A tower crane is used for lifting, lowering, and moving loads, typically for constructing tall buildings, and differ from self-erecting cranes which do not split into separate mast/jib elements.

According to the WHS Regulations:

  • a tower crane is a crane that has a boom or a jib mounted on a tower structure.
  • a self-erecting tower crane is a crane that is not disassembled into a tower element and a boom or jib element in the normal course of use, and where erecting and dismantling processes are an inherent part of the crane’s function.

A hammerhead tower crane is a fixed construction crane featuring a vertical mast and a fixed, horizontal working jib that resembles a hammerhead. It utilises a rolling trolley to move loads horizontally along the jib and a rear counter-jib, providing excellent lifting capacity and wide worksite coverage.

A topless (flat top) tower crane eliminates the A-frame and pendant lines of a hammerhead tower crane. The jib and counter-jib attach directly to the top of the tower, creating a flat profile. Can also be called a topless hammerhead.

A luffing tower crane has a hinged jib that can be raised and lowered (a motion called ‘luffing’). Unlike traditional hammerhead cranes that rely on a trolley moving along a fixed horizontal arm, a luffing crane changes its working radius by adjusting the angle of its boom.

Luffing jib tower crane

A self-erecting tower crane is a folding crane that can deploy itself using built-in hydraulics and cables which allows them to be deployed and dismantled quickly. They don’t have a concrete foundation but sit on their own platform with adjustable legs. They are often used for low rise projects with small construction sites.

Self-erecting tower crane

Hazards

Tower crane operations may present a risk of injury to workers and other people from:

  • Structural failure may include the failure of any crane component, such as the boom, jib or wire rope. A tower crane may suffer structural failure if the crane has been overloaded or operated outside the approved area of its load chart. Structural failure may occur without warning. This may be influenced by a number of factors including rapid slewing and high wind conditions.
  • Contact or collision with other plant and structures may occur where sufficient clearances are not maintained between the tower crane and other plant and structures, such as other cranes, buildings and overhead powerlines.
  • Falling objects may result from erecting and dismantling activities, and the way loads are secured during lifting operations.
  • Falls from height: operators falling while accessing the crane or performing maintenance.
  • Other hazards: noise, fatigue, psychosocial hazards (e.g. high job demands, remote or isolated work, or poor physical environments).

Safety requirements

  • Safe Work Method Statements (SWMS): working with tower cranes requires a site-specific High Risk Construction Work Safe Work Method Statement (SWMS) being implemented before work commences. See SWMS for high risk construction work | SafeWork SA.
  • Training: ensure operators are trained on the specific crane controls, including emergency procedures, and are licenced and follow SOPs and SWMSs.
  • Working with loads: never exceed the Working Load Limit and ensure loads are balanced and secured before lifting.
  • Exclusion zones: ensure they are in in place.
  • Communication: have an agreed system of communication with support personnel who have line of sight of the operator.
  • Operation: avoid lifting over people.
  • Wind: monitor wind speeds and their effect on size and shape of the suspended load and crane boom.

High Risk Work Licence

According to the WHS Regulations:

  • for high risk licensing purposes, a tower crane, if a jib crane, may be a horizontal or luffing jib type and the tower structure may be demountable or permanent, but ‘tower crane’ does not include a self-erecting tower crane.

A person who operates a tower crane must hold a Tower Crane Licence (Class CT).

A person who operates a self-erecting tower crane must hold a Self-erecting Tower Crane Licence (Class CS).

For further information go to: High Risk Work Licence.

Registration

Tower cranes and self-erecting tower cranes require both design and plant item registration.

Cranes that are manually powered do not require registration.

Registration costs can be found at Registration Fees.

Design registration

Plant design registration – Guidance notes

To register or alter the design of plant:

Plant design - New or alteration to design

Tower crane design registration can take two forms:

  1. design registration of the tower crane consisting of both the crane structure design and site-specific foundation design, or
  2. design registration of the tower crane structure alone.

The crane can be designed to any internationally recognised published technical standard with the following documents being required for the registration of the crane design:

  • each crane model must have a separate design registration application form.
  • statement signed by the designer of the plant stating:
  • the designer has complied with their obligations under section 22 of the WHS Act.
  • the published technical standards and engineering principles used in the design.
  • design calculations and drawing(s) in English, as referenced in the designer's statement
  • an independent design verification statement.
  • payment of the fee which lasts for the life of the design (payable on completion of the online application).

