Q4 2019

PROMOTING SAFETY IN THE CRANE INDUSTRY

Multi-crane lifts
Engineering and executing
safe multi-crane lifts
 Thanks to this edition’s contributors

CALL Are you an aspiring author? Are you passionate

about the safety of your workmates? Do you

FOR have an idea for improving safety or efficiency in

your workplace? We want to hear from you.

CONTENT Contribute to Lifting Matters’ vision of a safer industry by

submitting your ideas and articles to
liftingmatters@writestrategy.com.au

We are seeking stories about recurring incidents,

significant incidents, ideas about safer and more
efficient ways of working, any prevalent issues, good
reminders, anything of a safety related nature.

You can submit a full article, anywhere from 200 to

1000 words, or you can send us ideas about what you
would like to hear us discuss in future issues of Lifting
Matters. If you’re from a business, we will mention you
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We can’t wait to hear from you!

2 LIFTING MATTERS ISSUE Q4 2019

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From the Editor
Q4, October - December, 2019
Welcome to the Q4 2019 edition of Lifting
Matters.
This quarter we decided to explore multi-
crane lifts (also referred to as tandem
lifts). It was a fantastic learning experience
for me in the compilation of this edition.
In pulling together various contributions,
it became apparent that multi-crane lifts
are something we really struggle with as an
industry! There is difficulty in interpreting
the Australian Standards, as well as
state regulations to meet, and of course,
differences internationally. Multi-crane
lifts provide an interesting intersection
between safety and engineering that we
often don’t fully appreciate. Thankfully,
I was able to connect with some highly
experienced lift engineers and safety
personnel to work through this, including
Kevin Ball who is the Group Safety Manager
at Smithbridge Group/Universal Cranes
and a representative on the Australian
Standards and ISO committees, Alice
Edwards from CICA and subject matter
experts at Worksafe Qld. I hope you all
learn as much from these people as I have!
4 LIFTING MATTERS ISSUE Q4 2019
Please get in touch with us! You can visit us
on Facebook, LinkedIn or drop us an email
any time. If you have an incident report,
ideas about safer and more efficient ways
of working, widespread issues, valuable
reminders or anything else safety-related,
we want to hear from you. We look forward
to working together to protect our people
and save lives in the crane industry. Any
contributions for our next edition are due
by 15 November 2019.
If you prefer printed glossy copies for
your crane cabs, cribs, mess hall, or
reception, please send your postal address
and the number of copies you require to
liftingmatters@writestrategy.com.au.
Lifting Matters is available to view at
www.liftingmatters.com.au, or you can
subscribe to receive an email copy each
quarter.
Stay safe and see you next edition!
Thank you
DASHELLE BAILEY,
EDITOR
liftingmatters@writestrategy.com.au
Contents

EDITORIAL 4

FEATURE ARTICLE
Multi-crane lifting 6

INCIDENT REPORT
Caracas, Venezuela 14
Mississippi, USA 16
Alphen aan den Rijn, The Netherlands 19
New Delhi, India 22

IN THE NEWS LATELY

Crane hits powerline 24
Crane overturned 25

SPOTLIGHT ON MULTI-CRANE LIFTS

Taking collaboration to new heights 26

TOPIC COMMENTARY
Understanding the load distribution for multi-crane lifts 30

WORKING SAFELY
Multi-crane lifts in Queensland 34

OPERATOR’S OPINION
How technology is key to improving safety 38

PEOPLE PROFILE
Gordon Stone 40

MENTAL HEALTH WEEK 2019

Four steps to prevent psychological injury in your workplace 42
Feature Article
Multi-crane lifting
KEVIN BALL Group Safety Manager, Smithbridge Group/Universal Cranes
Standards Australia Committee Member
Several of the most high-profile crane
accidents of recent times have been those
involving multiple cranes (also referred
to as tandem lifts). When there are two
or more cranes involved in an incident,
the impact and outcome of the incident is
often magnified. It figures – right? Double
the equipment, double the personnel,
double the consequences! The complex
nature of lifts involving multiple mobile
or crawler cranes makes them particularly
hazardous.
6 LIFTING MATTERS ISSUE Q4 2019
It’s always important to properly plan
any lift, but even more so when there
are several cranes involved. Multi-crane
lifts are among the most technically
complex lifts to plan and execute. As an
industry, we generally struggle with lifts
involving multiple cranes. The Australian
Standards or international equivalents
can be difficult to interpret. There is also
often a layer of state or local guidelines to
meet, which can be at odds with national
standards. Guidelines differ between
Feature Article

states and countries. Therefore, I

must preface this article by saying it
will not be possible for me to outline
the specific requirements of your
local region. I encourage you to do
your own research in this regard, It’s always important
but I will attempt to provide some to properly plan any
general things to be considered when
lift, but even more so
planning and executing a multi-crane
lift. when there are several
cranes involved
What is a
multi-crane lift?
Put simply, multi-crane lifts are
those which involve two or more
cranes to support a load either with
hooks attached directly to the load by
slings, through shackles attached to
pad eyes, or directly to an equaliser
beam. Upending a vertical vessel
using two cranes, one at the top end
and a tailing crane on the bottom end
is also considered a multi-crane lift.

