Posted on

Lifting Christmas Into Place At Martin Place

xmas 2024.4 Lifting Christmas Into Place At Martin Place

In November 2025, AOR Cranes rolled into the centre of the Sydney CBD to help build one of the city’s most recognisable festive landmarks. Over two days, our 90 tonne crane and a two-person crew helped raise the Martin Place Christmas tree into position in front of The Fullerton Hotel.

The installation ran across the 17th and 18th of November, with the tree taking shape in the middle of Martin Place during day shifts. For our operator and dogman on site, that meant a concentrated window to get the heavy work done while the city moved around them.

The tree itself is an impressive lift. It stands nearly eight storeys high once complete, with more than 300 baubles and around 100,000 lights. The structure arrives in carefully engineered sections. Each section is rigged, lifted and lowered into position, then locked off so the next layer can follow. Inside the tree electricians move through the core of the structure connecting the power and programming the lighting so the display comes to life once the sun goes down.
When all the major lifts are complete, a cherry picker circles the outside of the tree for final detailing. The design team works from a precise plan that sets out the exact placement of baubles and decorations.

For this project AOR Cranes supplied a 90 tonne mobile crane that covered the entire installation without the need for extra reach or specialised attachments. The tree sections are designed with cranage in mind. Each piece fits comfortably within the crane’s capacity and works with our standard chains and rigging, which keeps the lifting process efficient while still meeting strict safety requirements. Two AOR team members handled the work on the day, an experienced operator in the cab and a skilled dogman on the ground managing rigging and signalling.

The team worked closely with Ironhorse Installations who manage the install in partnership with the City of Sydney and Christmas specialists Chas Clarkson. More than five separate crews were active on site at different times, including traffic controllers, electricians, designers and other contractors. Jobs like this rely on planning that starts long before the crane arrives at Martin Place. That way every team understands the sequence of work and the space they’ll need.

Martin Place stays busy from first light, so working with pedestrians is the main challenge. The crane and support truck take up a significant footprint in a high-traffic area. A dedicated traffic control team manages exclusion zones and vehicle movements, and makes sure heavy vehicle access happens early so the streets are clear before the morning office rush. Clear signage, barriers and ground crew support keep people moving through the area while the lifts take place without compromising the safe working area around the crane.

For AOR, this project is a chance to see how our work shows up in people’s lives once the rigging gear is packed away. As one AOR Cranes director puts it, “This job never gets old for us. There’s something magical about being in the centre of Sydney and seeing people’s faces light up as the city’s biggest Christmas tree goes up. It’s why we love what we do, especially at this time of year.”

The Martin Place tree has become a meeting point for families, friends and city workers who want to feel a bit of Christmas spirit on their way through the CBD. It all starts with a coordinated effort behind the scenes from crews who know how to work safely in tight city spaces. Our team is proud to play a part in that experience and to support the City of Sydney’s festive program alongside trusted project partners.

If you’re planning an event installation or need crane support for work in the Sydney CBD, AOR Cranes can help with mobile crane hire, experienced operators and careful planning for complex lifts. Reach out to our team to talk through your next project and the kind of crane you’ll need to get it off the ground.

Posted on

Rooftop HVAC Unit Crane Lift Safety For Commercial Buildings In Sydney

AOR Crane Service at Condell Park Public School

When a rooftop HVAC crane lift goes to plan, the crane sets up smoothly, traffic keeps moving, tenants stay comfortable, and the new system drops onto the plant platform with zero drama. That positive outcome starts with solid information and a clear lift plan. Weights, dimensions, roof layout, access, traffic control and the right choice of crane all shape how safe and successful the project goes on the day. 

HVAC contractors, builders and facility managers who line these details up early with their crane hire partner get shorter crane hire windows, fewer site issues and a smoother changeover for everyone in the building. The more you know about the factors that go into planning a HVAC lift, the more successful the outcome.

Please Note: Always check the current NSW laws, the Work Near Overhead Power Lines Code of Practice and the electricity supply authority’s written advice for your specific site.

Why Careful Planning Matters For Rooftop HVAC Lifts

Safety Above Live Workspaces

A rooftop plant lift puts heavy HVAC units over offices, retail spaces and public areas. Poor planning increases the chance of near misses, damaged equipment or debris in public zones. Clear lift paths and well defined exclusion zones keep the load under control from street to plant platform. The goal is always to protect people on the ground and the crews on the roof.

Time, Cost And Tenant Impact

Crane hire is charged by the hours. Vague details lead to extra setup time, late changes to rigging and longer traffic control shifts. When everything is confirmed early, the crane turns up sized correctly and sets up faster. That keeps crane hours tighter, reduces disruption to tenants and helps mechanical teams complete the changeover in a single clean window.

Step 1: Gather The Right Project Details

Weights And Dimensions

Start with the numbers for every rooftop HVAC crane lift. Confirm unit weight, overall dimensions and, if available, centre of gravity from the manufacturer. Include frames, skids and any duct or plant sections that travel on the hook. Clear figures let the crane hire team check capacity at the working radius and match the lift to a suitable city crane or all terrain crane.

Roof Layout And Plant Platform

Now it’s time to map the roof. Mark plant platforms, parapets, balustrades and services that sit near the lift path. Take photos from several angles and share any roof or structural drawings you can access. The crane crew can then see how the load will travel and where riggers can move safely around the plant.

