PROCEDURE

Title: Cranes and Mobile Cranes

Procedure No: Issue: Revision: Operative Date: Author:

P314.414 2 1 01/05/2010 M Kynigalakis
Department: Sect./Classification: Category: Owner Role: Approver Role:
HSEC Safety Vehicles / Mobile Health, Safety & HSEC Manager
Equipment Security
Superintendent
Appr. Signature:

CONTENTS
1.0 PURPOSE ......................................................................................... 1

2.0 SCOPE .............................................................................................. 1

3.0 RESPONSIBILITIES .......................................................................... 1

4.0 REFERENCES .................................................................................. 2

5.0 DEFINITIONS .................................................................................... 3

6.0 ACTIONS........................................................................................... 4
6.1 Site Approval for Cranes and Mobile Cranes ........................ 4
6.2 Equipment Selection ............................................................. 4
6.3 Operation of Cranes and Mobile Cranes ............................... 4
6.4 Inspection and Maintenance ................................................. 7
6.5 Training and Qualifications.................................................... 8
6.6 Records ................................................................................ 8
6.7 Manuals ................................................................................ 8
7.0 ATTACHMENTS................................................................................ 8

1.0 PURPOSE
To provide standards for the safe operation of cranes and mobile cranes on the QAL site, and to establish a
system to ensure that equipment brought on site complies with legal requirements.

2.0 SCOPE
This procedure applies to all cranes and mobile cranes that move loads on the QAL site. The procedure
applies to both QAL and Contractor owned equipment.

3.0 RESPONSIBILITIES
Crane Base Supervisor (or delegated representative)
• Co-ordinate the selection and provision of all mobile cranes used within QAL under their control.
• Retain completed Crane Job Safety Environment Analysis (JSEA) for 3 months.
• Retain all completed critical lift plans.
• Maintain critical lift plan register.
• Inspect, site approve and maintain inspection records and crane risk assessments for all mobile
cranes entering QAL under their control.
• Participate in development of all critical lift plans under their control.

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Last amendments to this Document are Highlighted in Bold Italic Print

 Title: Cranes and Mobile Cranes No: P314.414 Approval:
Issue: 2 Rev: 1 (Inits)

Crane Operator
• Complete and record a pre-start check at the commencement of each shift or the first use of the
equipment.
• Complete a QAL JSEA on all crane load lifts.
• Complete a QAL Crane JSEA for all mobile crane load lifts.
• Complete a QAL Crane JSEA (Part A and Part C) for critical lifts involving personnel in workboxes.
• Participate in development of all lift plans.

Dogger/Slinger
• Sling loads taking into consideration the nature of the load, its mass and its centre of gravity.
• Control a load in transit using a hand held tag line or load control pole.
• Participate in development of all lift plans.
• Qualified person in control of non-critical lifts.

Lead Asset Management Engineer

• Ensure all QAL owned mobile cranes over 10 tonne lifting capacity are registered with WHSQ.

Lift Supervision
• Responsible for the management of all ‘critical lifts’ under their control.
• Participate in development of all critical lift plans.
• Responsible for ensuring all stakeholders clearly understand the critical lift plan and their roles in the
plan.

Superintendent
• Approve physical handling of a suspended load.

Supervisor of the Contract

• Co-ordinate the selection and provision of all contractor mobile cranes used within QAL.
• Retain completed QAL Crane JSEA for 3 months.
• Shall forward critical lift plan to Crane Base Supervisor.
• Inspect, site approve and maintain inspection records for all mobile cranes entering QAL under their
control.
• Participate in development of all critical lift plans under their control.