Note, we are not talking about

synchronised lifts here. As outlined
in AS 2550.1, clause 1.4.13, a
Synchronized motion means “Two or
more crane motions under the control
of a single command output with bi-
directional communication so that
the behaviour of one motion causes
identical behaviour of the others”,
which means they are electrically or
mechanically connected – something
that overhead and gantry cranes can
achieve. However, it is not practical
in the mobile crane world. Therefore,
we are concentrating on most of the Note, the powerlines in this photo were
lifts that utilise mobile cranes. de-energised for the lift execution.

LIFTING MATTERS ISSUE Q4 2019 7

Feature Article
Hazards of multi-crane lifts
We have come across many tragic incidents
from all across the world that involved
multiple cranes, a few of which are profiled
in this issue of Lifting Matters. These
incidents reveal critical areas of required
understanding when planning a multi-
crane lift:
Appropriate load planning
• for tandem lifts (more
on that later)
Real-time information and
•
communication for operators
to ensure lift and travel is
carried out in unison
Side loads/forces acting on
• the crane boom or unin-
tended load distribution
Ground preparation and the
• compounding ground pressures
if cranes are close to each other
•
Appropriate use of lift
rigging or equaliser beams
This list is by no means exhaustive but
does represent some of the key areas of
consideration for tandem lifts.
Lift Planning –
developing the Lift Plan
Lifts involving two or more cranes are
complex operations requiring considerable
skill and planning. As a result, tandem lifts
must be planned and carried out under a
competent person’s supervision.
8 LIFTING MATTERS ISSUE Q4 2019
As always, multiple lift operations must be
preceded by a documented risk assessment
that records known hazards and details
the relevant controls. In other words, plan
the works thoroughly well before the work
commences.
The most important thing to note in your
lift plan is that tandem lifts require you
to make specific calculations about the
required capacity of the cranes. You must
understand the load share for each crane,
the total weight of everything under the
boom head (including the hook, rigging,
spreader beams, equalising devices etc.)
and then add a percentage factor to the
total lift load. The percentage depends on
the number of cranes involved in the lift,
depicted as follows for each crane:
a. 2 cranes – add 20% of the
calculated share of the load
b.
3 Cranes – add 33% of the
calculated share of the load
c. 4 or more cranes - add 50% of
the calculated share of the load
The result of this calculation will provide
the required capacities for each crane.
In all options above, note the load may
not always be even, thus load sharing
must be taken into consideration. Alice
Edwards from Crane Industry Council
of Australia provides more detail on this,
and I encourage you to take a look at her
information at www.cica.com.au
Some of the other key components of
the Lift Plan that must be taken into
consideration are:
Feature Article

A site visit to understand the

1. environment, overhead structures,
ground conditions, access and site
restrictions etc.

2.
The lift study must be completed by
competent personnel and include the
crane selection criteria
Cranes should be of the same type (i.e.
3. all telescopic mobile cranes). If not,
the lift is deemed as a designed lift (see
clause 6.27 of AS 2550.1)
The centre of gravity requires

4.
special attention, especially for
complex structures and loads, when
determining crane sizes and load
sharing
Load sharing for rigid structures
5. requires special attention, as the
weight transfer when lifting or placing
a rigid load is critical
An analysis is required to understand
6. the stiffness – strength of the load
to identify the load shift effect if the
cranes get out of sync
Remember the load is everything

7.
below the boom head, so all hooks,
rigging, spreader beams, load equal-
ising devices etc. are to be included
in the load calculations

8. Cranes must travel in the same

direction
The communication method is critical
to enable unison in movements – for
9. example, using two-way radios, or
when a clear line of sight is possible
between all crane drives and the lift
caller, then hand signals may suffice

LIFTING MATTERS ISSUE Q4 2019 9

Feature Article

On the Job
Aspects to keep in mind when on the job:

Review the Lift Plan with all people

involved in the lift. If there are any
1. changes to the Lift Plan ensure
these are documented and all
changes are communicated to all
members of the lift team.

For Australian based work,

2. person(s) involved with any rigging

work, must hold a High-Risk
Intermediate Rigging Licence (RI)
as a minimum.

Appoint a senior lift supervisor

on-site to coordinate the lift who
3. is the sole person in charge of the
lift for clear accountability. The
senior lift supervisor must hold a
RI licence as a minimum.

Make sure the person calling the

4. lift (i.e. in radio communications

with all personnel involved in the
lift) holds an intermediate rigging
qualification as a minimum.

Stay committed to your

5. communications plan for the

lift. It is critical that this is
implemented and maintained as
per the Lift Plan.

Consider dropping the auxiliary

hook around 4m, which then acts
6. as a great plum bob to help you
keep your hoist ropes vertical,
thus preventing side loading on
the boom.

10 LIFTING MATTERS ISSUE Q4 2019

Feature Article

Take note of passover load

transfers - where the load is
7. lifted from one end of a truck as
it moves forward or backwards
for the other crane to pick up the
other end of the load.
Take note of tailing load transfers

8. – where a load is rotated from

the vertical to horizontal, or in
reverse.
Ensure there is only one motion at
a time and in the same direction.
For example:
a. If pick and carrying, lift the
load, then move into position.
Don’t do both and make sure
all cranes are travelling in
same the direction
b. Special note to crawler cranes,
9. make sure the drive sprockets
are to the rear of the travel,
and the cabs are facing the
same way.
c. Special care needs to be
exercised when crabbing. If
multiple cranes are crabbing,
care must be exercised so that
all are travelling in the same
direction and do not exceed
the loads detailed in the Lift
Plan.