Step 2: Choose The Right Crane For The Lift

City Cranes In Sydney

City cranes suit tight commercial streets and narrow loading bays. They can be set up close to the facade and still deliver useful reach for rooftop HVAC units on low to mid-rise buildings. For many plant lift jobs in Sydney, a well planned city crane setup keeps traffic impacts smaller and makes the lift feel more controlled.

When To Use An All Terrain Crane

All terrain cranes step in when the plant is heavier, the roof is higher or the radius grows. They carry stronger load charts and offer more boom length. This suits large chillers, grouped plant replacement and taller commercial buildings where extra reach and capacity give a bigger safety margin.

Step 3: Plan Rigging, Lift Points And Load Stability

Confirm Safe Lift Points

Check manufacturer drawings for rated lifting points or seek an engineer’s sign off. Mark those points clearly before crane day so everyone knows where slings attach. A short toolbox talk on the roof helps the crew agree on orientation and how the unit should sit on the hook.

Protect The Unit During The Lift

Select spreader bars, lifting beams, soft slings and shackles that protect coils, casings and finishes. Aim to keep the HVAC unit level as it rises, slews and lands on the plant frame. Riggers and dogmen control the hook and guide the load through tight spots, especially near parapets or glass.

Step 4: Plan Access, Crane Setup And Traffic Management

Choose A Safe Setup Location

Look at ground conditions around the building. Confirm bearing capacity, check for basements or underground services and note any weak pavements. From there, pick a crane position that gives a clean lift path and keeps the radius within the crane chart. Plan staging areas for new units, old plant and waste bins so nothing clutters the setup zone.

Manage Traffic, Pedestrians And Permits

If the crane or load sits over a road or footpath, you’ll need a traffic management plan. Factor in lane closures, traffic controllers, pedestrian detours and barriers under the lift path. Council permits and notifications can take time. Line these up early with support from your crane hire partner.

Step 5: Sequence The Lift To Reduce HVAC Downtime

Schedule The Plant Lift Window

Pick a lift window that works for the building. Early mornings, evenings or weekends often suit commercial tenants and reduce traffic pressure around the site. Keep an eye on local noise rules and allow a buffer for weather so the crane isn’t rushed.

Coordinate Trades And Changeover

Do as much assembly as you can at ground level. Pre-build frames, skids and small sections so the crane places complete units on the roof. Sequence the work so the old systems come down first. New HVAC units will land straight after, then ancillary items follow. Electrical and mechanical teams should be ready to reconnect once the last lift is done to keep downtime short.

Step 6: Run A Safe Crane Day On Site

Pre-Start, Roles And Communication

Hold a pre-start before the first lift. Bring together the crane operator, riggers, HVAC contractor, builder, facility manager and traffic controllers. Confirm the lift plan, exclusion zones, radio channels and signals, wind limits and emergency procedures. Clear roles stop confusion once the crane starts moving.

Documentation And Compliance

Keep paperwork close at hand. That includes SWMS, lift plans, crane logbooks, Crane Safe Certification and inspection records for rigging. Site-specific inductions, permits and access conditions for the commercial building should also be closed out before the crane sets up. A tidy file keeps auditors happy and shows everyone on site that the rooftop HVAC crane lift is under control.

Rooftop HVAC Crane Lift Planning Checklist

  • HVAC unit weight confirmed from manufacturer data
  • Overall dimensions and centre of gravity noted
  • Frames, skids and loose items on the hook listed
  • Roof layout mapped with photos and drawings
  • Plant platform, parapets and nearby services marked
  • City crane or all terrain crane selected with real radius checks
  • Lift points confirmed by manufacturer or engineer
  • Lift points marked on the unit before crane day
  • Spreader bars, lifting beams and slings selected
  • Crane setup location checked for ground capacity and services
  • Staging areas for new and old plant agreed
  • Traffic management plan prepared with lane and footpath controls
  • Council permits lodged where public roads or paths are affected
  • Lift sequence agreed for removal and installation
  • Electrical and mechanical teams booked to match the crane window
  • Pre-start meeting planned with all key people
  • SWMS, lift plan, logbooks and certifications ready on site

Plan Your Next Rooftop HVAC Lift With AOR Cranes

A well planned rooftop HVAC crane lift is the best way to ensure a successful operation. The crane sets up cleanly, traffic keeps flowing where it needs to, and the new unit touches down on the plant frame without drama. That outcome needs a crane partner that knows Sydney’s streets, understands commercial buildings, and treats safety as non-negotiable. 

AOR Cranes brings more than 30 years of lift planning and execution across Sydney, including complex work for major utilities and live sites, with crews who are used to tight access and sensitive environments.

Their team can help lock in the right city crane or all terrain crane, prepare lift studies and SWMS, and coordinate traffic control so each plant lift runs to plan. If you’re lining up a rooftop HVAC or plant lift in Sydney, share your unit data, drawings and photos early so AOR can build a safe, efficient lift plan around your window of downtime.

If you need crane hire for a rooftop HVAC or plant lift in Sydney, get in touch with AOR Cranes or call 02 9024 9425.

Rooftop HVAC Crane Lift FAQs

How Early Should I Book A Crane For A Rooftop HVAC Lift?

Aim to lock in crane hire as soon as you know the plant changeover date. Two to four weeks gives time for lift planning, traffic management and any council permits.

