High Risk Work Licence - Derrick Crane (CD) cheat sheet

Primary duty of care sits with the person conducting a business or undertaking (PCBU); officers must exercise due diligence, and workers must take reasonable care for their own and others' safety.

A high risk work licence for a derrick crane (class CD) is personal and non-transferable; the operator must carry or be able to produce it and must not operate outside the class or conditions endorsed.

Licences are issued under the model WHS Regulations; the regulator may suspend or cancel a licence for unsafe conduct, and unlicensed operation is an offence with substantial penalties.

Duty holders must consult with workers and their representatives on matters that affect health and safety, including lift planning, rigging methods and site layout changes.

Notifiable incidents include death, serious injury or illness, and dangerous incidents such as a crane or load collapse, uncontrolled load, or contact with energised electrical equipment.

Site-specific safe work method statements or lift plans are required where the work is high risk construction work, and the operator must work to the approved plan.

A person with management or control of the workplace must ensure plant is safe, inspected and maintained, and that the ground and supporting structures can bear the imposed loads.

Records that must be retained include licences, logbooks, inspection and maintenance reports, lift plans, and proof of training and competency for riggers and doggers.

Hierarchy of control: eliminate, substitute, engineer (isolation, guarding, interlocks), administrate (procedures, training), then PPE as the last line of defence.

Common derrick hazards: overloading, shock loading, load swing, guy or anchorage failure, ground bearing failure, powerline contact, crush zones, and manual handling during rigging.

Risk score = likelihood x consequence; controls are applied until residual risk is as low as reasonably practicable (ALARP).

Define a no-go zone under and around the load path; the exclusion radius must account for load radius, swing, and potential failure of rigging or load attachment.

Shock loading from rapid hoisting or sudden release can multiply the static load several times; smooth starts and stops reduce dynamic amplification.

Overhead and underground services must be located and, where possible, de-energised or isolated before erecting or operating the crane; maintain the regulated safe approach distance.

Weather limits: stop lifting when wind, visibility, lightning or heat make the lift unsafe; the manufacturer's wind speed limit and the load's sail area govern the decision.

Review the risk assessment whenever the load, rigging, ground conditions, personnel, or crane configuration changes.

A derrick crane is a guyed or stiff-leg crane with a mast (post), a boom (jib), and a load hoist and boom hoist; it is typically used for heavy lifts in confined or fixed locations.

Guy derrick: the mast is held by multiple guy ropes anchored to fixed points; stiff-leg derrick: the mast is supported by rigid structural legs rather than flexible guys.

Stability depends on the tension in the guys or the strength of the stiff legs, the anchorage capacity, the mast base support, and the counterweight or ballast arrangement.

The load moment about the mast base increases with radius; the crane's rated capacity decreases as the boom radius increases, per the manufacturer's load chart.

Mast base must be plumb and seated on a foundation capable of carrying vertical load, moment and shear; footings must be designed by a competent person.

Components include the mast, boom, head fitting, guy ropes or stiff legs, slewing arrangement, hoist and boom winches, sheaves, hooks, and the load chart and limiting devices.

Limiting devices may include rated capacity indicators, boom angle or radius indicators, and limit switches; these are aids, not substitutes for the operator's judgement.

Erection, alteration and dismantling of the derrick must be carried out under a documented procedure by competent persons, with the structure verified before loading.

Ground bearing pressure = total imposed load divided by the effective bearing area; verify against the geotechnical or manufacturer's allowable bearing capacity.

Foundations must resist overturning moment, sliding and uplift; the design must account for the maximum load moment at the worst permitted radius.

Anchors for guys must be designed for the maximum guy tension, including dynamic and wind effects, and be located so that the guy angle matches the manufacturer's specification.

Guy angles: the included angle between guys and the mast, and the horizontal spread, must follow the manufacturer's data; excessive or insufficient angle alters the load in the guys and mast.

All guys must be equally tensioned and fitted with turnbuckles or tensioning devices; slack or uneven guys cause mast sway and unequal loading.

Ballast or counterweight must match the configuration in the load chart; adding or removing ballast without reference to the chart changes stability and rated capacity.

Clear the working area of obstructions, provide drainage so footings do not soften, and barricade the guy anchor points and the slewing and load zones.

Verify the capacity of any structure used as an anchorage (building columns, deadmen, rock anchors) with a competent person before attaching guys.

Pre-start checks: inspect mast base and foundation, guy tension and anchor condition, structural members for cracks, corrosion or distortion, and all pins and locking devices.

Inspect ropes for broken wires, kinks, birdcaging, corrosion, abrasion and correct spooling; compare against the discard criteria in the applicable standard.

Check sheaves for groove wear and free rotation, hooks for throat opening, wear and safety latch function, and shackles and fittings for wear and correct rating.

Test limit switches, rated capacity indicator, alarms and emergency stops where fitted, and confirm the load chart is present and legible in the cabin or at the controls.

Logbook entries must record inspections, defects, repairs, and any alteration; defective equipment must be tagged out and not returned to service until repaired and re-verified.

