COURSE OVERVIEW:

Welcome to the Manage Critical Safety Threats in Rigging Operations course. This comprehensive program is designed to develop your capability to recognise, assess and control the most serious risks associated with rigging and complex lifting operations, including structural steel erection, precast installation, plant placement and temporary works.

This course begins by exploring the nature of critical safety threats in rigging and lifting tasks, outlining the legal WHS duties, high-risk work licensing and regulatory requirements that apply to riggers, doggers, crane operators, supervisors and PCBUs, and explaining how clearly defined roles, risk assessment, lift planning, safe work method statements (SWMS) and permit systems must be integrated to manage lift risks reliably from planning through to execution and close-out.

Falls from height are among the most serious and frequently fatal risks in rigging and lifting, particularly where work is performed on exposed structures and cranes. This section examines structural steel work conducted without effective fall protection, climbing on crane booms, masts and tower sections contrary to procedures, and the use of elevating work platforms (EWPs) and man baskets without correct harness use and attachment. It also considers the dangers posed by unprotected edges, open floors and penetrations where riggers and doggers are positioning loads, and slips and trips at height on wet, muddy or debris-covered surfaces that can quickly lead to catastrophic falls.

Same-level slips, trips and falls create both direct injury and knock-on effects that can compromise lifting operations and stability. This section explores how uneven ground, rubble and scattered hardware underfoot, combined with mud, water, oil and hydraulic fluid on access ways, increase the risk of sudden loss of balance. It considers hoses, slings, chains and leads running across walk paths in set-up areas and near cranes, and the effects of poor lighting during early-morning, night or internal work on the ability of rigging crews to identify trip hazards. The focus is on housekeeping, defined walkways and surface management as critical controls.

Falling objects and dropped loads present high-consequence risks wherever rigging work is undertaken above people, plant or critical infrastructure. This section examines loads dropping from sling or hardware failure, including damaged or incorrectly selected lifting gear, and the danger posed by tools, pins and small parts falling from height during assembly, bolting and connection work. It also considers components slipping from lifting points or beams due to poor attachment or unexpected movement, loose items on loads falling during lifting or slewing, and the extreme consequences of rigging failure on man baskets or suspended platforms carrying personnel.

The movement, swing and rotation of loads introduce complex crush and impact hazards that must be anticipated in every lift plan. This section explores uncontrolled load swing or rotation from wind, out-of-level set-up or crane movement, and situations where workers are caught between moving loads and fixed structures such as columns, walls, scaffolds or plant. It examines pinch and crush injuries to hands during hooking and unhooking, body parts trapped under or between loads and dunnage during landing and packing, and sudden load movement when the crane first takes the strain, emphasising clear exclusion zones, tag line use and disciplined communication.

Interaction between cranes, other plant and vehicles creates significant site-wide risks in rigging environments where multiple operations occur in the same footprint. This section examines the potential for people to be struck by mobile cranes, forklifts or telehandlers, and the consequences when exclusion zones around the crane slew radius are breached by workers or other plant. It also considers reversing vehicles with limited visibility and no spotter, crane or plant overturning due to poor ground conditions or overloading, and the dangers of working beneath or too close to booms and counterweights where visibility is limited and space is constrained.

Structural collapse and rigging failure can have catastrophic outcomes, particularly in temporary configurations and during staged construction. This section examines the collapse of temporary structures arising from poor rigging, inadequate bracing or incorrect sequence, and failure of lifting beams, spreaders, eyebolts or lugs due to overloading, damage or design error. It also considers overloaded structural members used inappropriately as anchor points, and failure of guy wires or stay cables on masts and temporary towers, highlighting the vital role of engineering verification, inspection and adherence to lift plans.

Lifting gear and rigging equipment form the backbone of safe rigging operations and can themselves become a source of danger if not selected, maintained and used correctly. This section explores the risks associated with damaged or worn slings, shackles, hooks and rings, and incorrect sling angles that create excessive leg loading beyond rated capacities. It addresses mismatched or incompatible rigging components, the use of uncertified, improvised or untagged lifting equipment, and mechanical failure of winches, chain blocks and lever hoists when they are overloaded, poorly maintained or used outside manufacturer instructions.

Tensioned lines and snap-back effects introduce high-energy risks that can cause severe injury or death in a fraction of a second. This section examines the snap-back of wire ropes, chains and synthetic slings under tension when they fail or release suddenly, and the consequences of anchor point failure under high line tension on structures, vehicles and temporary anchors. It also considers the recoil of load binders, chains and ratchet straps during load restraint and release, emphasising the need for exclusion zones, safe standing positions and careful tensioning practices.