10.
Perform the lift with extreme care
and at low speeds.
Remember anyone can stop the

11. lift. If something is not quite right,

stop the lift and consult with the
senior lift engineer.

LIFTING MATTERS ISSUE Q4 2019 11

Feature Article

Want to know more?

There are various guidelines and
standards applicable to different
states within Australia, nationally
and internationally. We strongly
recommend you research and
understand the local applicable
guidelines and standards. As an
example, Western Australia has its
own unique regulations, which are
outlined in more detail by a local
specialist later in this issue.

Here’s a starting point for guidelines

on multi-crane lifts:

• Australian Standard AS
2550.1 – Cranes, hoists and
winches – Safe use, General
Requirements – Section 6.28
Multiple Hoist or Crane
Operation

• Australian Standard AS 2550.5

- Cranes, hoists and winches
– Safe use, Mobile cranes –
Section 3 Selection

• The Crane Association of

New Zealand has published
an excellent handbook called
the Crane Safety manual
and Section 9: Part D covers
multi-crane lifts in detail.

12 LIFTING MATTERS ISSUE Q4 2019

LIFTING MATTERS ISSUE Q4 2019 13
Incident Report

December 2013
Caracas, Venezuela

Project 60t truss beam lift

Cranes Two 100t Liebherr LTM1100-5

Damage to both cranes
The Outcome Punctured diesel storage tank resulting in road closure
Minor injuries
Key Learnings • Understanding ground conditions is critical.
• Appropriate ground studies should be conducted and
recommendations made, especially as consequences are
compounded in multi-crane lifts.

On 6 December 2013, two crane

operators escaped with minor injuries after
their five-axle all-terrain cranes collapsed
while attempting a 60t truss beam lift at
the site of the Tamanaco Station in Caracas,
Venezuela.
It is understood the two cranes performing
the dangerous maneuvre were 100t Liebherr
LTM 1100-5. They were positioned on
opposite sides of a large access shaft,
working in tandem to move a truss beam
into place on top of the shaft.
An outrigger on one of the cranes sank into
the ground, destabilising the crane, and
causing it to turn onto its side. As one end
of the truss beam dipped into the shaft, it
pulled the second crane over and into the
shaft. Initially, the second crane was hanging
on by one outrigger beam. However, it is
reported to have later slipped all the way in.

14 LIFTING MATTERS ISSUE Q4 2019

Incident Report

A diesel storage tank was punctured as

the second crane collapsed into the shaft,
resulting in a leak and closure of the adjacent
road for a few hours.
Thankfully, both crane operators survived
their respective falls, walking away with
only minor injuries given the severity of the
incident.

Key learnings from this

incident
As can be seen from this incident,
understanding ground conditions is critical.
A geotechnical engineer must be engaged
to conduct appropriate ground studies
and make recommendations on the crane
location and pad design. This is even more
critical in multi-crane lifts because if ground
pressures are not adequately planned for,
and this results in a crane collapse, the
connected crane will be pulled down by the
lateral movement of the other crane, thus
compounding the consequences.
Image source: Vertikal.net https://vertikal.net/en/news/story/19048/tandem-lift-overturn-in-caracas
While likely not the case in this incident
because the cranes were located on
opposite sides of the shaft, the topic of
ground conditions is also a reminder that
in tandem lifts when cranes are near to
each other, the ground pressures for each
crane will be affected by the other crane,
requiring sophisticated calculations on
ground conditions.

LIFTING MATTERS ISSUE Q4 2019 15

Incident Report

June 2014
Mississippi, USA

Project Supply vessel assembly

Cranes Two 16000 Manitowoc Cranes plus third

The Outcome One operator permanently disabled. Four others injured.

Key Learning • Appropriate de-rated load planning is required

for tandem lifts backed up by real-time
information for operators to enable both the
lift and travel to be carried out in unison.

Multiple cranes were engaged to lift
and place a 250-tonne bow unit for the
assembly of a large supply vessel at a
Mississippi shipyard. The tandem ‘lift and
travel’ maneuver required two Manitowoc
16000 Crawler Cranes to lift, travel and
align in unison.
When one crane pulled ahead of the other,
the second Manitowoc tipped forward.
While the operator attempted to recover,
the massive weight meant the crane’s load
slipped, crushing the cab and throwing the
operator through the windshield in the
process. The operator suffered a broken

16 LIFTING MATTERS ISSUE Q4 2019

Incident Report

pelvis and crushed skull. While he

survived, he suffered a traumatic brain
injury. He is now blind and has severely
reduced mental capacity. One of the
cranes fell into a warehouse building
at the VT Halter shipyard, injuring four
others.

The shipyard bore the most

responsibility for the accident. The
jury’s verdict found Manitowoc should
bear 40 per cent of the responsibility,
and the operator, 10 per cent.

The shipyard was cited with four

serious violations due to:

•
the absence of clearly visible
load charts;

• exceeding the rated load

capacity;

the designated person did not

• ensure proper positioning
of spotters and did not
ensure the cranes made the
predetermined movements;

• failing to load test the lower

load cell sensor on the main
hoist after it was repaired.