4.0 REFERENCES
P312.402 – Pre-Task Hazard Assessment
P312.605 – Competent To Operate
P314.311 – Work at Height
P314.405 – Inspection, Servicing & Testing of Lifting Devices
P314.408 – The Safety Inspection & Non-Destructive Testing of Chain Slings
P314.615 – Electrical Proximity Permit
P314.701 – Operation of Mobile Equipment
P314.980 – Lightning Warning System
P315.102 – Protective Equipment – Plant Minimum Requirements
Queensland Workplace Health & Safety Act 1995
WH&S Regulation 2008
Code of Practice – Plant 1995
Code of Practice – Working near live parts (Electrical Safety Office) 2002
AS1418.1 – 2002 Cranes, Hoists and Winches – Part 1 General Requirements
AS1418.3 – 1997 Cranes, Hoists and Winches – Part 3 Bridge, gantry, portal and jib cranes
AS1418.5 – 2002 Cranes, Hoists and Winches – Part 5 Mobile Cranes
AS1418.17 – 1996 Cranes Part 17: Design and Construction of Workboxes
AS2549-1996 Cranes (including hoists and winches) – Glossary of terms
AS2550.1 – 2002 Cranes, Hoists and Winches – Safe Use Part 1 General Requirements
AS2550.5 – 2002 Cranes, Hoists and Winches – Safe Use Part 5: Mobile Cranes
BSL 02-00-SWS-2.15 Safe Work – Lifting Gear and Machinery
Mobile Crane Code of Practice 2006

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 Title: Cranes and Mobile Cranes No: P314.414 Approval:
Issue: 2 Rev: 1 (Inits)

QM50-102-02 – In Service Inspection of Alloy Lifting Chains

Rio Tinto Critical Lift Plan – Safe Work Standard (SAF-WSD-0010.08)
Rio Tinto HSE Performance Standard C6 – Cranes and Lifting Equipment
PG 105 – Basic slinging training module

5.0 DEFINITIONS
Chain Sling - System of chains, rings, hooks or other accessories used to move a load.

Competent Operator – A person who has an appropriate QAL CTO for controlling lifts of less than 5 tonne.

Crane - Means a machine for raising or lowering a load and moving it horizontally, including any supporting
structure or foundation, but does not include forklifts, conveyors, backhoes, excavators, front end loaders
i.e. Earth moving equipment (AS2549 – 1996 Cranes Glossary of Terms).

Crane Operator - A person holding a WHSQ Certificate of Competency (or other State qualification) and a
QAL CTO (or Contractor equivalent) who can operate cranes to a specified level of competency.

Critical Lifts - Critical Lifts are:

• Lifts of a load requiring two or more cranes.

• Where the load is being lifted onto or passed over buildings.
• Operation or load passing over or within the electrical wires exclusion zone and / or over electrical
equipment (i.e., High Voltage yards / transformers) as per 6.3.8.
• Lifts at maximum rated load capacity of crane.
• Lifts involving personnel in workboxes.

Critical Lift Plan – A document that specifies the crane configuration, rigging techniques, load details,
hazards and controls required to perform a critical lift.

Critical Lift Register – A register of all critical lift plans held by the Crane Base Supervisor.

CTO – Competent to Operate

Dogger - A person holding a WHSQ Certificate of Competency for Dogging (or other similar State
qualification) and a QAL Dogger CTO who:

• uses techniques, including the selection or inspection of lifting gear, to safely sling a load; or
• directs a crane or hoist operator in the movement of a load when the load is out of the operator’s view.

Electrical Proximity Permit – A permit that authorises lifts in the vicinity of high voltage electrical lines and
equipment or within the limits of approach of low voltage equipment (i.e., sub-stations, switchyards and
switch rooms).

Intermediate Rigger – A person holding a WHSQ Certificate of Competency for Intermediate Rigging (or
other similar State qualification) and a QAL dogger CTO.

Lift Supervision –a competent person who manages a critical lift and at a minimum holds an Intermediate
Rigger qualification.

Load Control Pole – a piece of non-conductive equipment that is manageable in length, sturdy to control
and light enough to assist in controlling and guiding a load for placement where tag lines are not suitable.
An example is a length of wooden dowel (i.e., broom handle) and / or conduit tube which may have a
recessed “V” notch (eliminate slippage) or a hook attached.

Load Shadow – The shadow of the load is the area that the load would likely fall to or through if it was to
fall in an uncontrolled manner.

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 Title: Cranes and Mobile Cranes No: P314.414 Approval:
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Mobile crane – A crane capable of travelling over a supporting surface without the need for fixed runways
(i.e., railway tracks) and relies only on gravity for its stability.

Slinger – A person who has completed PG105 basic slinging training module for loads up to 1 tonne.

Suspended Load – A load suspended by lifting equipment and not fully supported by a structure or stand
from below or fixed into position e.g. welded or bolted.

