High Risk Work Licence - Slewing Mobile Crane C2 (20t) cheat sheet

A slewing mobile crane C2 licence authorises operation of a slewing mobile crane with a maximum rated capacity (MRC) up to and including 20 tonnes; cranes above 20 t require the C1 or C0 class.

The licence class is set by the crane's MRC, not by the load being lifted on the day; a 60 t crane is never a C2 machine even when lifting 5 t.

High risk work licensing operates under model WHS laws: WHS Act 2011, WHS Regulation 2011 and the Managing the Risks of Plant in the Workplace Code of Practice.

The PCBU must ensure the operator holds a current licence for the class of crane; the operator must carry the licence (or a copy) at the workplace and produce it on request.

Licences are issued for five years; renewal must be applied for before expiry, and an expired licence means the operator is unlicensed until it is reissued.

A trainee may operate only under direct supervision of a licensed operator for that class, with a log book recording supervised hours.

Regulator notifications are required for certain incidents (serious injury, dangerous incident) - the site must be preserved so far as is reasonably practicable until an inspector allows otherwise.

Safe Work Method Statements (SWMS) are mandatory for high risk construction work, and crane operation in construction is commonly designated high risk construction work.

Primary duty: a person conducting a business or undertaking must eliminate risks so far as is reasonably practicable, then minimise remaining risks with the hierarchy of controls.

AS 2550.1 (general) and AS 2550.5 (mobile cranes) set the Australian requirements for safe crane use, inspection, maintenance and operation.

AS 1418.5 covers the design and construction of mobile cranes; AS 1418.1 is the general series requirement.

Design registration and item registration apply to some plant under WHS Regulation; the crane must be registered where required and registration kept current.

Workers must take reasonable care for their own and others' safety, follow reasonable instructions and not interfere with safety devices.

The crane must not be used outside its design parameters; manufacturer's instructions and load charts are the authoritative capacity source.

A competent person is one who has the training, qualification or experience to perform the task; inspections and maintenance must be done by competent persons.

Consultation with workers is a legal duty and should cover lift planning, exclusion zones, and changes to crane configuration.

Typical hazards: powerline contact, crane overturn, load drop, crush between load and structure, wind, ground collapse, blind lifts, and personnel in the slew zone.

Hierarchy of control order: elimination, substitution, engineering controls, administrative controls, then PPE as the last line.

Risk score = likelihood × consequence; controls are applied to the highest-scoring hazards first, and residual risk is re-assessed after controls.

A lift plan must be prepared and documented for complex, critical or tandem lifts, and communicated to all personnel involved.

Exclusion zones should be set at a radius that accounts for load radius plus load swing plus a margin; persons must not enter without authorisation.

Wind speed must be checked against the manufacturer's limit for the boom/jib configuration; a load's sail area increases wind loading significantly.

Powerline clearance distances are set by state/territory rules and the crane's voltage-dependent approach limits; if in doubt, isolate or use a spotter.

Environmental hazards include slope, soft ground, excavations, underground services, overhead structures, and adjacent crane operations.

Slewing mobile crane types include truck-mounted, rough-terrain, all-terrain and crawler cranes; each has distinct travel and stability characteristics.

Rated capacity is determined by load radius, boom length, boom angle, counterweight, outrigger configuration and jib/extension setup - all read from the manufacturer's load chart.

Load radius is measured horizontally from the crane's slewing centre to the centre of gravity of the load.

Working radius increases as the boom lowers or extends; capacity falls sharply as radius increases.

The load chart capacity must be reduced for non-standard configurations (e.g., fly jib, reduced counterweight, partial outrigger extension).

Gross load includes the load, rigging, hook block, slings and any attached lifting gear; the net capacity is the gross capacity minus these deductions.

Boom deflection, wind and dynamic effects mean the working radius can exceed the static radius; always use the worst-case radius.

The crane's data plate and load chart must match the actual configuration; a missing or unreadable chart means the crane is not to be used.

Pre-start checks cover tyres, outriggers/pads, boom sections, wire rope (broken wires, kinks, corrosion, bird-caging), hook and latch, sheaves, brakes, slew ring, and safety devices.

Daily inspection records must be completed and retained; defects affecting safety must be reported and the crane taken out of service until repaired.

Wire rope discard criteria follow AS 2759/ISO 4309; broken wires in a given length, diameter reduction and corrosion determine retirement.

Safety devices to verify: load moment indicator (LMI), rated capacity limiter, anti-two-block, boom angle/radius indicator, and outrigger interlocks.

Maintenance must follow the manufacturer's schedule and be performed by competent persons; records are kept for the life of the crane.

The hook must have a functioning safety latch, no cracks, and the hook throat opening must not exceed the manufacturer's limit.

The crane must be set up on a level, stable surface with outrigger pads sized to spread the load; check for underground services before setting pads.

