Tower Crane Operations — Safe Work Method Statement
Safe Work Method Statement for the erection, operation, and disassembly of tower cranes on construction sites, including lift planning, load management, weather monitoring, and exclusion zone control.
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Tower crane operations on Australian construction sites are regulated as HRCW under Schedule 3 of the model WHS Regulations and require a SWMS to be prepared before any lifting operations commence. The erection and dismantling of tower cranes is separately regulated because it involves additional HRCW — work at height exceeding 2 metres on the crane structure itself — and typically requires a lift study prepared by a structural engineer, given the sequential nature of the self-erecting or assisted erection process.
Tower crane operators must hold a HRW licence in the tower crane class (C4 or C6). Erection and dismantling is typically carried out by the crane manufacturer's or supplier's specialist team using a mobile crane, with all workers involved holding relevant HRW licences for their roles. Tower cranes are registered plant under the WHS Regulations and require design registration and plant registration before use. Pre-commissioning inspection by a competent person to the requirements of AS 2550.4 (Tower cranes) and the crane manufacturer's requirements is mandatory before each erection.
Wind speed management is a critical operational control for tower cranes. All tower cranes have an out-of-service wind speed limit specified by the manufacturer (typically 72–100 km/h for the jib-weathervaning free-slew condition) and an in-service wind speed limit that varies by configuration and radius. A site-specific wind monitoring protocol must be documented in the SWMS, including the anemometer location, the in-service and out-of-service limits for the specific crane configuration, and the procedure for securing the crane in storm or high-wind events.
Collision risk between adjacent tower cranes on multi-crane sites must be assessed and managed through a crane collision avoidance protocol — this may include operational limits, anti-collision systems, or crane coordination procedures involving both operators and a designated lift coordinator.
Customise this template with the crane registration number, maximum load chart data at the relevant radii, the site-specific wind protocol, and the communication system between operator, dogman, and site supervisor. This SWMS applies in all Australian jurisdictions, including Victoria under OHS Regulations 2017.
Personal Protective Equipment
High Risk Construction Work Types
- •Crane or hoist work
- •Work at height above 2 metres
- •Erection or dismantling of a building or structure
- •Work near energised overhead powerlines
Risk Assessment
1.Tower crane erection
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Crane collapse during erection due to foundation or structural failure | Catastrophic | Crane foundation (pad or piled) must be designed by a structural engineer to withstand all rated crane loads including overturning moment, and inspected before mast erection commences. Use only an OEM-supplied erection sequence and erection crew directed by a crane manufacturer-certified erection supervisor. Verify all pin connections, bolts, and splice plates are correctly assembled and torqued to specification before climbing to next section. Site engineer to inspect each mast section before erection continues. Keep non-essential workers clear of the entire crane radius during erection. | Low | Crane Erection Supervisor / Structural Engineer |
| Falls from height during mast climbing and component handling | Catastrophic | All workers climbing the mast or working above 2 m must use a safety harness with a rated climbing safety device (fall arrest device on vertical lifeline) attached to the mast climbing ladder fall arrest rail. Harness to be inspected and tagged before each use. Workers must not carry tools in hands while climbing — use a purpose-built tool bag clipped to harness or haul line. Work at height must not commence in winds exceeding 45 km/h. Inspect all climbing safety equipment daily. All workers to hold valid Working at Heights competency. | Low | All Workers / Erection Supervisor |
2.Pre-lift planning and load assessment
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Overloading crane due to inaccurate load assessment | Catastrophic | A Lift Plan must be prepared for every crane lift, and a Specific Engineered Lift Plan (SELP) for all critical lifts (loads exceeding 80% of crane capacity at any radius, unusual loads, tandem lifts, or lifts over occupied areas). Load weights must be confirmed from weigh certificates or manufacturer data sheets — never estimated. The lift plan must account for radius changes during the lift, allowance for rigging gear mass, and dynamic load factors. Crane operator must verify lift plan details match actual load and rigging before commencing lift. | Low | Crane Supervisor / Dogman |
| Crane operating in proximity to adjacent crane or structure | High | Where multiple cranes share airspace, a formal Anti-Collision Procedure (ACP) must be prepared and agreed between all crane operators and site supervisors. Install electronic anti-collision systems on cranes operating with overlapping radii. Conduct a dedicated two-crane synchronisation test before commencement of works. Establish communication protocol (radio channel allocation) between crane operators. Slewing into the anti-collision zone requires both operators to stop and confirm visual clearance by radio before proceeding. | Moderate | Crane Supervisor / All Crane Operators |
3.Daily crane operations and load handling
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Load swing or loss of load control injuring workers | Catastrophic | All loads must be rigged by a licenced rigger and all crane signals given by a licenced dogman in constant visual or radio contact with crane operator. Tag lines of minimum 10 m length must be attached to all loads exceeding 200 kg to control swing during lift. The operator must maintain slow, controlled hoist speeds when load is near workers or structures. If a load begins uncontrolled swinging, operator must lower the load to the ground immediately rather than attempting to control at height. Exclusion zone below the lift path must be enforced at all times. | Moderate | Crane Operator / Dogman / Rigger |
| Structural failure of jib or slewing ring | Catastrophic | Perform Daily, Weekly, and Monthly inspections in accordance with the crane manufacturer's maintenance schedule and AS 2550.1. All inspections must be recorded in the crane logbook. Defects identified must be tagged out and reported to crane owner before continued operation. Slewing ring and mast connection inspections must be conducted by a crane technician holding OEM authorisation. Do not operate crane if any inspection is overdue. Crane must be de-rated or taken out of service during scheduled maintenance windows. | Low | Crane Owner / Crane Operator |
4.Operations in adverse weather
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Crane damage or collapse in high winds | Catastrophic | Monitor wind speed on site using a calibrated anemometer. Cease lifting operations when mean wind speed exceeds the manufacturer's rated wind speed for operations (typically 45–72 km/h depending on model). Park the crane in free-slew mode (jib free to weathervane) with hook block raised and secured to jib in storm parking position when wind speeds approach operational limits. Conduct formal storm park procedure as per manufacturer instructions when Bureau of Meteorology forecasts winds exceeding 70 km/h. All workers to evacuate the tower before storm parking begins. | Low | Crane Operator / Crane Supervisor |
5.Tower crane disassembly and removal
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Loss of control of crane components during disassembly | Catastrophic | Crane disassembly must be performed by the same OEM-authorised crew that erected the crane, following the reverse of the approved erection sequence. All mast sections and jib components must be securely attached to the mobile assist crane before any pin connections or bolts are removed. Exclusion zone equal to full crane radius must be maintained throughout disassembly. Disassembly supervisor must have direct line of sight to all connection points during disassembly. Weather must be within the manufacturer-rated limits for disassembly operations. | Low | Crane Erection Supervisor / Mobile Crane Operator |
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.