Tagline - A rope attached to an object before a lift takes place and used to control the sway, stability and
placement of the object. It will be a minimum of 12mm (recommended 16mm) fibre rope, dry and of a non-
conductive material.

Workbox - Means a device designed to AS 1418.17 to be suspended from a crane to provide a working
area for a person.

WHSQ - Workplace Health and Safety Queensland

6.0 ACTIONS

6.1 Site Approval for Cranes and Mobile Cranes

6.1.1 Site Access

Prior to site entry, mobile cranes shall be annually inspected and approved by the Crane
Base Supervisor (or delegated representative) / Supervisor of the Contract under their
control. All cranes and mobile cranes shall be approved before entry on site. Approval shall
be given by the Crane Base Supervisor or the QAL Supervisor of the Contract using the
check sheet for approval of mobile equipment entry to site is shown in Attachment 7.1 and
Attachment 7.2. The “site approved” sticker (Attachment 7.3) shall be attached to the
equipment in a prominent position.

Any equipment found to be substandard shall be taken out of service immediately.

A minor defect that does not affect the safe operation of the equipment, shall be logged in the
machines daily pre-start check sheet for the equipment owner to rectify within seven working
days.

6.1.2 Registration / Certification

The Crane Base Supervisor (or delegated representative) or the QAL Supervisor of the
Contract shall ensure any mobile crane (with a lifting capacity of more than 10 tonne) under
their control is compliant with WHSQ annual registration and certification. Registration and
certification is the responsibility of the equipment owner. For QAL owned mobile cranes (with
a lifting capacity of more than 10 tonne), registration and certification is the responsibility of
the QAL Lead Asset Management Engineer. The registration sticker must be displayed
clearly within the cabin.

6.2 Equipment Selection

If a mobile slewing crane is required, the selection and provision of the appropriate crane and crane
operator (if applicable) must be co-ordinated by the QAL Crane Base Supervisor / or the QAL
Supervisor of the Contract / or Lift Supervision.

6.3 Operation of Cranes and Mobile Cranes

6.3.1 Operation
All cranes and mobile cranes shall be operated strictly in accordance with the manufacturers
operating handbook.

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Title: Cranes and Mobile Cranes No: P314.414 Approval:
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6.3.2 Mobile Crane Risk Assessment

All mobile cranes shall have a risk assessment completed by the Owner prior to initial
use. The risk assessment shall:
• involve operators and maintainers who will use the equipment, and
• address all aspects of safe operation including handling, driver vision, brake
failure, tyre blow out and access and egress for operators and maintainers.
A comprehensive risk analysis shall be conducted to clearly identify the behavioural
and conditional factors that impact mobile equipment and driving safely. The risk
analysis must cover all aspects of mobile equipment and driving and will have up-to-
date action plans in place to manage identified issues.

The risk assessment template can be located in File/New/On My

Computer/Excel/HS&E/HSE-028-mmyy.

The risk assessment shall be reviewed annually by the owner of the equipment.

6.3.3 Pre-Operational Inspections

Pre-operational inspections are the responsibility of the operator and are required to be
performed at the commencement of each shift or at the first use of the crane or mobile crane
in the shift. Information is to be recorded in the equipment daily pre-start check sheet.

All faults that may affect the safe operation of the equipment must be reported immediately to
Supervision, and the equipment removed from service until the risk has been assessed by a
competent person and rectified as appropriate.

Before operating a crane from the towered position, a check for the presence of overhead
conductors and powerlines shall be undertaken.

6.3.4 Lift Plans for Mobile Crane Non-Critical Lifts

For mobile crane non-critical lifts, a documented lift plan shall be developed prior to the lift
commencing. This shall be documented in Part A of the QAL Crane JSEA that can be
sourced in Word template File>Word>New>On My Computer>Maintenance Services>Crane
JSEA>MS-017.

When completing the risk assessments, consideration should be given to where a load may
bounce or skid off another structure increasing the potential load shadow area.

6.3.5 Lift Plans for Critical Lifts

If the lift is defined as a critical lift (see definition in 5.0), a documented and approved lift plan
shall be developed prior to the lift commencing. The plan will address the crane
configuration, rigging techniques, load details and the associated hazards of the lift.