After any incident, overload or contact with a powerline, the crane must be inspected by a competent person before returning to service.

Sling tension in a two-leg sling: tension per leg = (load / 2) / cos(angle from vertical); the included angle between legs increases tension as it widens.

Working load limit (WLL) of a sling assembly must be at least the load being lifted; never exceed the WLL marked on the sling.

Sling angle factor: at 60° from horizontal, tension multiplier ≈ 1.155; at 45° ≈ 1.414; at 30° ≈ 2.0.

Sling configurations: single leg, two-leg, four-leg and endless; a four-leg sling is rated for only three legs carrying load in most standards.

Shackles, hooks, swivels and master links must have a marked WLL and be compatible with the sling and load.

Load centre of gravity must be below the hook; unbalanced loads require a spreader beam or multiple pick points to keep the load level.

Sharp edges, heat, chemicals and abrasion damage slings; use softeners or protectors, and inspect slings before each lift.

Sling inspection rejection: cuts, fraying, broken wires, heat damage, chemical damage, missing or illegible tags, or distortion of fittings.

Ground bearing pressure under each outrigger = (crane weight + load share) / pad contact area; the ground must have adequate bearing capacity.

Outrigger pads increase contact area; a larger pad reduces bearing pressure on the ground and reduces the risk of penetration.

Crane must be set up on a level surface within the manufacturer's maximum slope; check with a level before lifting.

Locate underground services (power, gas, water, comms) before setting outriggers; use a service locator and dial-before-you-dig records.

The crane must be positioned so the load can be lifted and slewed without passing over personnel or occupied areas.

Exclusion zones and barricades must be set before lifting starts; a spotter or banksman controls access.

Overhead structures, powerlines and other cranes must be checked for clearance at the planned radius and boom height.

The site must be compacted and stable; excavations, trenches and backfilled areas are high-risk for outrigger placement.

Plan the lift: confirm load weight, radius, boom length, capacity, rigging, path and landing point before starting.

Slew slowly and smoothly; sudden starts and stops cause load swing and increase dynamic loading on the crane and rigging.

Never exceed the rated capacity for the working radius; the LMI will alarm and cut out if capacity is approached.

Keep the load as close to the ground as practical while slewing to reduce swing and the consequences of a drop.

Use tag lines to control load rotation; personnel must not stand under the load or between the load and a fixed structure.

Travel with a load only if the manufacturer permits it, the load is within the travel capacity, and the boom is in the specified travel position.

The operator must maintain visual contact with the load or use a competent signal person; if communication is lost, stop the lift.

Stop operation in wind, lightning, poor visibility or if the crane is unstable; never leave a suspended load unattended.

Standard hand signals are defined in AS 2550.1; the operator must respond only to the designated signal person, except for a stop signal from anyone.

Radio communication must use clear, standard phrases; the operator confirms each command and repeats critical instructions.

One signal person is designated for each lift; multiple signal persons cause confusion and are a hazard.

A stop signal - hand raised, palm out, or a single blast - must be obeyed immediately regardless of who gives it.

Pre-lift briefing covers the lift plan, roles, signal person, exclusion zone, emergency stop and communication channel.

If radio contact is lost, the operator stops the lift and holds the load until communication is restored or the load is safely landed.

Tag line handlers must be briefed on their role and must not stand under the load or in the slew path.

Teamwork requires the operator, rigger, signal person and spotter to share a common understanding of the lift plan.

Emergency stop: release controls, lower the load to a safe position if possible, and stop the crane; do not attempt to catch or hold a falling load.

Powerline contact: stay in the cab, warn others to stay clear, and do not touch the crane or load until the power is isolated by the authority.

If evacuation from the cab is necessary due to fire, jump clear and shuffle away without touching the crane and ground at the same time.

Crane overturn: do not attempt to right the crane; secure the area, account for personnel, and notify the regulator and emergency services.

Incident notification: serious injury or dangerous incident must be reported to the regulator; the site is preserved so far as reasonably practicable.

Shutdown procedure: land the load, retract the boom, lower to travel position, apply parking brake, chock wheels, and isolate power.

After an emergency, the crane is inspected by a competent person before being returned to service.

Emergency drills and contact numbers should be part of the pre-lift briefing and site induction.

Park the crane on firm level ground, apply the parking brake, and chock wheels where required.

Retract and lower the boom to the manufacturer's travel position; fit the boom pin or travel lock if specified.

Fully retract outriggers and fit outrigger pads in their stowed position; secure any loose pins or dunnage.

Switch off the engine, remove the key, isolate the battery master switch where fitted, and lock the cab.

Inspect the crane after the shift; record any defects and report them so the next operator is aware.

Secure the hook block, slings and rigging in their designated storage; do not leave rigging hanging.

Complete the post-operational checklist and handover notes, including any incidents or near misses.

Refuel and check fluids as required by the maintenance schedule; record fuel and hours for maintenance planning.