Periodic inspections and proof load testing are required at intervals specified by the manufacturer or regulator, and after erection, alteration, or a damaging event.

Maintenance must follow the manufacturer's schedule; lubrication, rope replacement, brake adjustment and fastener torque are typical scheduled tasks.

Only competent persons may inspect, test or repair; the operator's daily check supplements, but does not replace, the formal inspection regime.

Total load = load mass + rigging mass (sling, shackles, spreader beam); the crane's rated capacity must not be exceeded at the working radius.

Sling tension in a two-leg sling: tension per leg = (load / 2) / sin(angle to horizontal); as the angle to horizontal decreases, leg tension rises sharply.

Sling angle factor: at 90 degrees to horizontal, each leg carries half the load; at 60 degrees, about 0.577 of the load; at 30 degrees, the full load per leg.

Working load limit (WLL) of a multi-leg sling assembly is not simply the sum of leg WLLs; it depends on the included angle and the configuration.

Centre of gravity must be below or directly under the hook; an off-centre CoG causes tilt, unequal leg loading and load swing.

Select gear rated for the load and environment: wire rope slings, chain slings, synthetic slings, shackles and hooks must be tagged with their WLL and inspected before use.

Sharp edges require edge protection; synthetic slings must be protected from heat, chemicals and UV, and wire rope from kinking and crushing.

Shock loading and snatch loads can exceed the static calculation; use soft starts and avoid dragging or jerking the load.

Read the load chart for the specific configuration: boom length, radius, counterweight or ballast, and any outrigger or foundation condition shown.

Rated capacity decreases with increasing radius; never interpolate beyond the chart's stated values or assume capacity for a configuration not listed.

Know the difference between rated capacity, gross capacity and net capacity (net = gross minus the mass of hook block, slings and other lifting gear).

Operate smoothly: raise the load just clear of the ground, check the rigging and brake, then hoist; avoid rapid slewing or booming that induces swing.

Keep the load under control with tag lines; never allow personnel under a suspended load or ride on the load or hook.

Slewing and booming change the radius and therefore the load moment; monitor the radius indicator and the load moment as the load moves outward.

Stop the operation if the rated capacity indicator alarms, if the load begins to swing uncontrollably, or if the wind or visibility deteriorates beyond the limits.

At the end of the lift, land the load, slacken the slings, and leave the crane in the manufacturer's specified parked configuration.

One designated person, usually the dogger, gives signals to the operator; only one signal source at a time prevents conflicting commands.

Standard hand signals include stop, hoist, lower, slew left/right, boom up/down, and emergency stop; all crew must use the same recognised signal set.

An emergency stop signal from anyone must be obeyed immediately, regardless of who gave it.

Radio communication requires a dedicated channel, clear call signs, and read-back confirmation of critical commands; loss of communication means stop.

The dogger verifies the load, rigging, CoG and clearance, and directs the load; the rigger prepares and attaches the load and controls tag lines.

The operator maintains visual contact with the dogger or has a confirmed radio link; if neither is available, the lift must not proceed.

Pre-lift briefing covers the lift plan, roles, signals, exclusion zone, emergency stop, and the sequence of moves.

Handover between shifts or operators must include the crane's condition, current configuration, any defects, and the status of the lift.

Emergency stop: engage the stop, lower the load to a safe position if possible, and secure the crane; do not leave a suspended load unattended.

If the load cannot be landed, barricade the area beneath it, keep people clear, and seek competent advice before attempting recovery.

Power failure: apply brakes, secure the controls, and follow the manufacturer's procedure for lowering the load manually or by auxiliary means.

Structural or guy failure: stop all work, evacuate the exclusion zone, and do not re-enter or re-load until a competent person has inspected and cleared the crane.

Contact with electrical services: keep clear, do not touch the crane or load, and have the supply isolated by the utility before anyone approaches.

Injury or fatality: provide first aid, secure the scene, notify the regulator as required, and preserve evidence for investigation.

Fire: isolate power where safe, use the appropriate extinguisher, and evacuate to the assembly point; do not fight a fire that threatens the crane structure.

After any emergency, complete an incident report, tag out defective equipment, and conduct a review before resuming operations.

Dismantling follows a documented sequence in reverse of erection: unload the crane, remove the load and rigging, release guy tension in the specified order, then lower the boom and mast.

Only competent persons under a supervisor may dismantle; the area must be barricaded and the sequence must match the manufacturer's or engineer's procedure.

Inspect and tag all components during dismantling; record damaged or worn items and quarantine them from service.

Transport: secure components to the vehicle, check load restraint, and comply with load dimension and mass limits for the route.

Storage: keep ropes, slings and fittings off the ground, dry, ventilated and protected from UV, chemicals and corrosion; store pins and small parts in labelled containers.

Post-operational records include the logbook, inspection reports, maintenance records, lift plans, incident reports, and a handover or shutdown checklist.

Any defect found at shutdown must be recorded and reported so it is rectified before the next use; do not rely on verbal handover alone.

Documentation must be retained for the period required by the regulator and be available for audit or incident investigation.