Overhead Crane Operation SWMS

Overhead travelling cranes are essential in metal fabrication workshops for moving raw materials, positioning components during fit-up, and handling completed assemblies. Load drop, swing, and crush hazards can cause fatalities. The WHS Regulation 2025 requires High Risk Work Licences for crane operators (over 3 tonnes capacity) and doggers who sling loads. All lifting operations must be planned, with lift studies required for complex or heavy lifts. This template maps controls to the binding Managing Risks of Plant in the Workplace Code of Practice effective 1 July 2026 under Section 26A.

Legal Requirements

regulation

WHS Regulation 2025 Part 4.5 — High Risk Work Licences and Part 4.7 — Plant

hrcw category

Work involving powered mobile plant — crane operation

code of practice

Managing Risks of Plant in the Workplace (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

hrwl required

CN class licence for crane operator (>3 t); DG class licence for dogger/rigger

Hazards

Hazard	Consequence	Likelihood
Load drop from rigging failure or overloading	Crush fatality, severe crush injuries	Unlikely
Load swing striking workers in the travel path	Traumatic brain injury, fractures, death	Possible
Crush between load and fixed structure during positioning	Crush injuries, amputation, death	Possible
Crane structural failure from overloading or poor maintenance	Multiple fatalities, structural collapse	Rare
Electrical contact with overhead powerlines or busbar	Electrocution, death	Unlikely
Workers under suspended load during lifting	Crush fatality from unexpected load drop	Possible

Controls (Hierarchy of Controls)

Verify HRWL currency for all crane operators and doggers before work commences

Conduct pre-start inspection of crane, hooks, slings, and shackles before each shift

Calculate load weight and verify it is within the crane safe working load for the lift radius

Establish exclusion zones beneath suspended loads and along the travel path

Use tag lines to control load swing during positioning

Conduct lift studies for all lifts involving multiple cranes, blind lifts, or loads above 80 per cent of SWL

Maintain crane inspection and maintenance records per manufacturer specifications

Install and maintain anti-collision and overload protection devices on all overhead cranes

Recent Prosecutions

BI Australia Pty Ltd$400,000

Crane incident during steel fabrication resulting in serious worker injuries due to inadequate lift planning and safety controls.

2025 — SafeWork NSW v BI Australia Pty Ltd [2025]

Orica Australia Pty Ltd$1,200,000

Multiple safety failures in industrial operations including inadequate plant management.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

What Your SWMS Must Include

✓HRWL verification records for all crane operators and doggers

✓Pre-start inspection checklist for crane, hooks, slings, and shackles

✓Load calculation procedure and safe working load verification

✓Exclusion zone establishment and communication procedures

✓Crane maintenance schedule and inspection records

Need a compliant Overhead Crane SWMS?

Our WHS consultants build lift-specific SWMS that address load management, HRWL verification, and exclusion zone protocols for your crane operations.