Lift plans for cranes in Australia: when you need one

No single rule in Australia says "you need a lift plan for this lift". A lift plan is needed when a lift is complex, close to the crane's limits or near other hazards, and most crane work on a construction site is high-risk construction work that needs a SWMS before it starts. A lift plan sets out the detail of one lift: the site, the crane, the load, the rigging, the sequence and who does what.

When is a lift plan required?

Work through three questions for each lift.

1. Is the work high-risk construction work? Crane work often is. It can involve a risk of falling more than 2 metres, work where powered mobile plant is moving, work near energised electrical installations or overhead lines, or work next to a road in use. Any of these means a SWMS must be prepared before the work starts (regulation 291 and regulation 299). See our guide to high-risk construction work in Australia.
2. Is the lift close to a limit? Think about loads near the crane's rated capacity, long reaches, unusual radii, tandem lifts, lifts over people or occupied structures, and lifts with an unknown or uneven load. Expect a plan for each of these.
3. Does the site or the crane hirer require one? Principal contractors and crane hire companies often set their own thresholds, and they may ask for a plan for every lift above a set weight. The AS 2550 series covers the safe use of cranes, hoists and winches, including AS 2550.1. Check what it asks for in your job.

If the answer to any of these is yes, write the plan before the crane arrives, not on the day.

What a lift plan covers

Each lift needs its own plan, or an addendum to a standing plan if the same crane does the same type of lift every day. It should cover:

The load chart is the limit, not the target. Its rating is for the crane in the configuration the chart shows, so you have to allow for the weight of the hook block and rigging, and for the radius as the load moves.

Lift plan vs SWMS

A SWMS and a lift plan do different jobs, and you usually need both for high-risk crane work.

• The SWMS covers the task: the hazards for everyone working on the job, the controls, and how they're monitored and reviewed (regulation 299).
• The lift plan covers one lift: the crane, the load, the rigging and the sequence.

A mobile crane SWMS can cover the general hazards of the work, and the lift plan covers the specifics of each lift on the day. For a starting point, see the crane lift plan template and the mobile crane SWMS.

How to build a lift plan

1. Confirm the load. Use a certified or weighed figure, not an estimate. Check the rigging is rated for that weight and that it has been inspected.
2. Check the ground. Assess the bearing capacity, and use outrigger mats or a prepared base where the ground is soft or uneven. Keep the crane clear of excavations and voids.
3. Choose the crane and check the chart. Confirm the boom length and radius for this lift on the load chart, and allow for the rigging and the wind.
4. Map the path. Plan the route and the swing radius, and check every overhead hazard. Keep the clearances required by the overhead power lines hazard guide and the network owner.
5. Set the exclusion zone and the roles. Keep people out of the swing and the drop zone. Name the operator, the signaller and the person who can stop the lift.
6. Brief everyone before the lift. Walk the crew through the sequence and the signals. Agree one set of hand signals or radio calls, and a fallback if the radio drops out.
7. Set the weather limits and check them. Check the forecast before the lift, and again during it. Stop when the limit is reached.
8. Review after the lift. Check the equipment for damage, record anything that went wrong, and update the plan if the method changed.

Most crane operators need the right high-risk work licence for the crane class, and dogging or rigging may need its own licence in your state. Every worker needs a construction induction card (white card) and the training their role needs. The plan is only as good as the people who follow it.

Keep the records with the plan

Store each lift plan with the records it depends on: the crane's inspection and maintenance reports, the operator's licence, the rigging certificates, and the SWMS for the job. Keep incident reports and near misses with the same records, so the next plan learns from the last lift. Our guide to plant safety covers the wider plant duties, and Safe Work Australia's code of practice on managing the risks of plant in the workplace is the guide to use with them.

How SafetyDocs helps

SafetyDocs has more than 1,250 expert-written templates, including crane lift plans, mobile crane SWMS and SOPs for tower and gantry cranes. Job, client and site details fill themselves in, so you change only the lift-specific detail. Builders can comment on the exact line and approve the plan before the job starts. Workers sign free on any phone from a text, a link or a QR code, and when the plan changes, everyone who signed is asked to sign the new version. It helps you meet your duties, but it doesn't make you compliant on its own. Check each plan against the site and the crane's load chart.

Common questions

When is a lift plan required in Australia? There's no single national rule that lists when a lift plan is needed. Write one for any lift that's complex, near the crane's limits or close to other hazards. Check the SWMS requirement for the work, and any rules from the principal contractor or the crane hire company.

Is a lift plan the same as a SWMS? No. The SWMS covers the task and its hazards for everyone on the job. The lift plan covers the detail of one lift. High-risk crane work usually needs both.

Who writes the lift plan? Usually the crane hire company, with the person in charge of the lift. The PCBU managing the work should approve the plan and check that it fits the site.

Can I use one lift plan for a whole job? Only if the crane, the load, the rigging, the ground and the path stay the same. Any change means a new or revised plan.

This is general information, not legal advice. Check the current law with your WHS regulator.