectified and verified before return to service.

Daily, periodic, and major inspections have different intervals and scope; the operator performs the pre-start check, while competent persons perform periodic inspections.

Hooks must have a functioning latch and be free of cracks, deformation, or excessive throat opening; hook wear limits are specified by the manufacturer.

Outrigger beams, pads, and hydraulic systems must be checked for leaks, cracks, and full extension before set-up.

If the load becomes uncontrollable, lower it to a safe location if possible; if not, clear the exclusion zone and stop the crane.

In a powerline contact, the operator stays in the cab and warns others to stay clear; if evacuation is necessary, jump clear and shuffle away without touching the crane and ground simultaneously.

If the crane becomes unstable or an outrigger sinks, stop the lift, lower the load if possible, and evacuate the area; do not attempt to slew or travel.

Fire response: isolate the fuel and electrical systems, use the appropriate extinguisher, and evacuate to the assembly point.

Incident response includes making the area safe, preserving the scene, notifying the regulator where required, and recording statements and evidence.

Emergency lowering procedures must be known before the lift; the operator must know how to lower a load with a failed power source.

Shutdown procedure: land the load, retract the boom, stow the jib, set the park brake, lower outriggers, and isolate the crane.

Post-incident, the crane must not be returned to service until inspected and cleared by a competent person.

Operating rules: never exceed the charted capacity, never bypass the load moment indicator, and never lift personnel unless the crane and procedure are approved for it.

Smooth control inputs reduce load swing and dynamic amplification; sudden starts and stops increase the effective load on the crane and rigging.

The load must be kept within the charted radius and clear of obstructions; the operator monitors the load moment indicator throughout the lift.

At the end of the lift, land the load, release the rigging, and confirm the load is stable and supported before removing slings.

Shutdown: park on stable ground, apply the park brake, retract and stow the boom, secure the jib, and lower the outriggers or fit the travel configuration.

Post-operational checks include fuel, hydraulic leaks, tyre condition, and reporting of any defects found during the shift.

The crane is isolated and keys secured where required; the next operator receives a handover of any defects or restrictions.

Records of the shift, defects, and any incidents are completed and filed before leaving site.