Electrical and service contact hazards intersect with rigging whenever cranes, loads and control lines operate near live services or electrical tools are used on site. This section explores scenarios where cranes, loads or taglines contact overhead power lines, exposing workers to electrocution and arcing, and contact with building services during structural rigging that can damage live systems or create hidden energised components. It also considers risks from portable electrical tools with damaged cords or plugs, and the use of electrical tools and leads in wet or damp conditions, reinforcing the importance of isolation, clearances and equipment inspections.

Weather, wind and environmental conditions exert a major influence on the safety and stability of rigging operations and must be built into all planning and supervision decisions. This section examines how high wind causes load swing and loss of control, including gusts affecting tower cranes, mobile cranes and suspended loads, and how heat stress and dehydration in hot outdoor conditions reduce concentration and physical capacity. It also explores the effects of cold, rain and ice on grip and surface traction, and the heightened risk of lightning exposure on tall structures and crane work, stressing the need for defined weather limits, monitoring and stand-down criteria.

Manual handling and ergonomic strain are inherent to rigging work due to the size and weight of equipment and the challenging access conditions. This section looks at handling heavy chains, wire ropes, spreader bars and lifting beams, and carrying rigging gear and tools over uneven ground, through congested work areas and up structures. It also examines repetitive handling of slings, hooks and hardware during multiple lifts, and awkward postures in confined, elevated or overhead work spaces where balance, reach and secure footing are difficult to maintain.

Noise, communication and hearing risks are critical factors in rigging, where clear signals and instructions are essential for safe lifting. This section explores high noise levels from cranes, piling, cutting, grinding and other construction plant that can interfere with verbal communication, whistles and alarms, and the inability to hear instructions, signals or alarms clearly in these conditions. It also addresses long-term hearing loss without adequate protection and the way communication failures contribute to near misses and serious incidents during complex lifts.

Exposure to oils, fluids and chemical agents is common in rigging environments where cranes, winches and associated plant are operating and maintained. This section examines skin contact and slips from oils, greases and lubricants on equipment and walking surfaces, hydraulic fluid leaks that present both injection injury and slip risks, and solvent and cleaner vapours that can cause irritation and fire risk when used around machinery and lifting gear. It also considers paints, coatings and treatments that introduce solvent exposure during surface preparation and protection, and dusts and fumes from nearby cutting, welding and grinding activities.

Hot work and welding hazards often occur adjacent to or in preparation for rigging tasks, introducing combined risks of burns, fire and fume exposure. This section explores burns from sparks, hot metal and slag in areas where riggers are working or where lifting gear is positioned, arc flash eye damage without suitable eye protection, and fire outbreaks when welding, cutting or grinding takes place near combustible materials. It also examines welding and cutting fumes in poorly ventilated areas and the need to coordinate rigging activities with hot work controls, fire watches and ventilation.

Confined spaces, biological agents and fatigue-related pressures create additional layers of risk that can undermine otherwise well-planned rigging operations. This section examines rigging in pits, shafts, tanks and plant rooms with limited access, restricted visibility and constrained escape routes during emergencies, and poor air quality where diesel plant, welding, cutting or solvent use creates fume and gas build-up. It also considers contamination from dust, mould, bird droppings and old materials in refurbishment and industrial sites, and the human factors associated with high schedule pressure driving shortcuts and risk-taking, long hours, shift work and night work causing fatigue, stress from coordinating complex lifts with multiple parties, and conflict or aggression in high-pressure site environments affecting safety decisions and communication.

By the end of this course, you will be equipped with comprehensive knowledge, structured risk-assessment methods and practical control strategies to identify, manage and escalate critical safety threats in rigging operations, supporting safer lifting outcomes for workers, plant and structures across a wide range of construction and industrial projects.

Each section is complemented with examples to illustrate the concepts and techniques discussed.

