High Risk Work Licence - Portal Boom Crane (CP) cheat sheet

A CP licence authorises operation of a portal boom crane; it does not authorise rigging, dogging, or operating other crane classes.

PCBU primary duty: ensure health and safety so far as reasonably practicable, including plant, systems of work, training, and supervision.

Operator duty: take reasonable care of own and others' safety, comply with instructions, and not operate while impaired by fatigue, drugs, or alcohol.

WHS Act requires notification of serious incidents; a crane collapse, uncontrolled load drop, or contact with electricity is notifiable.

Safe Work Australia model WHS Regulations: high-risk work licensing, plant registration, and inspection requirements apply to portal boom cranes.

Records that must be kept include operator licence, logbook, pre-start inspections, maintenance, and proof of load-testing/verification.

A portal boom crane used to lift persons requires a compliant platform, risk assessment, and emergency lowering system; not permitted without specific controls.

Site-specific SWMS or JSA must be signed and followed; deviation without authorisation is a breach of duty.

Hierarchy of control: eliminate, substitute, engineering, administrative, then PPE - PPE is last resort.

Common portal crane hazards: powerline contact, load swing, ground collapse, wind, poor visibility, crush zones, and unsecured loads.

Risk score = likelihood × consequence; controls must reduce risk to as low as reasonably practicable (ALARP).

Exclusion zones must be established under and around the load path; no person under a suspended load.

Wind speed must be monitored; stop lifting when wind exceeds the manufacturer's rated limit or when load control is compromised.

Ground bearing pressure check: outriggers/rails must be on stable, compacted ground with spreader mats if required.

Pre-lift hazard hunt: inspect path of load, slew arc, blind spots, and proximity to structures or other cranes.

Dynamic risk assessment is continuous; stop work if conditions change (e.g., wind gust, ground movement, personnel entering zone).

Rated capacity (SWL) is the maximum load including rigging, at a specified radius and configuration; never exceed it.

Load moment = load × radius; the load chart is derived from structural and stability limits.

Radius is measured horizontally from the slewing centre to the centre of gravity of the load.

Boom length, counterweight, outrigger/rail span, and slew angle affect capacity; always use the correct load chart for the configuration.

Duty cycle: portal boom cranes are typically classified for moderate duty; continuous heavy cycling reduces capacity.

Terminology: hoist, lower, slew, luff (boom up/down), travel (portal movement), and trolley (if fitted).

Limit switches: hoist high limit, lower limit, slew limit, and overload protection must be tested and functional.

Rated capacity must be displayed in the cabin; load charts are specific to the crane model and setup.

Pre-start checklist: tyres/rails, outriggers, levels, wire rope, hook, latches, brakes, alarms, lights, limit switches, and load chart.

Wire rope rejection criteria: broken wires, kinks, corrosion, diameter reduction, and end fitting damage per AS 2759 or manufacturer.

Hook inspection: no cracks, deformation, excessive throat opening, or missing safety latch.

Setup: fully extend outriggers on stable ground, level the crane, and verify rail clamps or anchors if rail-mounted.

Stability: never rely on counterweight alone; ground conditions and outrigger penetration are critical.

Pre-operational checks must be recorded and defects reported; do not operate a crane with a safety-critical defect.

Verify load chart matches the actual boom/outrigger configuration before lifting.

Check fire extinguisher, first aid, and emergency stop function during pre-start.

Total load = load weight + rigging weight (slings, shackles, spreader beam, hook block if not included).

Sling tension in a two-leg sling: T = (W/2) / cos(θ/2), where θ is the included angle between legs.

Sling angle factor: at 60° included angle, tension ≈ 0.577W per leg; at 90°, ≈0.707W; at 120°, ≈1.0W.

WLL of sling assembly is limited by the weakest component and the angle factor; never exceed the sling's rated capacity.

Centre of gravity must be under the hook; off-centre lifts cause load swing and unequal sling tension.

Shock loading increases dynamic force; use soft-start and avoid jerking the load.

Load weight can be estimated from volume × density; confirm with weighbridge or manufacturer data where possible.

For multi-leg slings, use the mode factor from AS 1353/AS 3775 tables; symmetric loading only.

Before lifting, ensure the load is free, balanced, and rigged correctly; lift slightly to test stability.

Use smooth accelerations and decelerations; avoid sudden slew or hoist movements that cause load swing.

Travel with load low and secure; use a spotter and follow site traffic rules; never travel with a suspended load over personnel.

Slewing: anticipate load swing; lead the load with the slew and allow it to settle before lowering.

Never leave controls with a load suspended; if unavoidable, secure the area and maintain control.

Tag lines control rotation; personnel must not wrap lines around hands or stand in the bight.

Blind lifts require a designated spotter/rigger with radio or hand signals; stop if communication is lost.

Park crane with boom lowered, hook secured, and controls isolated per manufacturer.

Only one designated signal person directs the crane at a time; the operator must obey that person's signals.

Standard hand signals per AS 2550.1: hoist, lower, slew left/right, stop, emergency stop, dog everything.

Radio communication: use clear, concise language; repeat back critical instructions; use a dedicated channel.

Emergency stop signal: any person may give a stop signal; operator must stop immediately.

Pre-lift briefing: confirm roles, load weight, path, exclusion zone, and emergency plan.

Loss of communication: stop the lift and hold the load safely until communication is restored.

Rigger and operator must agree on tag line use and load orientation before the lift.

Hand signals must be visible; if not, use radio or repeaters.

Emergency stop: press the E-stop, lower the load if safe, and isolate power.

Power failure: engage brakes, secure the load, and follow manufacturer's emergency lowering procedure.

Fire: isolate power, use the correct extinguisher, evacuate, and call emergency services.

Incident: preserve the scene, report to supervisor, and complete an incident report; notifiable incidents require regulator notification.

Injury: provide first aid, call emergency services, and do not move the crane unless directed.

Load drop or collapse: establish an exclusion zone, do not re-enter, and await inspection.

Shutdown procedure: park in designated area, lower boom, secure hook, isolate power, and apply locks.

Post-incident inspection by a competent person is required before returning to service.

Daily pre-start inspections are recorded; periodic inspections (e.g., 3-monthly, annual) by a competent person.

Major inspection (10-yearly or as per manufacturer) includes structural and mechanical integrity checks.

Defects must be reported immediately; safety-critical defects require the crane to be tagged out and isolated.

Maintenance records include date, nature of work, parts replaced, and person performing the task.

Wire rope and hook inspections are documented; rejection criteria must be applied.

Load test certificates and verification of rated capacity must be available on site.

Operator logbook records hours, lifts, and any anomalies; it supports maintenance scheduling.

Defect reporting system: verbal report followed by written record; track corrective action to closure.