High Risk Work Licence - Self-Erecting Tower Crane (CS) cheat sheet

A person conducting a business or undertaking (PCBU) has the primary duty of care under WHS legislation to ensure health and safety so far as reasonably practicable, including for self-erecting tower crane (SETC) operations.

A high risk work licence (class CS) is required to operate a self-erecting tower crane; the licence must be carried or available for inspection and renewed before expiry.

The model WHS Regulations require a Safe Work Method Statement (SWMS) for high risk construction work, and crane operation may be high risk construction work if it involves a risk of falling, moving plant, or proximity to overhead lines.

Crane owners must ensure the crane is registered with the regulator where required, and that plant is inspected, maintained, and records kept for the period specified by the regulator.

Designers, manufacturers, importers and suppliers must ensure plant is without risks to health and safety, and provide information on intended use, limitations, and maintenance.

A person with management or control of plant must ensure the plant is used only for its intended purpose and that all safety features are operational.

Notifiable incidents (death, serious injury, dangerous incident) must be reported to the regulator immediately; the site must not be disturbed except to assist an injured person or make the area safe.

Licence holders must operate within the scope of their licence and follow the manufacturer's instructions and site-specific procedures; breaches can lead to licence suspension or cancellation.

Hazard identification must consider the crane, the load, the environment, and people; use a systematic process such as inspecting the site, reviewing incident records, and consulting workers.

Risk assessment matrix: likelihood × consequence; controls follow the hierarchy of control: eliminate, substitute, isolate, engineering, administrative, then PPE.

Common SETC hazards include contact with overhead power lines, crane collapse, falling loads, crush zones, ground collapse, wind, and inadequate communication.

The hierarchy of control must be applied in order; PPE is the last line of defence and never a substitute for higher-order controls.

Exclusion zones must be established around the crane and lifting area; the zone size is determined by the load radius, potential fall zone, and site conditions.

A risk assessment must be reviewed when new hazards arise, after an incident, or when site conditions change.

Emergency procedures must be developed for crane collapse, fire, power line contact, and personal injury, and communicated to all workers.

Hazard reporting systems must be in place, and workers must be trained to identify and report hazards without fear of reprisal.

A designated dogger or rigger must direct the crane operator using standard signals; only one signaler at a time, except in an emergency when anyone may give a stop signal.

Standard whistle signals: one short whistle = stop; two short = hoist; three short = lower; one long = emergency stop.

Standard hand signals: raise arm with forearm vertical and finger pointing up = hoist; arm extended downward with finger pointing down = lower; arm extended horizontally = stop; arm extended and moving in direction = slew.

Radio communication must use clear, concise language, identify the crane, and include a read-back or confirmation for critical moves.

Signals must be distinguishable and agreed upon before work starts; if signals are unclear, the operator must stop until communication is re-established.

The operator must obey a stop signal from anyone, but only the designated signaler may direct other movements.

Exclusion zones must be communicated to all personnel; unauthorized entry must be prevented by barriers, signage, and supervision.

Communication failure (radio dead spot, signal loss) requires stopping operations until reliable communication is restored.

A self-erecting tower crane (SETC) is a tower crane that can be erected, climbed, and dismantled without external assistance, often using its own hydraulic system.

Major components: mast, jib, counter-jib, slewing unit, hoist winch, trolley, hook block, counterweights, base, and control cabin or remote control.

Stability depends on the relationship between load moment and counterweight moment; the crane must never exceed its rated capacity for the given radius.

The load moment = load × radius; the counterweight moment = counterweight × distance from slew centre; the crane tips when load moment exceeds resisting moment.

The rated capacity decreases as the radius increases; the load chart must be consulted for every lift.

Wind loading increases with height and sail area of the load; the crane must be operated within the manufacturer's wind speed limits.

The base and foundation must be designed to withstand the maximum overturning moment and ground bearing pressure.

Terminology: radius, load moment, rated capacity, tipping load, back radius, and out-of-service wind condition.

Ground bearing pressure must be assessed by a competent person; the foundation must be designed by an engineer to support the crane's maximum loads.

The base must be level and stable; on slopes, the crane must be leveled using appropriate packing or a designed foundation.

Rail-mounted cranes require the track to be laid on a properly prepared subgrade, with correct gauge, alignment, and drainage.

The foundation must be free of voids, soft spots, or underground services that could compromise stability.