What Information Does A Crane Hire Company Need For A Rooftop HVAC Lift?

You’ll need unit weight, dimensions, any extra items on the hook, roof layout and clear photos. Drawings of the plant platform and street access help the crane team pick the right city crane or all terrain crane.

Do I Need A Lift Plan For A Rooftop HVAC Crane Lift?

Yes. A lift plan sets out crane size, setup location, radius, rigging, lift path and exclusion zones. It keeps the site safe and helps everyone work to the same sequence.

Who Organises Traffic Control And Permits In Sydney?

Traffic control and permits are usually coordinated between the builder, HVAC contractor and crane hire company. Many clients ask the crane team to help arrange traffic management plans, controllers and council approvals as part of the plant lift package.

How Does Weather Affect A Rooftop HVAC Lift?

High wind, lightning and heavy rain can stop lifts. Your crane hire partner will work to wind limits on the crane chart and may pause or reschedule if conditions change on the day.

Posted on

Working Near Overhead Power Lines In NSW: Mobile Crane Safety Checklist

AOR Franna mobile crane Lifting Load

When a mobile crane contacts an overhead power line in NSW the outcome can be catastrophic. SafeWork NSW expects PCBUs, supervisors and crane crews to treat work near these assets as a specific electrical hazard. It must be controlled through planning, approach distances, exclusion zones, spotters and permits. 

Teams that build these controls into their lift planning protect their people, reduce shutdown costs and keep critical work moving on program.

Please Note: Always check the current NSW laws and Codes of Practice for advice for your specific site.

Understanding Your Responsibilities In NSW

PCBU Duties For Crane Work Near Power Lines

In NSW the PCBU has the lead role in managing the risk of a crane operating near overhead power lines. That duty covers the whole job, from planning and consultation through to supervision on the day of the lift. You’re expected to identify electrical risks early, eliminate them where you can and, where you can’t, put controls in place that bring the risk down as far as reasonably practicable.

For crane work that usually means deciding whether the lift can be re-planned to stay outside all approach distances or if you need higher level controls, such as shutdowns, relocations or physical barriers arranged with the network operator.

Code Of Practice And WHS Regulation

SafeWork NSW points PCBUs toward the ‘Work Near Overhead Power Lines Code Of Practice’ and the ‘Work Health & Safety Regulation’ as the main references for this type of task. They set out how far plant and people must stay from live lines, when you need a safety observer, how to consult with the electricity supply authority and what to do if contact occurs.

On a live site, that guidance needs to sit alongside your own systems, including project-specific risk assessments, lift plans, SWMS and traffic management plans. When everything lines up the expectations are already clear to the crane crew and the rest of the workforce.

When The Rules Apply On Your Site

These requirements apply whenever mobile plant can reach an overhead line, not only when you plan to work directly underneath it. Common triggers include bridge work near existing roads, culvert and pipeline projects in easements, rail corridor jobs, subdivision work near street lines and lifts in built-up areas where assets cross the property boundary.

If a crane’s boom, jib or load could enter the approach distance under any part of the planned or potential lift path, you should treat the task as work near overhead power lines and plan it with that level of care.

Step 1 – Identify Overhead Power Lines Early

Check Plans And Network Information

Start with information:

  • Network plans and asset maps
  • Design drawings and survey data
  • Online tools from Ausgrid, Endeavour Energy, Essential Energy or the private network

Confirm for each line:

  • Voltage
  • Ownership
  • Pole or structure numbers

Walk The Site From The Crane’s Point Of View

On site, stand where the crane could set up and look at:

  • Boom path and slew radius
  • Load route in and out
  • Sagging spans, trees, light poles and nearby buildings
  • Access tracks and laydown areas

You’re trying to see every way the crane or load could end up near a line.

Lock The Details Into Your Documents

Capture what you’ve found in:

  • Site layout drawings with lines and clearances marked
  • The lift plan
  • The SWMS and pre start notes

The crew should see the same picture on paper that you saw on site.

Step 2 – Set Approach Distances And Plan The Set Up

Understand The Zones

For work near overhead lines you’ll deal with:

  • Approach distance – minimum gap between the line and any part of the crane, rigging or load
  • Exclusion zone – guarded space where extra controls apply
  • No go zone – area the crane must stay out of unless the supply authority sets conditions

Confirm Minimum Distances

Distances change with:

  • Line voltage
  • Construction type
  • Whether the line is live, de energised or relocated

Use the NSW Code of Practice, then confirm exact distances in writing with the electricity supply authority before you sign off the lift plan.

Plan Crane Type And Position

Use those distances to shape the set up:

  • Pick a crane type and configuration that gives capacity and keeps the boom and load path clear
  • Choose a set up position where the outrigger footprint and slew radius sit outside marked zones
  • Use built in features such as height limiting, slew limiting and rated capacity indicators where available

If any planned movement would cut into a zone, move the crane or change the configuration on paper before it arrives.

Step 3 – Use Spotters And Site Controls

Know When A Spotter Is Required

If any part of the crane or load could enter the exclusion zone, plan for a dedicated safety observer. It shouldn’t be someone juggling other tasks. Their job is to watch the clearance and call instructions, and they need training in work near overhead power lines in line with the Code of Practice and any network conditions.