For critical lifts, Part A and Part B of the QAL Crane JSEA shall be completed.

For critical lifts involving personnel in workbox, Part A and Part C of the QAL Crane JSEA
shall be completed.

The critical lift plan shall be approved by one of the following roles (or their designate):

• Refinery Support Superintendent

• Engineering and Maintenance Services Manager
• Descale Shift Supervisor (out of normal business hours)

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Title: Cranes and Mobile Cranes No: P314.414 Approval:
Issue: 2 Rev: 1 (Inits)

All critical lifts must be carried out in accordance with the critical lift plan and be under the
control of Lift Supervision. Lift Supervision must be present throughout the duration of the
critical lift. If the task scope changes or there is a need to move away from the original lift
plan, the lift must stop and the critical lift plan must be up-dated and re-approved.

All critical lift plans shall be submitted to the QAL Crane Base Supervisor who shall maintain
a register of critical lifts.

For lifts that do not meet the critical lift definition but are complex in nature, i.e. requires a
detailed analysis of the load and slinging arrangements, Part B of the Crane JSEA may be
used.

6.3.6 Pre-Task Hazard Assessment for All Crane Lifts

For all crane lifts a QAL JSEA shall be completed at the worksite as a pre-task hazard
assessment. This needs to consider the requirements of the Work at Height procedure
P314.311.

6.3.7 Slinging the Load

Slinging shall only be carried out by persons holding a basic Slinging qualification or a QAL
Dogger CTO or under direct supervision of a qualified QAL CTO Dogger for the purpose of
training, i.e., completion of logbook hours. Critical lift slinging shall ONLY be undertaken by a
Dogger.

If the load is outside the vision of the Crane Operator, a Dogger must direct the crane
operations.

Where rigging arrangements have the ability for the load to be adjusted through a mechanical
aide (e.g. chainblock, cum-along, turn buckle) or shortening of chains, potentially increasing
the inclusive angle greater than 60o, the load prior to suspension shall be rigged by a single
lifting device (e.g. shackle, ring) attached to the crane hook.

When a load has the ability to be adjusted through mechanical aides whilst suspended from
the crane hook, a dedicated Dogger shall be in place to monitor the lift and its rigging
arrangements.

Rigging equipment that has been used for towing purposes shall not be used in any crane lift.

Under no circumstances shall a person work under or be positioned under a

suspended load or its shadow.

6.3.8 Suspended Load Control

The physical touching of a suspended load is prohibited if the load is more than 450mm from
the final attachment, mounting or set-down point or the load is in transit. The use of
taglines or load control poles shall be used to guide suspended loads into that position and to
control the sway and stability of the load in transit.

Where a suspended load requires physical handling outside the prohibition zone (e.g.
lowering and placing counterweights on cranes), a detailed documented risk assessment with
Superintendent approval shall be completed.

A tagline or load control pole shall be attached to the load and not the actual lifting equipment
and be of an appropriate length where its use does not introduce additional hazards.

6.3.9 Working Near Live Electrical Lines

A person must not operate any part of a crane or other lifting device within 3m of electric lines
rated low voltage up to 132kV.
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Title: Cranes and Mobile Cranes No: P314.414 Approval:
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For all critical crane lifts within 10 metres of power lines, an Electrical Proximity Permit is
required as per Procedure P314.615.

6.3.10 Communication

A method of communication must be established and documented in the JSEA or lift plan
before commencement of work. The chosen method must take into account the operating
environment in which the lift will occur. If radio communication is chosen, it must be
conducted on a closed channel.

For critical lifts there must be a means of communication between people involved in the lift
from Lift Supervision through to Crane operators.

6.3.11 Crane Checks

Prior to leaving the crane, the operator shall record in the pre-start check sheet the crane
checks, adjustments, renewal of parts, repairs and inspections performed, the hours worked
by the crane, duties performed by the crane including maximum loading and all incidents and
irregularities of loading, operation, wear, damage and the like concerning the safe use of the
crane. Each load entry shall be signed by the responsible person making the entry and
should contain details of that person's identification and qualification.

The crane shall also be parked fundamentally stable as per procedure P314.701.

