Overhead Gantry and Bridge Crane Operations — Safe Work Method Statement
Safe Work Method Statement for operating overhead bridge and gantry cranes in workshops, fabrication shops, precast yards and warehouses, covering pre-use checks, slinging, travelling loads, pendant and remote control and maintenance isolation.
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Overhead bridge and gantry cranes move steel, precast elements, moulds, machinery and stock in fabrication shops, precast yards and warehouses. Most of this work happens in a factory and is not construction work, so it doesn't automatically trigger the high-risk construction work (HRCW) categories. A SWMS isn't legally required for routine workshop lifts, but it is good practice, it is the clearest way to document the safe system of work that the WHS Regulations require you to have for plant, and principal contractors and clients often ask for one. If the crane is used as part of construction work and a HRCW trigger applies, such as workers on the runway more than 2 metres above the floor during maintenance, a SWMS is required.
Licensing depends on how the crane is controlled. A bridge and gantry crane (CB) high-risk work licence is needed to operate a crane controlled from a permanent cabin or control station on the crane, or a remotely controlled crane with more than three powered operations. Many pendant-controlled workshop cranes don't need a licence, but the PCBU must still train and assess operators on that crane. Slinging that requires judgement about load weight, centre of gravity or sling selection should be done by a licensed dogman. Larger bridge and gantry cranes are also registrable plant. Check your state or territory regulator for licensing and registration requirements.
The hazards specific to overhead cranes are loads travelling over people, loads swinging or spinning when the crane starts or stops, two-blocking or hoisting into the end of travel if limit switches fail, collisions between cranes on the same runway, walking backwards while using a pendant and tripping over stock, and electrocution or falls during maintenance on the runway and conductor bars. Cranes should be inspected and maintained to the manufacturer's manual and AS 2550, with a logbook showing pre-use checks and periodic inspections.
Customise this template with the crane's identification number, rated capacity and control type (pendant, radio remote or cabin), the operator's licence or training record, the workshop layout with walkways and no-load zones, the below-hook lifting devices used, the procedure for cranes sharing a runway, and the maintenance isolation procedure.
Personal Protective Equipment
Risk Assessment
1.Pre-use inspection of the crane
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Using a crane with a faulty brake, limit switch or pendant | High | Before each shift, check and record in the logbook: pendant or remote buttons and emergency stop, upper hoist limit, hook and safety latch, wire rope or chain condition, travel and cross-travel brakes, warning devices and the WLL markings. Test the hoist limit unloaded. Tag out and report any fault, and do not use the crane until it is repaired. | Low | Crane Operator |
2.Planning the lift and selecting lifting gear
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Load exceeding the crane, hoist or lifting gear capacity | Catastrophic | Confirm the load weight from drawings, a weight label or a load cell. Include the weight of below-hook devices (spreader beams, plate clamps, magnets) when checking against the crane and hoist WLL. Select slings and shackles rated for the load and sling angle. Use a licensed dogman where the slinging requires judgement. | Low | Crane Operator / Dogman |
| Load slipping from plate clamps or lifting magnets | High | Use plate clamps only within their rated plate thickness and orientation, and lock them before lifting. Use lifting magnets only within their rated capacity for that plate thickness and surface. Keep loads as low as practicable and never above people. | Low | Crane Operator |
3.Slinging and test lift
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Hands crushed between sling and load as slack is taken up | Moderate | Position slings, then step clear before signalling to take up. Use push sticks or tag lines, not hands, to guide slings. Use packers so slings can be removed after landing without lifting the load. | Low | Dogman / Crane Operator |
| Unbalanced load tilting or dropping | High | Centre the hook over the load's centre of gravity. Raise 100 to 200 mm and hold to check balance and rigging before travelling. Lower and re-rig if the load tilts. | Low | Crane Operator |
4.Travelling the load
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Load passing over or striking workers | Catastrophic | Plan the travel path to avoid walkways and workstations. Sound the warning device before and during travel. Never carry loads over people. Stop if anyone enters the path. Keep the load low, just clear of obstacles, and start and stop smoothly to limit swing. | Low | Crane Operator |
| Operator tripping while walking with a pendant | Moderate | Walk forwards beside the load with a clear view. Keep floor routes clear of stock and offcuts. Use a radio remote where layout allows the operator to stand clear. | Low | Crane Operator |
| Collision between two cranes on the same runway | High | Use anti-collision devices where fitted. Agree a written procedure for shared runways, including communication between operators and no tandem lifts without an engineered lift plan. | Low | Supervisor / Crane Operators |
5.Landing the load and parking the crane
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Load rolling or toppling after landing | High | Land onto dunnage or a stand designed for the load. Chock round items. Confirm the load is stable before slackening slings. Park the crane at the designated position with the hook raised clear of head height and isolate it at the end of the shift. | Low | Crane Operator |
6.Maintenance and work on the runway
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Electric shock from conductor bars or the crane moving during maintenance | Catastrophic | Isolate and lock out the crane's main supply and the conductor bar, and test for dead before any work. Each worker applies a personal lock. Lock out adjacent cranes on the same runway, or fit physical stops. | Low | Maintenance Electrician / Competent Person |
| Fall from the runway beam or crane bridge | Catastrophic | Access the crane from an EWP or a fixed platform with guardrails. Where workers must go onto the bridge or runway, use a rated anchor or static line and a harness, with a rescue plan. | Moderate | Competent Person / Supervisor |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.