High Risk Work Licence - Bridge and Gantry Crane (CB) cheat sheet

Model WHS Act imposes a primary duty of care on a PCBU to ensure health and safety so far as is reasonably practicable; officers must exercise due diligence.

Workers must take reasonable care of their own health and safety, comply with lawful instructions, and not adversely affect others; a crane operator can be personally liable under this duty.

A high risk work licence (class CB) is required for bridge and gantry crane operation; the licence must be current, carried or produced on request, and matched to the crane class.

Duty holders must consult with workers on matters affecting health and safety, including changes to plant, systems of work, and hazard controls.

Reasonably practicable weighs the likelihood and severity of harm against the cost, availability and suitability of controls; cost alone is not a defence.

The hierarchy of control ranks elimination, substitution, engineering controls, administrative controls, then PPE; PPE is the last line of defence.

PCBUs must manage risks to health and safety, and for high-risk plant must register, inspect and maintain it under the relevant WHS regulations.

Notifiable incidents include death, serious injury or illness, and dangerous incidents; the regulator must be notified immediately and the site preserved.

Common bridge and gantry crane hazards: dropped loads, crush zones, electrical contact with overhead lines, snagging, structural failure, and uncontrolled travel.

Risk assessment ranks hazards by likelihood and consequence; controls are applied in hierarchy order and residual risk is re-assessed after controls.

The exclusion zone is the area under and around the load plus a margin; no person may stand or pass beneath a suspended load.

Load chart limits must never be exceeded; wind loading, dynamic effects and off-centre loads reduce the effective capacity.

Overhead power line contact is controlled by de-energising, isolating, or maintaining safe approach distances in accordance with the electricity safety rules.

Hazard controls must be monitored and reviewed, and re-assessed whenever plant, task, personnel or environment changes.

Emergency stops, limit switches, brakes and warning devices are engineering controls that must be tested before each shift.

A hazard is anything with potential to cause harm; a risk is the likelihood and consequence of that harm occurring.

Bridge cranes span between runway beams and travel along them; gantry cranes run on ground-level rails or tyres and do not require a building structure.

The load chart states rated capacity as a function of span, trolley position and hoist configuration; capacity decreases as the trolley moves toward the end of the bridge.

Structural components include the bridge girder, end trucks, runway rails, trolley, hoist drum, wire rope, sheaves, hook block and festoon or conductor systems.

The hoist drum and reeving determine the mechanical advantage; parts of line multiply rope pull but reduce hoist speed.

The hook must have a functioning safety latch, no cracks, and wear within the manufacturer's limits; hook throat opening is measured with a gauge.

Wire rope must be inspected for broken wires, corrosion, kinks, bird-caging and diameter reduction; discard criteria follow the manufacturer's and standard's rules.

Limit switches include hoist upper and lower limits, bridge and trolley travel limits, and overload protection where fitted.

Slew, luff and travel functions on gantry cranes are controlled separately; the operator must know which motions are interlocked.

Pre-start checks cover wire rope, hook and latch, brakes, limit switches, warning devices, controls, festoon, rails and structural members.

Defects found during pre-start checks must be recorded and reported; the crane must be isolated and tagged out if the defect affects safe operation.

Maintenance is scheduled by the manufacturer's recommendations and by usage; records of inspection and maintenance must be kept.

The logbook records pre-start checks, defects, maintenance, and handover; it is a legal record and must be completed legibly and in a timely way.

Brake testing includes checking holding performance under load and verifying that the brake engages when controls are released.

Electrical inspections and insulation tests must be carried out by competent persons at the intervals specified by the standard.

Rope and hook inspections are visual and tactile; a competent person must inspect at intervals not exceeding those set by the standard.

Any modification or repair to load-bearing components must be approved by the manufacturer or a competent engineer.

Load mass estimation uses known mass, density times volume, or manufacturer data; if uncertain, the load must be weighed or verified before lifting.

The total load includes the load, slings, spreader beams, shackles and hook block; the crane's rated capacity must exceed the total.