Image source: Crane Institute of America https://craneinstitute.com/news/three-cranes-lifting-a-load-what-can-be-more-complicated

LIFTING MATTERS ISSUE Q4 2019 17

Incident Report

Key learnings from this

incident
With multiple cranes working in tandem,
both the movement of the load and crane
travel needs to be perfectly choreographed.
Travelling means that dynamic forces
come into play when synchronisation is
off. Being off by the slightest amount can
result in a catastrophic imbalance. This
incident shows how wrong a tandem lift
can go when load planning failures are
compounded by inadequate sensor and
positioning information being available to
the operator. 

18 LIFTING MATTERS ISSUE Q4 2019

Incident Report

July 2009
New Delhi, India

Project Metro Rail Project

2 x 250 tonne Grove; 350 tonne Krupp; 400 tonner
Cranes (unspecified)
Three of the four cranes collapsed.
The Outcome Five people received minor injuries.
Key Learning This lift was ‘planned’ and executed in less
than a day. The level of planning required was
completely underestimated or ignored.

Three cranes collapsed injuring five

people less than a day after a 6-person
fatality was recorded at the same site.
The Metro Rail – part of New Delhi’s
preparations for hosting the 2010
Commonwealth Games – was a significant
project with disturbing safety statistics.

The day before the attempted four-crane

lift, a subway beam under construction
collapsed killing six people and injuring
15 others. The four-crane lift was an
attempted recovery of the collapsed beam
which got underway the next morning. It
is understood once the full weight of the
beam was taken by the four cranes, the
boom of the first crane (a 250 tonner)
snapped under the weight passing a greater
load onto the 350 tonne Krupp causing its
boom to tear off entirely. The next crane
(a 250 tonne Grove TM2500) tipped and
its counterweight sections plummeted to
the ground. The fourth crane (400 tonner)

LIFTING MATTERS ISSUE Q4 2019 19

Incident Report

remained upright as that end of

the bridge beam had only been
lifted marginally when the collapse
occurred at the other end.

Key learnings from this

incident
A four-crane lift of an unsteadily
placed beam in congested
conditions requires a tremendous
planning effort. While there is
limited data available, less than 24
hours of planning took place for
this complex lift. The immediate
failure of the 250 tonne Grove and
complete shearing off of the 350
tonner would suggest planning was
wholly inadequate or non-existent.
It was remarkable no-one was
seriously injured.

20 LIFTING MATTERS ISSUE Q4 2019

Incident Report

The first 250t Grove tipped

on its end. The boom of the
350t was torn in two.

Image source: ABC News https://www.abc.net.au/news/2009-07-14/heavy-cranes-collapse-during-clearing-operations/1351922

LIFTING MATTERS ISSUE Q4 2019 21

Incident Report

August 2015
Alphen aan den Rijn, The Netherlands

Project Koningin Juliana Bridge

Cranes Terex AC700 and Liebherr LTM 1400-1

The Outcome Major damage to shops and houses. No injuries.

Key Learning • Dual lifting over water has added complexity.

• With multiple contracting parties, planning needs
to be integrated, and responsibilities made clear.

22 LIFTING MATTERS ISSUE Q4 2019

Incident Report
Miraculously no one was injured when
a lift involving two barge-mounted cranes
failed. Both cranes and the section of the
bridge they were attempting to lift crashed
into the neighbouring properties which
lined the banks of the Oude Rijn (Old
Rhine) river. Several homes and shops were
destroyed, but no one was injured in this
incident.
The aim was to lift and then maneuver
a new section of the Koningin Juliana
Bridge into place. Two mobile cranes – a
400-tonne and 700-tonne – were mounted
on separate barges and set to carry out a
dual-lift of the bridge section from a third
barge. The barge carrying the smaller crane
tipped to the extent the crane’s mast failed,
causing the 400-tonner to topple over. This
resulted in a domino effect as it pulled the
lifted bridge section with it, which in turn
caused the large crane to also topple.
The Dutch Safety Board’s report revealed
the lift engineering was entirely flawed.
No matter how precisely the lift
was executed, it was destined to
fail. Both crane operators involved
had limited tandem lift experience,
and both underestimated the
complexity and risks involved.
Information and photo source: Dutch Safety Board, Lifting Accident Summary Report
This incident was included in the
March 2019 edition of Lifting
Matters where we highlighted the
need for extensive planning and a
clear chain of responsibility when
working over water. It also highlights
the additional forces and risks to be
managed in tandem lift scenarios.
The official report found there was
inadequate stability in the lift design. The
lift plan did not allow for variables such
as wind, or the crane movements. On top
of this, the cranes were loaded to 100%
of their rated capacity, and there was no
ballasting plan for the barges to enable
timely adjustments to be made.
Multiple subcontractors were involved in
the lift, and each made assumptions about
what each other were planning. Despite this
work being carried out in an urban area,
no consideration was given to the safety of
people in the vicinity.
LIFTING MATTERS ISSUE Q4 2019 23
In the News Lately

Our December 2018 edition

of Lifting Matters looked at
overhead power lines and
dispelled common myths power
lines and flow of electricity. Go to
www.liftingmatters.com.au/
archives for more information.
July 2019

Crane Hits Powerlines

Little Mulgrave, Far North Queensland, Australia
In July 2019, a 49-year-old man sadly
lost his life by electrocution, and two
others were transported to the hospital
when a crane boom hit a powerline in Far
North Queensland.
The workers had been laying tracks for a
sugarcane train line at Little Mulgrave,
37km south of Cairns. It is understood
the crane driver was maneuvring a length
of track as the dogman walked beside
and steadied the load. The boom of the
crane came into contact with powerlines,
electrocuting the dogman.
second man was hospitalised with severe
burns, and a third man was treated for
emotional distress.
The 54-year-old crane driver is now
facing court in September 2019 after
police alleged he did not have appropriate
licences while operating the crane at the
time of the accident.
An ongoing investigation into the incident
was being conducted by Queensland
Workplace Health and Safety at the time
of publication.