6.4 Inspection and Maintenance

The equipment owner is responsible for inspecting and maintaining the equipment to the
manufacturer’s specification.

6.4.1 Crane Modifications and Maintenance

Modifications to crane or mobile cranes can only be authorised by a professional engineer,

and the design must be re-registered with Workplace Health and Safety Queensland.

Maintenance on cranes or mobile cranes shall be in accordance with the manufacturer’s

specification and regulatory requirements and only be undertaken by authorised persons who
must have the appropriate qualifications and CTO.

6.4.2 Crane Inspections

Crane and mobile crane owners are responsible to have the crane inspected by a competent
person prior to registration each year.

The frequency of major inspections shall be in conformance with the manufacturer's

recommendations and the requirements of AS2550.1 and the Mobile Crane Code of Practice.

• 10 Year Major Inspection

Cranes and mobile cranes shall be subjected to a major inspection after 10 years for
mechanical components. The 10 year major inspection is to be certified by an Engineer
who has experience in the inspection of cranes.

• 25 Year Major Inspection

Cranes and mobile cranes shall be subjected to a 25 year major inspection for their
structural integrity. The 25 year major inspection is to be certified by an Engineer who
has experience in the inspection of cranes.

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 Title: Cranes and Mobile Cranes No: P314.414 Approval:
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6.5 Training and Qualifications

All mobile crane operators must hold a certificate to work in a prescribed occupation (Certificate of
Competency) relevant to the type of crane being operated and a QAL CTO (or Contractor
equivalent).

For a gantry crane operated by remote control, (defined as load shifting equipment), a Certificate of
Competency and a QAL CTO is required if the load being lifted is greater than 5 tonn e. For loads
less than 5 tonne, a competent operator shall have an appropriate QAL CTO.

Any QAL employee and contractor performing dogging operations must hold a WHSQ Certificate of
Competency for Dogger (or other similar State qualification) and a QAL CTO Dogger.

An Intermediate Rigger must hold a WHSQ Certificate of Competency for Intermediate Rigging (or
other similar State qualification) and a QAL Dogger CTO perform dogging operations.

A Slinger must have completed PG105 basic slinging training module to perform slinging operations
for loads up to 1 tonne.

6.6 Records
Records of inspection and maintenance programs for each individual equipment must be held by the
equipment owner for auditing purposes. Records must be retained for the life of the equipment, and
if the equipment is sold, the records form part of the sale.

All critical lift document plans shall be forwarded to the Crane Base Supervisor and entered into a
register for keeping indefinitely.

QAL Crane JSEA’s for all other lifts shall be retained by the Crane Base Supervisor / Supervisor of
the Contract / Lift Supervisor for 3 months.

Mobile crane risk assessments shall be filed indefinitely in P:\general\Safety\Risk

Register\Vehicles & Mobile Equipment. Contractor mobile crane risk assessments shall be
filed in the Contractor’s system on site for the duration the crane is on site.

6.7 Manuals
Manufacturer supplied manuals and other service books to be kept in the crane area include:

The crane operators manual

The crane pre-start check book

The maintenance manual, service record (log book) and parts book can be kept at the office of the
equipment owner.

7.0 ATTACHMENTS
7.1 Check Sheet for Mobile Equipment Entry Onto Plant
7.2 Vehicle Housekeeping Standard - Scorecard
7.3 Site Approved Sticker

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 CHECK SHEET
FOR MOBILE EQUIPMENT ENTRY ONTO
PLANT

Company Name: ………………………………………………………………………

Vehicle Type: ………………………………………………………………………

Vehicle I.D.: …………………………………Crane Date of Manufacture……………

Yes No N/A

1. Annual inspection report current. (Where applicable.)

2. (Cranes) 10 Year Major Mechanical Inspection & recommendations

completed

3. Current WH&S Registration. (Where applicable.)

4. All warning systems operational, e.g., reverse alarm, computer cut

outs, anti two block alarm (where required), flashing light.

5. No synthetic slings.

6. No aluminium ferrules on winch ropes or slings.

7. All chains and chain slings, tested and tagged within last 12 month



period and in serviceable condition.

8. All operating levers clearly marked with their function.

9. Winch clearly marked with loading capacity and rope specifications.

10. Operators certificated and authorised to operate plant.

11. Operators aware of QAL JSA and procedural requirements, e.g.,

overhead work, road closures, etc.