Note:

  • design registration applies to all plant items manufactured to the same design.
  • design registration is valid for the life of the plant.
  • manufacturers, importers, and suppliers of plant are prohibited from supplying plant unless the design of that plant is registered.
  • design registration in SA is not required if the plant design is registered in another state under a corresponding WHS law (WHS Act 2012 (SA)).
  • any alteration to the design of registered plant that may affect health, and safety requires an alteration to its design registration.
  • the design of a fixed crane (i.e. tower crane) includes the supporting structure and foundations. Design verification must include the supporting structure and foundation. Therefore, a new Design Registration Certificate needs to be issued for the supporting structure and foundation together.

According to Regulation 244 – Altered Plant Designs to be Registered, you do not need to register a design alteration of the crane for the relocation of a gantry, bridge or tower crane if:

  • the crane is relocated to a different workplace and
  • the design of the supporting structure or foundations of the crane is altered in accordance with a site-specific design prepared for the safe operation of the crane at the new location and
  • the design of the crane is not altered in any other way.

Plant registration

Plant registration – Guidance notes

To register the item of plant:

Plan item registration

Plant - Variation / Change of ownership

To register plant for the first time in South Australia or to renew lapsed registration, the following documentation will be required:

  • completed online application form including fee payment.
  • Design Registration Certificate, or a Design Approval Letter (issued pre-July 1996), or exemption letter issued by SafeWork SA to you the applicant (not transferable).
  • statement from Competent Person that the plant is safe to use or operate which includes the supporting structure and foundation (issued within 12 months of application date).
  • date when plant item was first commissioned or first registered (whichever occurred first).
  • Commissioning Report (prior to first use in Australia). If the crane being registered has been in service for more than 10 years, attach a copy of the Major Inspection Report (10-yearly) in lieu of a Commissioning Report.
  • authorisation letter from the PCBU who will have management or control of plant (where the applicant is a third-party acting on behalf of the PCBU).

If you are applying for transfer of ownership of an existing SafeWork SA issued registration(s) the following documentation will be required:

  • completed online notification form lodged within 14 days of purchase.
  • date when plant item was first commissioned or first registered (whichever occurred first).
  • statement from competent person that the plant is safe to use or operate (issued within 12 months of application date).
  • if the crane being registered has been in service for more than 10 years, attach a copy of the Major Inspection Report (10-yearly) in lieu of a Commissioning Report.
  • authorisation letter from the PCBU who will have management or control of plant (If applicable where the applicant is a third-party acting on behalf of the PCBU).
  • letter from former owner confirming date that transfer of ownership occurred and that they no longer have management or control of the plant.

If you are applying to change the location of an existing SafeWork SA issued registration(s) the following documentation will be required:

  • completed online notification form lodged within 14 days of becoming aware of the change.
  • statement from Competent Person that the plant is safe to use or operate in the new location which includes the supporting structure and foundation (issued within 12 months of application date).
  • Design Registration Certificate for the tower crane footing at the new location (if applicable).
  • If the crane being registered has been in service for more than 10 years, attach a Major Inspection Report (10-yearly).
  • authorisation letter from the PCBU who will have management or control of plant (If applicable where the applicant is a third-party acting on behalf of the PCBU).

If you are applying to make changes to other information of an existing SafeWork SA issued registration(s) the following documentation will be required:

  • completed online notification form lodged within 14 days of becoming aware of the change(s).
  • where the change relates to a design alteration, then a copy of the design registration for the alteration and any relevant changes to recorded information
  • statement from competent person that the plant is safe to use or operate reflecting the updated information (if applicable).
  • if the crane being registered has been in service for more than 10 years, attach a copy of the Major Inspection Report (10-yearly).
  • authorisation letter from the PCBU who will have management or control of plant (If applicable where the applicant is a third-party acting on behalf of the PCBU).

Note:

  • SafeWork SA will notify plant registration holders in writing around one month prior to renewals being due. In making a decision to grant the renewal of a plant item registration, SafeWork SA will consider whether the plant has been regularly maintained and inspected in accordance with WHS Regulation 213 and 235.