A nearby resident heard screams and

rushed to the site of the accident,
performing CPR until emergency services
arrived. One man suffered fatal burns, a
Image source: The Australian https://www.theaustralian.com.au/nation/one-dead-as-crane-hits-powerlines/news-story/46b8b-
95151fb36884bdac8d347ce19ff - Pictures above: Anna Rogers

24 LIFTING MATTERS ISSUE Q4 2019

In the News Lately
July 2019
Crane Overturned
Mareeba, Far North Queensland, Australia
In Far North Queensland, July 2019, a
second crane incident in as many days saw
two men horrifically injured in a mobile
crane rollover.
A 38-year-old man and a 52-year-old man
were driving a Terex Franna crane along
Mareeba Dimbulah Road (~40 kilometres
south-west of Cairns) when they lost
control trying to overtake a slow-moving
tractor around 9.30am.
The crane came to a rest after flipping
onto its cab roof. According to police, the
two men were still inside the crane cabin
when emergency services arrived. The
road was closed in both directions to allow
emergency service and helicopter access.
Image source: ABC News https://www.abc.net.au/news/2019-07-29/two-men-were-critically-injured-when-this-crane-rolled-
over-at/11361218 - Picture: QPS
One man was flown by rescue helicopter to
Cairns Base Hospital suffering fractures to
his skull and neck, two broken collarbones,
12 broken ribs, punctured lungs and a
compound fracture to one of his legs. The
other man was taken to Mareeba Hospital
with severe head and neck injuries.
Both men were placed into an induced
coma but are now on the long road to
recovery surrounded by family.
Investigations were underway to determine
the cause of the crash.
Our September 2014 edition of Lifting
Matters covered the stability of Franna
cranes. Go to www.liftingmatters.com.
au/archives for more information.
LIFTING MATTERS ISSUE Q4 2019 25
Spotlight on multi-crane lifts

A 350t Liebherr LTM1350 & 130t Grove

GMK5130 were used to carefully lift
a redundant vessel onto transport.

Multi-crane lifts
Taking collaboration to new heights

26 LIFTING MATTERS ISSUE Q4 2019

Spotlight on multi-crane lifts

A Demag AC350 and

Grove GMK7450
worked together
to install bridge
beams for The
Northern Corridor
improvements (NCI)
project in Auckland.

LIFTING MATTERS ISSUE Q4 2019 27

Spotlight on multi-crane lifts

The St Pauls Cricket Pavilion

in Auckland was lifted by a trio
of Grove cranes (GMK5130,
GMK4100, and GMK3055).

These air conditioning

components were lifted by a
sweet pair of 5t Mini Crawler
Cranes (Maeda CC505).

28 LIFTING MATTERS ISSUE Q4 2019

Spotlight on multi-crane lifts

A Demag AC300 and crawler

crane synchronised a tandem
lift of a vessel in New Zealand.

LIFTING MATTERS ISSUE Q4 2019 29

Topic Commentary

Understanding the load distribution

for multi-crane lifts
Article contributed by Alice Edwards, Technical Project Engineer – The Crane Industry
Council of Australia (CICA)

Multiple crane (means a lift operation
that requires two or more cranes)
arrangements/methods are sometimes
used on lifting jobs when physical
dimensions, characteristics, mass, required
movement of the load, environmental
restrictions or other factors prevent the
lifting operation from being performed
by a single crane or single hoist. Multiple
crane lifts can range from rotating a
column using a lift crane at the top and
a tailing crane at the bottom, to lifting a
pre-assembled platform with eight cranes.

30 LIFTING MATTERS ISSUE Q4 2019

Topic Commentary

In general, these considerations may

determine when you would choose a
multiple crane lift (this is not a blanket
fixed set of rules):

If the load would be out of sight

•
of the crane operator if it were a
single crane or single crane dual
hook operation. X = 2m Y = 1m

4m
If there is a large distance between
lift point locations relative to the
• boom length, which would impact
on retaining pins, localised stress
distribution and other elements of
the crane.

Lifting with multiple cranes is always more

complex than lifting with just one crane,
so appropriate planning, engineering and
operational control measures need to be in
place to manage the risks associated with
multiple crane lifts. One critical control
measure is to calculate the distribution
of the load among the cranes and how
the load distribution will change for the
entire lifting process. Configuration of the
load to be lifted (i.e. size, centre of gravity
(CoG), lift point position) can be used
in the moment equation to calculate the
load distribution (see a simple example of
a load share calculation on this page). The
closer a crane is to the centre of gravity, the
more load the crane will receive.
This example uses two cranes, the same
principle can be used for three or more
crane lifts, but the calculation will be much
more complex as the cranes are not evenly
spaced either side of the centre of gravity.
From the above example, we can see that
knowing the centre of gravity is very
important, and through the planning
stages, attention needs to be applied
for non-uniform densities or weight
distributions.
When lifting a load from the supports or
placing the load onto the supports, because
the cranes may not be able to lift the load
in perfect tandem, the load share between
the load and the support can change
dramatically. In the load share calculation
example we mentioned above, if Crane B
put the load down on support C, and Crane
A is still holding the load, then load share
for Crane A changes from 0.67t to 1t, which
means 33% load increase for Crane A, this