Outriggers or base plates must be fully extended and supported on stable material; never use makeshift packing such as bricks or blocks.

The area around the crane must be drained to prevent water accumulation that could soften the ground.

The crane must be positioned so that the load can be lifted within the rated radius and the counterweight does not encroach on exclusion zones.

Before erection, the site must be checked for overhead power lines, underground services, and adjacent structures.

Erection, climbing, and dismantling must be carried out by trained and competent persons under a documented procedure and a safe work method statement.

The crane must be inspected and maintained in accordance with the manufacturer's instructions; pre-erection checks include structural condition, pins, bolts, and hydraulic systems.

Climbing and jacking operations must be performed only when wind speed is within the manufacturer's limits and the crane is balanced as specified.

During climbing, the crane must be stable at all times; the climbing frame and hydraulic system must be checked for correct engagement.

Dismantling must follow the reverse of the erection sequence; components must be lowered in a controlled manner and secured for transport.

Transport of crane components must comply with load restraint requirements; components must be secured to the vehicle.

Relocation requires re-assessment of the new site, foundation, and ground conditions; the crane must be re-erected and inspected before use.

Records of erection, climbing, and dismantling must be kept, including inspection reports and competent person sign-offs.

The load chart provides the maximum safe lifting capacity for a given radius, boom length, and configuration; never exceed the rated capacity.

Radius is measured from the centre of rotation (slew centre) to the centre of gravity of the load.

The total load includes the weight of the load, rigging, lifting accessories, and hook block; all must be subtracted from the rated capacity.

Load estimation: calculate the volume and multiply by the material density; verify with a scale or known weight when possible.

The load moment must not exceed the crane's rated load moment; the load chart already accounts for this, but the operator must ensure the correct chart is used.

Dynamic loads (wind, acceleration, deceleration) increase the effective load; reduce capacity accordingly.

When the load is unknown, use a load cell or weigh the load; never guess.

The load chart must be available in the crane cabin or with the operator; if missing or illegible, the crane must not be operated.

A daily pre-start inspection must be conducted before the first use of the crane each day, checking structure, ropes, hooks, limit switches, brakes, and safety devices.

Inspection records must be kept and signed by the competent person; defects must be reported and rectified before operation.

Maintenance must be carried out according to the manufacturer's schedule and by competent persons.

Defects affecting safety must be reported immediately; the crane must be tagged out and not used until repaired.

The pre-operational inspection includes checking the load chart, signage, fire extinguisher, and communication equipment.

After any incident or significant event (e.g., lightning strike, overload), the crane must be inspected by a competent person before further use.

The operator must conduct a function test of the crane's controls and safety devices before lifting.

Records of inspections and maintenance must be retained for the period required by the regulator.

Lifting accessories must be rated for the load, inspected before use, and used within their working load limit (WLL).

Sling angle affects capacity: the WLL decreases as the angle from horizontal decreases; use the sling angle factor (e.g., 1.0 at 90°, 1.155 at 60°, 1.414 at 45°).

Loads must be balanced and secured to prevent shifting; use tag lines to control rotation and movement.

The hook must be equipped with a safety latch; the load must be properly seated in the hook bowl.

Never use damaged or modified lifting accessories; remove from service and tag out.

The rigger must ensure the load is within the crane's rated capacity and that the rigging arrangement is appropriate for the load.

Load control: use the crane's controls smoothly; avoid shock loading and sudden stops.

The dogger must guide the load and ensure it is clear of obstructions and personnel.

Operate the crane smoothly, avoiding rapid slewing, braking, or reversing that could cause load swing or structural stress.

Slewing must be controlled to keep the load within the exclusion zone and avoid contact with structures or personnel.

Travel (if applicable) must be on a prepared surface, with the load lowered and secured, and within the manufacturer's limits.

Load placement must be on a stable surface, with the load fully supported before releasing the rigging.

Wind speed must be monitored; operations must stop when wind speed exceeds the manufacturer's limit (often 20 m/s or as specified).

Out-of-service wind conditions: the crane must be placed in the specified out-of-service configuration (e.g., slewing free, jib in the wind).

Visibility: if visibility is impaired (fog, dust, darkness), operations must cease unless adequate lighting and communication are available.

The operator must never leave the controls while a load is suspended; if leaving the cabin, the load must be landed and the crane secured.