Define The Spotter’s Role

Make the role clear in the SWMS and briefing:

  • Uninterrupted view of the boom and the lines
  • Agreed hand signals or radio calls
  • Authority to stop the lift if clearances tighten

Everyone on the crew needs to know that a stop call from the spotter is final.

Control Access Around The Lift

Support the spotter with physical controls:

  • Barriers, cones and bunting to mark exclusion zones on the ground
  • Signage that flags overhead power risk
  • Traffic routes that keep other trades and plant out of the crane work area

A simple, quiet work zone makes it much easier to hold safe distances.

Step 4 – Coordinate Permits, Shutdowns And Network Support

Call The Network Operator Early

Contact the supply authority if:

  • The crane or load could enter the no go zone
  • You’re unsure about voltage or construction
  • You need isolation or line work to make the lift safe

This might be Ausgrid, Endeavour Energy, Essential Energy or a private network operator.

Understand Available Controls

Depending on the situation the network may:

  • De energise and isolate a span
  • Raise or re route lines
  • Install approved visual indicators such as tiger tails
  • Provide written limits and conditions for work

Treat their written advice as the reference document for distances and conditions.

Allow Time In The Program

Permits and shutdowns take time. Build into your program:

  • Lead time for network approvals
  • Isolation windows matched to crane days
  • Contingency plans if shutdown dates move

Good coordination keeps cranes working instead of waiting for clearances.

Step 5 – Lock Controls Into The Lift Plan And Pre-Start

Document The Layout And Controls

Your lift plan should show:

  • Line locations and marked zones
  • Crane model, configuration and set up position
  • Any slew or height limits applied
  • Controls agreed with the network operator

Keep drawings simple so an operator or rigger can read them at a glance.

Define Roles And Communication

Confirm in the plan and briefing:

  • Who supervises the lift
  • Who operates and rigs
  • Who acts as spotter
  • Radio channels or hand signals

Clarity on roles stops people making their own calls near live assets.

Run Focused Pre-Start Checks

Before the first lift:

  • Walk the work area with the crew
  • Point out the lines, zones and crane limits on the ground
  • Check barriers, signage and spotter position
  • Revisit what to do if contact occurs, including staying in the cab, keeping others away and calling the network

Those ten minutes align the paperwork with what actually happens beside the crane.

AOR Cranes Supports Safe Lifts Near Overhead Power Lines

AOR Cranes works through overhead power risks from the planning stage. The team can review drawings, visit sites and suggest crane types, set up positions and lift sequences that keep clear of live assets while still meeting program and access constraints. That support is geared to civil and utilities work in Sydney and regional NSW, where power lines run through most streets, easements and corridors.

On the ground you’re working with operators and riggers who understand NSW rules for work near overhead lines and know how to run lifts with exclusion zones, spotters and crane limits in place. The office backs that up with clear lift plans and paperwork that slot into your SWMS and permit process. Bring AOR in early and you gain a crane partner who helps protect people, reduce shutdown headaches and keep critical work moving.

If you need crane hire in Sydney, get in touch with AOR Cranes or call 02 9024 9425 to discuss how we can help.

FAQ: Working Near Overhead Power Lines In NSW

What is the minimum approach distance for cranes near power lines in NSW?
There isn’t a single distance for every job. Clearances change with voltage, line construction and whether the line is live or de-energised. Always check the current Work Near Overhead Power Lines Code of Practice and get written distances from the electricity supply authority before you finalise a lift plan.

When do I need a spotter for crane work near power lines?
Plan for a dedicated safety observer whenever the crane or load can enter the exclusion zone set by the Code or the network. A spotter is also smart where visibility is poor, the lift is complex or the operator can’t see the lines for the full movement.

Who organises power shutdowns or permits?
The PCBU or principal contractor normally leads contact with the electricity supply authority and arranges permits or shutdowns. Your crane provider can supply lift information and diagrams so the application has accurate crane data.

What should I do if a crane or load contacts an overhead power line?
Keep the operator in the cab if it’s safe. Warn everyone nearby to stay well away from the crane, the load and the ground around it. Call emergency services and the electricity supply authority immediately and follow their instructions before anyone approaches the plant.

Posted on

What Is A Franna Crane And When Should You Use One?

UNIT020 FRANNA What Is A Franna Crane And When Should You Use One?

A Franna crane is a “pick and carry” mobile crane. It drives on the road like a truck, then comes onto site, hooks onto the load, lifts it, and moves with the load still in the air. There is no need to set up outriggers or a large pad first. This keeps things moving when the program is tight. The name comes from the Australian manufacturer Terex Franna but many people now use “Franna” as a general word for this style of crane. A typical unit has the operator’s cab at the front, a telescopic boom in the middle, and a hook hanging on a winch rope from the end of the boom. Frannas rely on their own weight, the steering design, and the way the operator positions the load to stay stable. That design makes them handy on busy Sydney streets, tight industrial yards, and large construction sites where loads need to move from one area to another during the day.

How A Franna Crane Compares To Other Cranes

Franna Vs All Terrain Crane

A Franna crane is built to lift a load, travel with it, and set it down somewhere else. It suits work where the load needs to move around a site or between nearby locations on the same day. An all terrain crane works in a different way. It sets up on outriggers, stays in one position, and uses a longer boom to reach over buildings or deep into a site. All terrain cranes often handle heavier lifts and higher hook heights, which suits large commercial and infrastructure projects. On a typical Sydney job, the Franna acts like the workhorse that moves gear around once the heavy or long-reach lifts are done. The all terrain crane handles the bigger, more complex lifts that need reach, height, or precise placement from one spot.