LIFTING MATTERS ISSUE Q4 2019 31

Topic Commentary

needs to be factored in when selecting the During the lift process, if the distance of
correct size crane for Crane A. the CoG to the lifting point changes (i.e.
rotation) the load share between the cranes
will change (see example graph below for
load share change between the main crane
and the tailing crane). This may happen
gradually or dramatically depending on the
geometry of the load and the lifting speed.
It is important to calculate the load share
X = 2m Z = 2m between the cranes for the entire lifting
process to size the cranes correctly.
4m

32 LIFTING MATTERS ISSUE Q4 2019

Topic Commentary

For multiple crane lifts, the movement of

the load between the cranes will create
extra loadings on the cranes. These
loadings include horizontal forces acting
on the boom and additional vertical load.
These can occur from misalignment in
cranes to load, load shifting, minor errors
in centre of gravity location and general
crane motions. When performing a
multiple crane lift, a documented lift plan
and procedure should be prepared by a
competent person (i.e. an engineer) and
followed. Lifting operations using two or
more cranes at the same time must use
cranes of the same type. If different types
of cranes are used together (i.e. mobile
cranes and tower cranes are used together
for a multiple crane lift), then the lift
would require a designed lift assessment.
Other than a designed lift, the following
minimum capacity requirements for each
crane shall apply as a safety margin:
If the calculated maximum load share
for the crane to be used is 10t, then in a
two-crane lift operation, the rated capacity
of the selected crane shall be at least 12t for
the planned crane configuration.
A multiple crane lift is a complicated
operation, so more precautions are
necessary when planning the lift. Detailed
control measures and using experienced
lifting personnel (the person in control of
the lift must hold at least an intermediate
rigging high-risk work licence) are key
success factors. However, understanding
the load distribution is the first step to a
safe lift.

For two cranes 20% greater than the calculated share of the load.
For three cranes 33% greater than the calculated share of the load.
For four or more cranes 50% greater than the calculated share of the load.

LIFTING MATTERS ISSUE Q4 2019 33

Working Safely
Multi-crane lifts in Queensland
Article contributed by Worksafe Qld
Workplace Health and Safety
Queensland has investigated two serious
incidents involving dual crane lifts over the
last two years.
In the first incident, two cranes on
outriggers were lifting a 50 tonne
Super T bridge beam, and the
driver was unable to see where
the load was being placed.
34 LIFTING MATTERS ISSUE Q4 2019
The beam was not symmetrical, with a
precast barrier attached to one side. When
the load was released from the crane hooks,
the beam fell to the outside, knocking out
both the temporary support brackets and
a wing wall on the bridge and injuring two
workers. The incident could have been
avoided if the beam had been tied to other
Super T’s already installed, before taking
the load off the hoist ropes.
In the second incident, two pick-and-carry
cranes were moving a load around a corner
Working Safely
when one of the cranes overturned. The
load indicator wasn’t working on one of the
•
cranes, and the load was much heavier than
previously thought.
Multiple cranes are simultaneously used to
lift a load when it is too heavy for a single
•
crane, or its shape requires multiple cranes
to make sure it’s stable during lifting or
rotate it during the lift.
Using multiple cranes simultaneously to lift
a load increases the risk of the lift because:
•
individual crane loads can increase
•
during the lift as the load’s centre
of gravity shifts or the hoist ropes
move away from vertical
each crane’s actions can affect the
•
stability of other crane/s involved
in the lift if operations are not
•
synchronised. Maximum rated
capacity limiters not designed for
this operation may not prevent the
crane from operating beyond its
limits
•
hoist rope angles can cause a push/
•
pull effect.
It’s important to properly plan crane lifts
and avoid using multiple cranes if it is
possible to do so safely. However, where
•
multiple cranes must be used, the following
precautions should be followed:
•
Conduct a lift study during the
planning phase (including load
share and how it will be managed
during the lift).
Identify structures, plant items
and powerlines which may restrict
crane movement or could be
contacted during the lift.
Seek advice from the crane
manufacturer or an engineer on
wind sail effects – particularly for
loads with a large surface area.
Make sure cranes of equal/similar
capacity and characteristics are
selected for the lift and that each
crane is capable of safely lifting its
share of the load at the maximum
radius to be lifted at, including
an additional factor of safety for
multiple crane lifts (outlined in
section 13.3.2 of the Mobile Crane
Code of Practice 2006).
Check the combined mass of
rigging gear, lifting hooks, slings
and fly jibs (if used) is deducted
from the maximum rated capacity
of the crane at the required
operating radius.
Analyse uneven mass distribution
in the load to be lifted.
Ensure ground conditions are
suitable for all cranes in operation.
LIFTING MATTERS ISSUE Q4 2019 35
Working Safely

•
Use experienced operators Remove non-essential personnel
for a multi-crane lift with from the work area.