Change of details

You must provide us with written notice within 14 days if:

  • you change your name or address, or any other information stated on your application for registration
  • the plant design has been altered to an extent where it is subject to new control measures

Inspection and maintenance

Inspections shall be carried out at sufficient frequency to ensure the crane is kept in a safe and satisfactory condition and carried out in conformance with AS 2550.1 and AS 2550.4 (for self-erecting cranes it is AS 2550.20) including:

  1. Pre-erection and commissioning inspection and testing: prior to erecting the crane, or where additional or modified components are used on an erected crane.
  2. Pre-operational inspection: before the beginning of each work shift or change of operator.
  3. Routine inspection: conducted at intervals of 3 months.
  4. Periodic
  5. inspection: conducted at intervals of 12 months.
  6. Major inspection: see below:

According to WHS Regulation 235 – Major Inspection of Registered Mobile Cranes and Tower Cranes, the person with management or control of a registered mobile crane or tower crane at a workplace must ensure that a major inspection of the crane is carried out by, or under the supervision of, a competent person:

  1. at the end of the design life recommended by the manufacturer for the crane; or
  2. if there are no manufacturer's recommendations—in accordance with the    recommendations of a competent person; or
  3. if it is not reasonably practicable to comply with paragraph (a) or (b)—every 10 years            from the date that the crane was first commissioned or first registered, whichever  occurred first.

In WHS Regulation 235, a major inspection means:

  • an examination of all critical components of the crane, if necessary, by stripping           down the crane and removing paint, grease and corrosion to allow a thorough  examination of each critical component; and
  • a check of the effective and safe operation of the crane.

For further information: Safe Work Australia Guide to inspecting and maintaining cranes.

Record keeping

A record (e.g. logbook) of the service and maintenance history of the plant needs to be kept and made readily available and be written in easy to understand English.

Refer to AS 2550.4 (for self-erecting cranes it is AS 2550.20) and WHS Regulation 237.

Contact us

Visit: safework.sa.gov.au

Call: SafeWork Licensing Unit on 1300 365 255

Email: licensing.safework@sa.gov.au

Further information

SafeWork SA

Resources

Legislation

  • WHS Act 22 - Duties of PCBUs that design plant, substances or structures
  • WHS Regulation 213 – Maintenance and inspection of plant
  • WHS Regulation 219 (3) – Plant that lifts or suspends loads
  • WHS Regulation 235 and 714 – Major inspection of registered mobile cranes and tower cranes
  • WHS Regulation 237 – Records of plant
  • WHS Regulation 244 – Altered plant designs to be registered

Australian Standards

Codes of Practice

FAQ - Frequently Asked Questions

Q1. What are the registration requirements for tower cranes?

In South Australia all tower cranes are classified as high risk plant under the Work Health and Safety legislation (WHS Reg. Schedule 5 Part 1). Every tower crane must hold design registration and item of plant registration before they are placed into service.

The crane supplier (who may also be the importer) has the legal duty to ensure the crane design is registered, and that they hold a copy of the design registration certificate prior to any distribution and sale of the crane.

The design registration number issued by SafeWork SA or an interstate regulator is unique to that model of crane and must be permanently marked on the crane.

The owner or person with management control of the crane is responsible for the item of plant registration. They will need copies of the design registration certificate, “Safe to Operate” certificate and commissioning report. They can then attach all the supporting documentation to a completed application form and send it to SafeWork SA along with payment of the fee.

Q2. Are there any registration fees?

Cranes incur a fee when they are first design registered which is valid for the life of the plant.

A design registration fee applies only once for the initial application because upon issue there is no expiry date.

Cranes incur a fee each time they are plant item registered for a 5-year period. The owner will receive an invoice from SafeWork SA before the renewal date. The invoice will have an associated fee.

Plant registration will remain valid for the 5-year period unless the crane is sold, scrapped, or a design alteration occurs to the level of safety requiring a review of risk control measures.

Q3. Who can apply for design registration?

  • a person conducting a business or undertaking (PCBU) that designs an item of plant may apply to the regulator for the registration of the design of that item of plant.
  • a person with management or control of an item of plant at a workplace may apply to the regulator for the registration of the design of that item of plant.

Q4. Duties of the crane Designer and Design Verifier.

The designer must undertake a design risk assessment and be satisfied through engineering calculations that the crane is at the appropriate level of safety in accordance with the published technical standards and/or engineering principles being used. The designer must declare that they “have complied with the designer’s obligations under Section 22 of the WHS Act in respect to the design of the plant.”

For design verification under regulation 252, a Design Verifier is a person who has the skills, qualifications, competence and experience to design the plant or verify the design

The Design Verifier has the important role of determining through their own independent assessment that the design satisfactorily complies with design intent published technical standards, and/or engineering principles. They must also declare that “they were not involved in the production of the design; and that the design was produced in accordance with the published technical standards and/or engineering principles specified by the designer’s statement and documents.”

The crane original design can be to any internationally recognised published technical standard including calculations and drawings. However, Design verification must declare full compliance with AS 1418.1 and AS 1418.4.