Franna Vs City Crane

City cranes are compact slewing cranes that set up on outriggers and work in tight areas. They don’t travel with the load. The crane stays put and uses its boom to swing materials into position. This layout suits inner city sites with narrow lanes, tower crane work, or lifts that need good reach on a small footprint. A Franna, on the other hand, drives in, hooks on, lifts, then carries the load. It needs enough room to travel safely with the load and room to position the crane. Frannas fit well on wider suburban streets, industrial estates, and open commercial sites where there is space to move.

Key Pros And Limits Of A Franna Crane

Pros:

  • Fast mobilisation and pack up
  • Can move loads around a large site in one visit
  • Road legal, so it can travel between nearby locations in a shift
  • Ideal for plant moves, materials handling, and repeat lifts through the day

Limits:

  • Shorter reach than many all terrain and city cranes
  • Needs room to travel with the load
  • Load charts change as the crane steers and moves, so it needs an experienced operator and proper planning

Knowing these differences makes it easier to pick the right crane for the lift instead of guessing from the crane size alone.

When A Franna Crane Is Appropriate

Short Jobs And Busy Schedules

A Franna crane suits work where you need plenty of lifts in a single day. It can arrive on site, hook onto a load, move it, then head to the next task with very little downtime between moves. This works well when the program is tight and different trades are lining up behind each other. The crane can shift steel from the street to the slab in the morning, move plant inside a warehouse after lunch, then help place materials on a different part of the site late in the day. One machine, one operator, several tasks ticked off.

Sites With Room To Move

A Franna needs firm ground and clear travel paths. It carries the load while it drives, so the operator needs enough space to steer, brake, and position the hook where the load will land. Think of wide suburban streets, industrial estates, open commercial developments, and infrastructure jobs with access tracks. On these sites a Franna can come in, take the weight of the load, travel at low speed, and place it exactly where the team needs it. If the site has a good laydown area, the crane can shuttle loads from the delivery point to that zone through the day.

Typical Loads For A 20 Tonne Franna

A 20 tonne Franna often handles:

  • Structural steel for houses, small commercial builds, and refurb work
  • Precast panels and lintels within the crane’s capacity and chart
  • Air conditioning units and other rooftop services
  • Machinery moves in factories and workshops
  • Tanks, generators, and similar plant on infrastructure jobs
  • Spas, small pools, and landscaping features on residential sites

These loads tend to be compact and heavy rather than long and awkward. The crane can lift them, travel carefully, then set them down so riggers and trades can finish the positioning work.

When A Franna Adds Real Value

A Franna adds value when the crane does more than a single static lift. If the day involves multiple pick points, a few different locations, or a mix of street and on-site lifting, a pick and carry setup keeps things moving. The crew spends more time installing and less time waiting for a crane to move, pack up, or reset. When you describe the job to AOR, mention how many lifts you expect, where the loads will start and finish, and how much room there is to travel. With that information, the team can confirm if a Franna crane is the right fit or suggest another option from the fleet.

Why Choose AOR Cranes

Proven Sydney Crane Specialists

AOR Cranes has spent more than three decades helping Sydney builders, trades and industrial sites get lifts done safely and on time. The business is local and family run, so you deal with people who know the suburbs, traffic conditions and access quirks around the city and across Greater Sydney.

Experienced Operators And Riggers

A Franna crane is only as good as the crew running it. AOR’s team includes trained operators, riggers and support staff who work with pick and carry cranes every day. They understand how load weight, steering angle and surface conditions affect a Franna, and they know how to keep the lift inside the chart while still getting the job done. On site this means clear communication, sensible lift plans and a focus on keeping trades, pedestrians and traffic safe around the crane.

Modern Fleet With The Right Options

AOR’s fleet covers far more than a single 20 tonne Franna. The team looks after mini crawler cranes, city cranes, pick and carry cranes up to 28 tonne, and Liebherr all terrain cranes from 40 to 100 tonne. Our extensive range of cranes for hire in Sydney gives you many options. If a Franna suits the lift, they can send the Terex Franna AT-20. If the load needs extra reach or capacity, they can move you into an all terrain or another crane from the fleet so the lift stays safe and efficient.

Safety Systems You Can Rely On

AOR runs CraneSafe-certified equipment and ISO-certified management systems. Every crane goes through regular inspections and maintenance so it turns up ready to work. For you this means fewer surprises on the day of the lift. The crew arrives with a crane that meets Australian standards, the right rigging, and a clear plan for how to set up and move the load.

Local Support And Straightforward Service

Because AOR is based in Sydney and services a wide list of suburbs across the metro area, response times stay tight and travel is predictable.

Book A Franna Crane

A Franna crane is a handy option when you need to lift, move and set down loads across a busy Sydney site. It works well for plant moves, materials handling and full days of short lifts where you want one crane to do a lot of work. If you think a pick and carry crane fits your next job, take a look at AOR’s 20 tonne Franna crane hire page for more detail. Ready to line up a lift or talk through the options? Request a quote and we’ll help you lock in the right crane for the job.