•
the appropriate high-risk
work licences - remember an Make sure both cranes are aligned

•
intermediate or advanced rigger in the same direction when using
must be in control of the lift. non-slewing type cranes in the
pick-and-carry mode.
Use equaliser lifting beams and
• associated equalising sheaves
where needed.
In summary, the use of multiple cranes to
simultaneously lift a load is a specialised
operation that should only be conducted
Ensure load indicators are fitted if the use of a single crane is not possible.
• to all cranes involved, and they are
working accurately.
In any type of crane lifting operation, the
failure to follow a safe system of work can
have catastrophic results.
Ensure clear methods of
• communication between all
parties involved are in place.

For more information on crane safety, visit worksafe.qld.gov.au.

Workplace Health and Safety Queensland

Get involved this

Safe Work Month
1-31 October
Register for a Safe Work Month
event near you or host your own
safety themed event. Dow
your nload
worksafe.qld.gov.au/safe-work-month even free
t kit.
@SafeWorkQLD @SafeWorkQueensland

#SWM19
36 LIFTING MATTERS ISSUE Q4 2019
Incident Report

CALL FOR CONTENT

Contribute to Lifting Matters’ vision of a safer industry by

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LIFTING MATTERS ISSUE Q4 2019 37

Operator’s Opinion
How technology is key to
improving safety
Ryan Pardoe
Auckland Cranes
Ryan Pardoe has been in the crane
industry for 13 years, working across
multiple countries including Australia,
New Zealand, and Papua New Guinea.
Ryan is currently based in New Zealand,
having recently started work with Auckland
Cranes as a Crane Operator.
38 LIFTING MATTERS ISSUE Q4 2019
Have you personally been involved in
any multi-crane lifts?
Yes, I have been involved in all stages from
planning through to performing the lift.
I have learnt that inexperience can result
in overcomplicating and overthinking
the lift – although there are factors you
must consider outside of general lifting –
sometimes less is more and it doesn’t need
to be as complex or difficult as people think.
What is the most common action or
behaviour you witness in the field
when operators don’t plan for multi-
crane lifts appropriately, and how do
you think we can fix it?
The most common behaviour I see is
communication consisting of head
nodding and shouting out the door
between operators.
It would be great for people to take the
time to understand what’s involved, plan
properly, and communicate accordingly.
I have a lot of faith in the likes of CICA
and the Crane Association of New Zealand,
and I believe they can make a substantial
impact on the industry through promoting
the right message for employers and
workers to upskill and get the required
training they need.
Operator’s Opinion

Have you any thoughts or ideas on

innovation or process that may help
to prevent or alert workers when
multi-crane lifts are potentially
unsafe?

I believe technology is key to improving

safety. Simplifying processes and making
tools more easily accessible will help
people make better, safer, and more
informed decisions.

Seeing a need to help educate people in

the industry is why I developed a free app
called Rigsafe. It’s designed to help riggers
select the right rigging for the task and
make the right decision from the start.

What do you feel is the most

important safety issue affecting
your particular role in the industry
today?

We have a bit of a laid-back culture of

“she’ll be right” or “I’ve done it like this
for 30 years mate!”

People need to understand why what

they’re doing is right – not just because
it’s the way they’ve been shown or
told, but because they recognise the Rigsafe helps you select the right
requirements of the task and can make lifting gear for the task. Head to
calculated decisions for the job. It’s so Google Play for your free download
important that this understanding is (only available on Android)”
passed on to future generations so that
they are equipped with the knowledge to
achieve the best possible outcomes. This
will not only help to reduce incidents but
will improve the overall safety culture of
the crane industry.

LIFTING MATTERS ISSUE Q4 2019 39

People Profile
Gordon Stone
e on to become Christchurch manager in
Gordon Ston
Director, on Ltd
& Constructi
Smith Crane
Gordon Stone retired from
full-time work in 2013 after a
45-year career at Titan Cranes
in New Zealand. It wasn’t long
before he was snapped up in 2017
as a Non-Executive Director at
Smith Crane and Construction
Ltd. Gordon is a mainstay of the
New Zealand crane industry,
having served on the Crane
Association for over a decade.
We were privileged to catch up
with Gordon to learn more about
his journey and impact on health
and safety in the crane industry.
40 LIFTING MATTERS ISSUE Q4 2019
Wow, congratulations on 50
years in the New Zealand crane
industry. Tell us about your
journey so far.
I started at the Ministry of Works
at Gracefield, where I obtained my
advanced trade certificate in fitting,
turning, and machining. There, I
connected with Max Whiley, founder
of Titan Cranes, and his workshop man
Frank Wicksteed, who both came to the
auctions to purchase used machinery.
After a bit of pay negotiation, I started
working for Titan Cranes in 1970 as a
fitter during my holidays. Eventually,
I took over crane maintenance, before
being dispatched to Christchurch in
1979 as Titan Cranes expanded. I went
1990, and then South Island manager
once a branch was opened in Dunedin.
In 2008, I was appointed General
Manager, and then Chief Executive in
2009. Meanwhile, I was also elected to
the Crane Association national executive
in 1994 and served as President from
1999-2001 then spent several years as
past president. In 2013 I retired from
full-time work at Titan Cranes. Around
this time, I was asked by Tim Smith to
join Smith Cranes on an advisory board.
Since I now had the time and was still
very interested in the crane industry, I
accepted and became Director of Smith
Cranes and Construction. It has been
great to see the growth in the company
to date.
People Profile

How have you been involved in

shaping health and safety in the New
Zealand crane industry, and what did
you learn in these experiences?