12. Fire extinguisher attached in a readily accessible position and is

current.

13. Meeting requirements compliant with QAL Housekeeping standard

for vehicles. (Standard attached.)

14. Current roadworthy certificate. (When required to be operated in

public access roads).

15. Controls on truck mounted crane have clear signage to “Operate

from opposite side to hook/load only”.

16. QAL Equipment. Sticker identifying “Competent to Operate

Required for this Equipment” must be clearly visible to intending
operators.

Please Circle:- PASS / FAIL

This vehicle has been inspected and is approved for Site Use.

Signed: ……………………………………… Print Name: ……….….……………….…….…

Date: ……………………………….
P314.414 Iss. 2 Rev. 1 Attachment 7.1 (010510) Page 1 of 1
 Queensland Alumina - Plant Housekeeping Standard - Scorecard
0-4 5-6 7-8 9 10 Score
VEHICLES
Cabin Lots of rubbish Some rubbish Acceptable. No Good. Requires Clean & tidy.
& dirty. Seats & & dirt. Seat & rubbish. Minor minor clean.
upholstery torn. upholstery in dirt. /10
fair condition.
Cargo Storage Area eg. Lots of rubbish, Some rubbish, No rubbish. Good. Requires Clean & tidy.
• Boots dirty, process dirt, process Minor dirt. minor clean. Everything
• Utilities encrustation. encrustation. Everything Everything secure.
Unsecured Unsecured secure. secure. /10
equipment. equipment.
Windscreens & Windows Windscreen Windscreen Windscreen Good. Requires All clean &
• Clean, operable cracked, pitted, windows clean. Wipers minor clean, serviceable.
• Wiper blades or dirty cracked or operable. Other however safe.
impairing pitted but not windows & / 10
drivers vision. impairing vision. blades fair.
Lights eg. Damaged lights Suspected All external All lights All lights
• Interior & exterior or lights blown bulbs in lights working. working & working &
• Clean & operable removed. external lights. visible. Clean clean. /10
necessary.
Tyres Exposed Unsafe tread. Tyres in safe All tyres in good All tyres in good
belting. Deflated. condition. condition. Dirty. condition. Clean
Severely Correct / 10
deflated. inflation.
Leaks eg Major leaks. Some minor No leaks but No leaks & No oil / water
• Oil & water leaks. some sign of very little sign of leaks. No
previous leaks residue from residue from
not cleaned previous leaks. previous leaks,
away as new /10
condition
Paintwork Major process Minor No Good but Clean & good.
encrustation. encrustation. encrustation. requires clean. / 10
Paint fair.
Body Panels Unsafe. Major Safe. Many Few minor Superficial No damage to
damage to body instances of instances of damage to body body panels,
panels, damage to body damage. panels, bumpers, tow
bumpers, tow panels, bumpers, tow bar.
bar. bumpers, tow bar. / 10
bar.
Service Book & Missing and/or Minor detail Complete & Complete, clean Service book
Information Stickers Many details incomplete. Had readily & readily complete, clean
incomplete. to chase it up. available. All available. All & stored in
Most Some appropriate appropriate specific
information information information information location. All
stickers missing stickers missing stickers in stickers in appropriate
or or defaced place, place, most information
inappropriate. need cleaning clean & or in stickers in
& or re- clear view place, clean & /10
positioning in clear view
Seat Belts Seat belts not Seat belts fitted Seat belts fitted Seat belts in Seat belts in
fitted. but inoperable. & operable. very good very good
condition. condition.
Reminder
sticker in /10
vehicle.

Total %

0 - 60% Unsatisfactory 80-90% Meeting Requirements

60-80% Marginal/Improvement Necessary 90-100% Exceeding Requirements

P314.414 Iss. 2 Rev: 1 Attachment 7.2 (010510) Page 1 of 1

 QUEENSLAND ALUMINA

SITE APPROVED
Company:………………………………….
Equip I.D.:…………………………………
Signed:…………………………………….

Next Inspection Date:

…………………………

P314.414 Iss. 2 Rev. 1 Attachment 7.3 (010510) Page 1 of 1