Franna Crane Hire FAQs

Is A Franna Crane Different To A Standard Mobile Crane?
Yes. A Franna is a pick and carry crane that travels with the load on site. Many other mobile cranes set up on outriggers and work from one fixed position.

Do AOR Franna Cranes Come With An Operator?
Yes. AOR supplies Franna cranes with experienced operators and riggers or dogmen.

What Information Do I Need To Book A Franna Crane?
Have the load weight, overall size, pick-up and set-down points, site access notes, and a few photos ready so the team can confirm if a 20 tonne Franna suits the lift and plan the work safely.

Posted on

How Much Does It Cost To Hire A Crane In Sydney?

Franna heavy loding mobile crane

Crane hire in Sydney doesn’t have a single fixed price. The final cost depends on the crane you choose, the lift you need, and what’s happening on site. When you understand the main cost factors, you can plan a realistic budget, pick the right crane for the job, and keep the lift running on time. Clear information up front also helps avoid last-minute changes, so everyone can lock in their schedules with confidence.

There Is No Single Standard Crane Hire Rate

Hourly Rates Only Tell Part Of The Story

Crane hire is priced to match the work. An hourly figure on its own doesn’t explain the load, reach, access, or safety setup behind a lift. Two jobs using the same crane can end up with different totals once travel time, site delays, or extra crew come into play.

Every Job Has Different Site Conditions

A small mini crane on a quiet suburban street works very differently to a large all terrain crane beside a busy Sydney road. When pricing reflects what’s happening on site, the crane arrives ready for the conditions, the crew follows a clear plan, and the lift can finish safely without wasted time or repeat visits.

Main Factors That Affect Crane Hire Cost

Clear job details lead to clear pricing. Once you know the basics about your site, load, and timing, it becomes easier to match the crane and crew to the work and keep the total under control. These five areas have the biggest impact on crane hire cost in Sydney.

1. Crane Type And Size

Different cranes sit at different price points because they do different jobs. A compact mini crawler suits tight backyards, narrow driveways, and light residential lifts where space is limited. A Franna pick and carry crane is built for moving plant, steel, and materials around a larger site.  Big all terrain cranes step in for heavy structural steel, precast panels, and higher lifts on commercial projects across Sydney. When the crane size fits the lift, setup is smoother, the crane works within its chart, and the crew can finish in fewer hours.

2. Time, Travel And Minimum Hire

Most crane jobs run on a minimum hire period, often a few hours, that covers travel to site, setup, lifting, and pack down. After that window, the work rolls into extra hourly blocks. If the area is clear, loads are ready, and access is sorted when the crane arrives, the lift can move through that minimum period efficiently.  When trades are still preparing loads or clearing space, the crane and crew can be waiting while hire time keeps ticking over. A tidy site, a clear lifting sequence, and a firm start time help keep both time and cost under control.

3. Site Access And Setup

The way a crane reaches its working position has a direct effect on price. Tight laneways, low carports, narrow driveways, overhead power lines, and soft ground all slow down setup and may limit which crane can safely enter the site.  Some locations need extra gear such as bog mats, steel plates, or additional rigging to create a safe standing area for the crane. Simple preparation helps a lot here. Photos of the driveway and street, measurements of gate widths, and a quick site check give the crew enough information to plan the safest and quickest setup.

4. Load Weight, Radius And Height

Crane selection always comes back to three numbers: how heavy the load is, how far it needs to reach, and how high it needs to go. A light air conditioner lifted a short distance from a driveway to a single-storey roof is one level of work. A concrete pool shell over a two-storey house in a tight street is another level entirely, with more reach and more capacity required.  Heavier loads and longer radiuses call for a larger crane with more counterweight and more setup time. When you can share load weight, dimensions, and the exact pick and set locations, the team can choose a crane that covers the lift without oversizing the machine.

5. Extra Crew, Equipment And Permits

Some lifts need more support around the crane. Riggers and dogmen manage the load on the ground and on the hook, and they’re a standard requirement on many construction sites. Specialist gear such as spreader bars, lifting frames, glass lifters, or man boxes comes in when the load shape, location, or task demands it.  Work on busy streets or in the CBD can also require traffic controllers and permits from council or road authorities. Each of these items adds to the quote and they also keep people, vehicles, and nearby buildings safe while the crane is working.

How AOR Cranes Helps Keep Your Costs Under Control

Careful Planning Before The Crane Arrives

Solid planning is the quickest way to keep crane hire costs under control. AOR Cranes looks at load details, site access, street layout, and timing before the crane leaves the yard. That means the right crane, crew, and gear arrive on site with a clear lift plan. Fewer surprises on the day mean less waiting time, smoother setup, and fewer return visits.

Matching The Right Crane To The Job

AOR’s team draws on decades of work across Sydney to match each lift with a suitable crane. A mini crawler, a Franna, or a larger all terrain crane each has a clear role. When the machine fits the work, it can handle the load safely without oversizing the hire. Jobs run efficiently, lifts finish sooner, and budgets stay closer to the original quote.

Price Your Crane Hire With AOR Cranes

A few basics are all you need for a clear crane hire quote in Sydney. When you have these details ready, pricing lines up with what will actually happen on site.