I helped form the Power Crane Association

ITO, where we wrote the first unit
standards and eventually got them
accepted by the Qualifications Authority.
I was also involved in the rewrite of the
Crane Association Safety Manual. In
this process, I learned that training and
safety culture simply go hand in hand.
Building an effective safety culture is all
about communication, finding solutions,
and continually reviewing procedures.
It’s important that we put resources into
training and preserve the mindset of
continual learning. Another little tip – get
to know the people in the regulatory bodies
and get alongside them, because they don’t
understand your business sometimes and
you’ve got to run alongside them. If you
can build relationships, it’s much easier to
get things done.

What do you think is the most

important issue in crane safety
today?

I believe that the most important issue

facing the crane industry today is ensuring
continuous improvement in the next
generation of workers. It’s so important to
get young people involved and interested in
making a career out of cranes. Whether it is
in operations, maintenance, management,
or other areas, they will be rewarded by
working in such an interesting and diverse
industry.

LIFTING MATTERS ISSUE Q4 2019 41

Mental Health Week 2019

Four steps to prevent psychological

injury in your workplace
Article contributed by Safe Work Australia

Just like work-related physical injuries and intervening early to identify hazards
and illnesses, psychological injuries or and eliminate and control the risks.
illnesses take a significant toll on worker
When identifying hazards, look for anything
health, safety and productivity. And just
that could cause harm. Psychological
like physical injuries, the impact extends
hazards are anything that increases the risk
from the individual to their families and
of work-related stress. Stress by itself is not
colleagues.
an injury but if prolonged or severe, it can
Psychological injuries are increasing cause psychological and physical injury.
in workplaces and are one of the most
Psychological hazards include:
expensive work-related injuries in Australia.

•
Safe Work Australia data states workers’
high or low job demand
compensation claims for psychological

•
injuries typically result in more than three
poor support
times as long off work and cost more than

•
twice as much as physical injuries1.
poor workplace relationships
Work pressure, harassment or bullying,
and exposure to workplace or occupational
violence are the leading causes of work-
• low role clarity

related stress and can happen to anyone in

•
poor organisational change
any workplace. management
The good news is psychological injuries
in the workplace are preventable. • poor organisational justice
Everyone has duties under work health
and safety (WHS) laws. Under WHS laws, • poor environmental conditions
psychological hazards and risks are treated
the same as physical hazards and risks. • remote or isolated work, and

Preventing psychological injuries, starts

with recognising that businesses can do
• violent or traumatic events.

something to prevent them by taking action

1
Sourced from Safe Work Australia’s National Data Set for Compensation-based Statistics. These are based on the figures for all serious
claims between 2012-13 and 2016-17p. Serious claims are defined as accepted compensation claims which resulted in one or more working
weeks lost (excluding fatalities and journey claims). The data for 2016-17 is preliminary and subject to change when new data is available.

42 LIFTING MATTERS ISSUE Q4 2019

 To manage psychological hazards,
follow the four-step process:

1. Identify psychological hazards

To identify hazards, talk and listen to workers, inspect the workplace, notice
how people interact, review records (e.g. reporting systems, staff turnover and
absentee reports) or use tools such as staff surveys.

2. Assess psychological risks

To assess risk, consider what could happen if someone is exposed to that
hazard, the degree of harm that may result and the likelihood of that outcome.
If the risks associated with a particular hazard are well known – you can skip
this step.

3. Control psychological risks

The hierarchy of controls ranks ways of controlling risks from the most reliable
to the least. This hierarchy helps to find the most effective control measure
(or combination of control measures) for risks, including psychological risks.

4. Review control measures

Control measures need regular review. Maintaining and monitoring them
regularly can ensure they are working. Reviews can include the same methods
used to initially identify the hazards.

Consultation
Consulting workers is essential. The people doing the work are the experts in
the work they do and the impact it has. Once a conversation is started, workers
can identify parts of their work which cause stress and may already have ideas
on how to fix them.

Safe Work Australia’s Guide Work-related psychological health and safety: A systematic
approach to meeting your duties steps you through how to apply the risk management
process to psychological risks and what to do at each step. Your WHS regulator can
provide advice on this process and tools to assist you.
Safe Work Australia is raising awareness of workplace mental health during National
Safe Work Month in October. This includes recognising Mental Health Week 2019, which
falls in the second week of October. To find out what is happening in your state, contact
your WHS regulator or visit safeworkaustralia.gov.au/nationalsafeworkmonth.

LIFTING MATTERS ISSUE Q4 2019 43

Any questions?
Want to support?
Contact us!
liftingmatters@writestrategy.com.au
www.liftingmatters.com.au

Content deadline for next issue: 15 November 2019

Next issue available: December 2019

Disclaimer – This newsletter is not an exhaustive list of all safety matters that need to be considered. Whilst care
is taken in the preparation of this material, Lifting Matters does not guarantee the accuracy and completeness
of this information and how it applies to your situation. Lifting Matters will not be responsible for any loss, dam-
age or costs incurred as a result of errors or omissions in relation to the material in our publication or for any
possible actions ensuing from information contained in our publication.

Any views or opinions represented in this publication are personal and belong solely to the author and do not
represent those of people, institutions or organisations that the publisher may or may not be associated with in
a professional or personal capacity unless explicitly stated.