Sling angle affects tension: as the angle from horizontal decreases, tension in each leg increases; the included angle should not exceed 120 degrees.

Sling selection depends on the load mass, centre of gravity, sling type, WLL and the environment; slings must be inspected before use.

The centre of gravity must be identified so the load is balanced and the hook is directly above it.

Communication uses standard hand signals, radio or whistle; one person must be designated as the dogger or signal person.

The lift plan identifies the load, route, hazards, controls, personnel, and emergency arrangements; it must be communicated to all involved.

Tag lines control load rotation and sway; they must be used where the load could rotate or where personnel need to guide it.

The operator must confirm the load is balanced, the slings are secure, and the area is clear before hoisting.

Hoisting must be smooth; sudden starts and stops cause load swing and dynamic loads that can exceed the rated capacity.

The load must be kept as low as practicable during travel and must not pass over people.

Travel speed is reduced near end stops, in congested areas, and when the load is large or the wind is strong.

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

Limit switches must not be used as operating stops; the operator must stop the hoist before the limit is reached.

Parking the crane requires the hook to be raised, the trolley positioned safely, controls in neutral, and the power isolated where required.

Wind speed must be monitored; operations must stop when the wind exceeds the manufacturer's or site's limit.

On emergency, the operator stops the crane, lowers the load if safe, isolates power, and raises the alarm.

Emergency stops are used for imminent danger; the cause must be investigated before the crane is returned to service.

If a load is suspended and cannot be lowered, the area must be cordoned off and the load secured; no person may enter the drop zone.

Incidents involving injury, dangerous occurrences or structural damage must be reported and the site preserved for investigation.

Fire response includes isolating power, using the correct extinguisher, and evacuating to the assembly point.

The emergency plan identifies wardens, evacuation routes, assembly points, first aid and communication methods.

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

Shutdown procedures include lowering the load, parking the crane, isolating and locking out power, and completing the logbook.

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

Radio communication uses a dedicated channel and clear, concise phrases; the operator repeats critical instructions to confirm.

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

Signage identifies the crane's rated capacity, exclusion zones, and any prohibited areas.

The exclusion zone extends beneath the load and around the crane's travel path; barriers and signage mark the boundary.

Teamwork requires the operator, dogger and rigger to agree on the lift plan and the communication method before the lift.

Pedestrians must be diverted around the exclusion zone; audible and visual warnings are used where sight lines are restricted.

If communication is lost, the operator stops the crane until communication is restored.

Wind loading increases with height and load area; operations must stop when wind exceeds the manufacturer's or site's limit.

Rain, ice and snow reduce brake effectiveness and traction on rails; rails must be cleared and brakes tested before operation.

Heat affects wire rope, hydraulics and electrical components; operators must monitor for overheating and reduced performance.

Ground conditions affect gantry crane stability; rail foundations and outrigger pads must be adequate for the load.

Confined spaces and overhead obstructions limit crane travel and hoist height; the operator must verify clearances.

Electrical hazards from overhead lines require isolation or safe approach distances; the spotter must be used.

Site-specific hazards include other cranes, vehicles, pedestrians, and changes in the work area; the operator must re-assess before each lift.

Noise and dust may affect communication; alternative communication methods must be planned.

At the end of the shift, the operator lowers the load, raises the hook, parks the trolley, and isolates the power.

The logbook records the pre-start check, defects, maintenance, and handover; entries must be made before leaving the crane.

Defects must be reported to the supervisor and recorded; the crane must be tagged out if it is unsafe.

Handover includes the crane's condition, any defects, work in progress, and any restrictions on use.

Controls must be placed in neutral, brakes applied, and the crane secured against movement before leaving.

Keys and lockout devices must be controlled so that only authorised persons can operate the crane.

Housekeeping includes removing tools and materials from the crane and walkways, and securing loose items.

The next operator must be briefed on the crane's condition and any outstanding maintenance before taking over.