  • Site address and a site contact
  • What needs lifting, including weight, size, and material
  • Where the load starts and where it needs to finish
  • Preferred date and time for the lift
  • Site access notes such as narrow lanes, low trees, power lines, or steep driveways
  • Photos or plans of the site and load if you can grab them

Share those details through the AOR Cranes request a quote form and the team can match a suitable crane to your job, plan the setup, and come back with clear numbers. The right crane turns up, the crew follows a solid plan, and your lift can be completed safely, on time, and with costs under control.

Crane Hire Cost FAQs

How Is Crane Hire Usually Charged?
Most jobs use a minimum hire period that covers travel, setup, lifting, and pack down, then roll into hourly rates if more time is needed.

Do Crane Hire Costs Include An Operator?
Yes, crane hire comes with a licensed operator, dogman and standard lifting gear, and extra crew or specialist equipment are added to the quote when required.

What Information Do I Need For A Quote?
You’ll need the site address, load details, pick and set locations, preferred date and time, and any access notes such as narrow driveways or overhead power.

Can I Get A Ballpark Price Over The Phone Or Email?
You can get an initial guide, and the price becomes more accurate once you share photos, measurements, and basic load details.

How Early Should I Book A Crane In Sydney?
Booking as soon as you know your dates gives the best chance of locking in the crane and crew you need, especially for larger or city jobs.

Posted on

Boom Length vs Load Capacity: Understanding the Inverse Relationship

Boom lenght vs load capacity

If you’ve ever planned a crane lift on a construction site in Sydney or anywhere across NSW, you’ve likely faced a critical question: “Do we need more boom or more capacity?”

The two often sound like they go together, but they’re usually at odds. In crane operations, increasing boom length can dramatically reduce how much weight a crane can safely lift. That’s not just a technicality, it’s a safety issue governed by Australian Standard AS 2550 and enforced under WHS regulations.

Understanding the Inverse Relationship 

Let’s start with a simple principle: The further the load is from the crane’s center, the less it can lift. 

Cranes operate on the concept of load moment, which is the turning force created by the load as it moves away from the crane’s base. The formula looks like this: 

Load Moment = Load Weight × Load Radius 

Where: 

  • Load Radius = horizontal distance from crane center to the load 
  • Load Moment must stay within the crane’s structural and stability limits 

So, when you extend the boom (increasing the radius), the same load suddenly generates more force, pushing the crane closer to its tipping or structural limit. 

Think of a fishing rod. The further out you hold the rod, the heavier the fish feels. Same idea, except with cranes, getting this wrong can topple hundreds of tons of steel. 

How Boom Angle and Length Affect Load Capacity 

As the boom length increases, the angle of the boom often decreases to reach the same spot horizontally. This increases the load radius, even if the boom itself hasn’t changed position drastically. 

Take this example: When a crane has a 30 m boom, the load radius (horizontal reach) changes depending on the boom angle: 

  • At 80°:
    Load Radius = 30 × cos(80°) ≈ 5.2m
    (Crane can lift ~28T) 
  • At 45°:
    Load Radius = 30 × cos(45°) ≈ 21.2m
    (Crane can lift ~6T) 

As the boom lowers (angle decreases), the radius increases. Because cranes have a fixed moment limit (Load × Radius), a longer radius means they must lift less weight to stay safe and stable. 

This is why boom angle directly affects lifting capacity and why you must check load charts at your exact lift angle and radius. If your site conditions demand a flatter boom angle, you’ll need to reduce the load weight or use a stronger crane than initially anticipated. 

Why Getting Bigger Crane Isn’t Always Better 

There’s a tendency among people to “just get the big one”, thinking it’s safer or more versatile. But choosing a crane with the longest boom can backfire. 

Here’s why: 

  • Longer booms reduce lifting capacity at wider radii. 
  • Setup and mobilization take more time and may require permits or escort vehicles. 
  • Larger cranes demand more site space for outriggers and swing clearance. 
  • Bigger cranes often exceed what’s needed for the actual load weight, wasting money. 

For example, a 130-tonne all-terrain crane might only lift 8 tons at a 28-metre radius with a 60-metre boom. Meanwhile, a smaller 60-ton crane may safely lift 12 tons at the same distance with a shorter boom at a steeper angle. 

The lesson is clear: don’t select cranes by capacity rating alone. The load chart and the boom configuration matter just as much. 

When to Prioritize Boom Length Over Load Capacity 

Sometimes, you don’t have a choice. Here are common site scenarios where boom length becomes more important than lifting power: 

  • Lifting equipment over tall buildings or structures 
  • Working around permanent obstructions like trees or overhead utilities 
  • Reaching across inaccessible zones or protected areas 
  • Installing mechanical units on rooftops or elevated platforms 

In these situations, the crane must be positioned further from the load or reach higher than usual. That means selecting a crane with sufficient boom length, even if it means compromising on lifting capacity. But even then, the load chart must be followed precisely to remain compliant under WHS law and AS 2550. 

Comparison Table: Boom Length vs Max Load Capacity 

This table helps readers quickly understand how different crane types perform in terms of boom length, load radius, and lifting capacity, critical factors when selecting the right crane for a job. It simplifies complex planning decisions by aligning crane specs with real-world site needs. 