LEARNING OUTCOMES:

By the end of this course, you will be able to understand the following topics:

1. Introduction to Safety Threats in Rigging Operations

• Nature of critical safety threats in rigging and complex lifting operations
• Legal WHS duties, high-risk work licensing and regulatory requirements
• Roles of riggers, doggers, crane operators, supervisors and PCBU in managing lift risks
• Applying risk assessment, lift planning, SWMS and permit systems to rigging work

2. Falls from Height

• Structural steel work without fall protection
• Climbing on crane booms, masts and tower sections
• EWPs and man baskets without correct harness use
• Unprotected edges, open floors and penetrations
• Slips and trips at height on wet or muddy surfaces

3. Same-Level Slips, Trips and Falls

• Uneven ground, rubble and scattered hardware
• Mud, water, oil and hydraulic fluid on access ways
• Hoses, slings, chains and leads across walk paths
• Poor lighting during early-morning, night or internal work

4. Falling Objects and Dropped Loads

• Loads dropping from sling or hardware failure
• Tools, pins and small parts falling from height
• Components slipping from lifting points or beams
• Loose items on loads falling during lifting or slewing
• Rigging failure on man baskets or suspended platforms

5. Load Movement, Swing and Crush Points

• Uncontrolled load swing or rotation from wind or crane movement
• Workers caught between moving loads and fixed structures
• Pinch and crush injuries to hands during hooking and unhooking
• Body parts trapped under or between loads and dunnage
• Sudden load movement when crane first takes the strain

6. Cranes, Plant and Vehicle Interaction

• Being struck by mobile cranes, forklifts or telehandlers
• Exclusion zones breached around crane slew radius
• Reversing vehicles with limited visibility and no spotter
• Crane or plant overturning from poor ground or overloading
• Working beneath or too close to booms and counterweights

7. Structural Collapse and Rigging Failure

• Temporary structures collapsing from poor rigging or bracing
• Failure of lifting beams, spreaders, eyebolts or lugs
• Overloaded structural members used as anchor points
• Guy wires or stay cables failing on masts and temporary towers

8. Lifting Gear and Rigging Equipment

• Damaged or worn slings, shackles, hooks and rings
• Incorrect sling angles causing excessive leg loading
• Mismatched or incompatible rigging components
• Uncertified, improvised or untagged lifting equipment
• Mechanical failure of winches, chain blocks and lever hoists

9. Tensioned Lines and Snap-Back

• Snap-back of wire ropes, chains and synthetic slings
• Anchor point failure under high line tension
• Recoil of load binders, chains and ratchet straps

10. Electrical and Service Contact Hazards

• Cranes, loads or taglines contacting overhead power lines
• Contact with building services during structural rigging
• Portable electrical tools with damaged cords or plugs
• Electrical tools and leads used in wet or damp conditions

11. Weather, Wind and Environmental Conditions

• High wind causing load swing and loss of control
• Gusts affecting tower cranes, mobiles and suspended loads
• Heat stress and dehydration in hot outdoor conditions
• Cold, rain and ice reducing grip and surface traction
• Lightning exposure on tall structures and crane work

12. Manual Handling and Ergonomic Strain

• Handling heavy chains, wire ropes and spreader bars
• Carrying rigging gear and tools over uneven ground
• Repetitive handling of slings, hooks and hardware
• Awkward postures in confined, elevated or overhead work

13. Noise, Communication and Hearing Risks

• High noise from cranes, piling, cutting and grinding
• Inability to hear instructions, signals or alarms clearly
• Long-term hearing loss without adequate protection

14. Oils, Fluids and Chemical Exposures

• Skin contact and slips from oils, greases and lubricants
• Hydraulic fluid leaks, injection injuries and slip risks
• Solvent and cleaner vapours causing irritation and fire risk
• Paints, coatings and treatments with solvent exposure
• Dusts and fumes from nearby cutting, welding and grinding

15. Hot Work and Welding Hazards

• Burns from sparks, hot metal and slag near rigging tasks
• Arc flash eye damage without suitable eye protection
• Fire outbreak from hot work near combustible materials
• Welding and cutting fumes in poorly ventilated areas

16. Confined Spaces, Biological and Fatigue Risks

• Rigging in pits, shafts, tanks and plant rooms with limited access
• Restricted visibility and escape routes during emergencies
• Poor air quality where diesel plant, welding or solvents are used
• Contamination from dust, mould, bird droppings and old materials
• High schedule pressure driving shortcuts and risk-taking
• Long hours, shift work and night work causing fatigue
• Stress coordinating complex lifts with multiple parties
• Conflict and aggression in high-pressure site environments affecting safety decisions

COURSE DURATION:

The typical duration of this course is approximately 3-4 hours to complete. Your enrolment is Valid for 12 Months. Start anytime and study at your own pace.

COURSE REQUIREMENTS:

You must have access to a computer or any mobile device with Adobe Acrobat Reader (free PDF Viewer) installed, to complete this course.

COURSE DELIVERY:

Purchase and download course content.

ASSESSMENT:

A simple 10-question true or false quiz with Unlimited Submission Attempts.

CERTIFICATION:

Upon course completion, you will receive a customised digital “Certificate of Completion”.