Q5. Does each tower crane require individual design registration?

No, once the design is registered, there is no restriction on the number of cranes that can be supplied, provided they comply with the registered design. The registration holder must ensure the design registration number is provided with each gantry and bridge crane that is supplied.

The design of a tower crane includes the supporting structure and foundations. Design verification must include the supporting structure and foundations. Therefore, a separate Design Registration Certificate is required for the footing.

Q6. Is interstate design registration recognised in South Australia?

Yes, interstate design registrations issued under a corresponding WHS law (i.e. a law of another Australian jurisdiction corresponding, or substantially corresponding, to the WHS Act 2012 (SA)) are recognised in South Australia. However, it is important to ensure the crane design also complies with relevant South Australian Approved Codes of Practice.

There may be Australian States or Territories who have introduced specific variations to the WHS model legislation and while the design may comply with the legislation in those jurisdictions, it may no longer fully comply with South Australian requirements. If this is the case, item of plant registration may be refused (i.e. design registration may not be recognised) because the design does not fully comply through a corresponding WHS law equivalent to that in South Australia.

Q7. Are overseas design registrations recognised?

Every crane installed in South Australia must have an Australian design registration.

Q8. When is an application for alteration to a design of a tower crane required?

The WHS Regulations state that “In this regulation a reference to the alteration of a design is a reference to an alteration that may affect health or safety.”

What does that mean?

'Alter' in relation to any plant means to change the design of, add to or take away from the plant where the change may affect health or safety, but does not include routine maintenance, repairs or replacements.

When a crane is first design registered, the design is based on certain criteria and specifications that set a minimum level of safety. If that level of safety is altered, then an application for the alteration must be submitted to SafeWork SA. Below are some changes that may affect the level of safety:

  • Structural modifications: changes that affect load-bearing capacity or stability must be registered. This includes modifying the frame.
  • Mechanical or Hydraulic Changes: alterations to lifting mechanisms, winches, hoists or hydraulic systems that impact performance or rated load.
  • Rated Capacity Adjustments: any modification that changes the crane’s maximum lifting capacity, load charts or operational limits.
  • Safety System Upgrades: installing or modifying safety devices such as load moment indicators, limit switches, or emergency braking systems that affect operational safety.

Note: Alterations must be compliant to the latest legislative requirements.

Q9. Does each manufactured tower crane require item of plant registration?

Yes, each crane must be individually registered before being placed into service.

The item of plant registration number issued by SafeWork SA is specific to that crane.

The design registration number issued by SafeWork SA or an interstate regulator is unique to that model of crane and must be permanently marked on the crane.

Q10. What is the process for obtaining Item of Plant Registration for the first time?

To register plant for the first time in South Australia or to renew lapsed registration, the following documentation will be required:

  • a completed online application form including fee payment.
  • a Design Registration Certificate, or a Design Approval Letter (issued pre-July 1996), or exemption letter issued by SafeWork SA to you (not transferable).
  • a copy of Statement from Competent Person that the plant is safe to use or operate (issued with 12 months of application date).
  • date when plant item was first commissioned or first registered (whichever occurred first).
  • a copy of the Commissioning Report (prior to first use in Australia). If the crane being registered has been in service for more than 10 years, attach a copy of the Major Inspection Report (10-yearly) in lieu of a Commissioning Report.
  • a copy of the authorisation letter from the PCBU who will have management or control of plant (where the applicant is a third-party acting on behalf of the PCBU).

Q11. What information should the Commissioning Report contain?

A commissioning report contains the technical information from the final manufacturer’s set up of a crane. The type and extent of the tests are based on the manufacturer’s instructions and the mandatory requirements from the technical design standard.

The data contained in the commissioning report is evidence that all the appropriate tests have been conducted and the results are in accordance with the manufacturer’s instructions and the technical standard applicable.

Q12. What happens after I submit an application for plant registration?

After SafeWork SA receives an application and fee payment has been receipted:

  1. SafeWork SA will audit each section of the application form and supporting documentation. It is important that correct information is provided.
  2. If any information is missing, SafeWork SA will contact the applicant. This may cause delays in processing.
  3. Once details are audited and any additional requested information and/or revised documents received the application will be processed and the plant registered.
  4. A registration document (certificate) will be sent to the applicant. The document will contain information as submitted in the application form, the applicant details and the issued item of plant registration number. The registration number must be displayed on or near the crane.
  5. The registration is valid for a 5-year term. When renewal is due, an invoice will be sent about one month before the registration expires to the recorded address of the registration holder.

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