Crane Type Typical Boom Length (m) Typical Load Radius (m) Max Safe Capacity (tons) Common Use Case
Mobile Crane 25-35 5-10 20-40 General lifting on commercial sites
All-Terrain Crane 40-70 10-30 15-100 Versatile for varied site access and reach
Crawler Crane 50-100+ 20-40+ 30-150+ Infrastructure projects, long-term lifts
Pick & Carry (Franna) 10-20 3-6 10-25 Material transport around site, short lifts
City Crane 20-35 6-12 5-10 Urban sites with tight access
Tower Crane 50-80 (horizontal jib) 30-60 (radius) 2-25 (varies by radius) High-rise construction, multi-story buildings
Lattice Boom Crawler 70-120+ 30-50+ 50-300+ Heavy lifts, wind farms, major infrastructure

These are indicative figures based on typical crane performance. Actual capacity depends on make and model, rigging setup, and counterweight configuration. This table helps visualize how dramatically capacity falls as boom length and radius increase. 

Boom Length vs Capacity vs Common Project Type 

Not all cranes are created equal, some are built for reach, others for heavy lifting, and some for mobility. As a contractor or site manager, understanding how boom length, load radius, and safe lifting capacity vary across crane types is essential for choosing the right machine for the job. 

The table below offers a general comparison of commonly used crane types based on typical specifications and real-world performance. 

Project Type Load Range Reach Needed Recommended Crane Boom Length
Tilt-up panel erection 5-12T Medium 60T Mobile 30 – 40m
Rooftop HVAC lift 1-3T High 130T All-Terrain 50 – 60m
Precast wall install 10-20T Medium-High 100T AT / Crawler 40 – 60m
Wind turbine install 5-10T Very High Lattice Crawler 60m+

Technology That Helps 

Modern lifting operations benefit from tools that take the guesswork out of boom length and load capacity planning. Common tools used in the Australian crane industry include: 

  • Manufacturer load chart software 
  • 3D lift simulation to model crane position, radius, and swing zones 
  • Real-time wind monitoring to ensure safe operation under dynamic conditions 
  • Digital Safe Work Method Statements (SWMS) that automatically flag non-compliance 
  • Crane supplier consultations to generate lift plans reviewed by qualified engineers 

Using these tools isn’t just a best practice, it’s often a requirement under WHS law, especially on high-risk or high-value job sites. 

Conclusion 

Choosing the right crane for your project is about far more than lifting capacity. The real variables to consider are boom length, load radius, and site constraints. A longer boom might allow you to reach higher, but it may also force you to reduce your load size—often significantly. 

The smart move is to plan early, use tools and charts, and work closely with your crane hire experts. With the right boom-to-load match, your lift will be safer, faster, and more efficient from the ground up. 

If you’re planning your next lift, AOR Cranes provides comprehensive crane hire services across Sydney NSW, including expert lift planning, certified equipment, and WHS-compliant documentation tailored to your project needs 

Posted on

How to Calculate the Right Crane Size for Your Construction Project

Crane size calculator

In Australian construction projects, whether it’s a commercial high-rise in Sydney or a wind farm installation in regional NSW, the crane you choose can either ensure a seamless lift or cause expensive delays and serious safety hazards. The right crane size impacts not only your lifting capacity but also your project timeline, budget, and compliance with Work Health and Safety (WHS) regulations. 

Why Selecting the Right Crane Size in Project Planning Is Critical 

Overestimating crane size often leads to unnecessary costs and operational inefficiencies. Larger cranes come with higher rental fees and longer setup times and often require special permits or road closures, especially on tight urban sites like in Sydney. They also take up more space, which can disrupt workflow and limit access for other trades on site. While a bigger crane might seem safer, it rarely adds value if it’s more than what the job truly needs. 

Underestimating crane size, however, is far more dangerous. A crane that’s too small for the load or radius increases the risk of tipping, failed lifts, or load drops, any of which can halt the job and compromise site safety. It also raises the chance of exceeding ground pressure limits, especially on soft or uneven terrain. These mistakes can result in serious damage, compliance breaches, and costly project delays. 

4 Key Factors That Determine Crane Size 

Crane size isn’t just about how “big” a crane looks, it’s defined by how much it can lift at a specific radius and height under given site conditions. Here’s a breakdown of what goes into that decision: 

1. Load Weight

This is the total mass the crane will lift and includes: 

  • The item itself (e.g., precast concrete slab) 
  • Rigging gear (slings, shackles, spreader beams) 
  • Hook block weight 

Formula: 

Total Load (t) = Object Weight + Weight+Rigging + Lifting Gear 

Pro tip: Always overestimate rigging by at least 10% if you don’t have the exact figure. Rigging loads often go overlooked in planning. 

2. Lift Radius

Lift radius is the horizontal distance between the crane’s center of rotation (slew ring) and the vertical center of gravity of the load. 

  • Why it matters: As the radius increases, the crane’s lifting capacity decreases dramatically due to the leverage effect. 
  • Example: A 100-ton crane might lift 80t at 4m but only 8t at 20m. 
  • How to measure: Use CAD software or physical site layout measurements from crane pad to load drop zone. 

3. Lift Height

Lift height is the vertical distance the crane must raise the load, from ground level to its final position. It directly influences the required boom length and may call for extensions like fly jibs or luffing jibs to reach over structures. 

When calculating lift height, account for 

  • Building or structure height 
  • Rooftop elements like parapets or plant equipment 
  • Necessary clearance above the load 
  • Final placement elevation 

In high or confined areas, accurate lift height is crucial to avoid boom collisions and ensure safe, efficient crane setup. 

4. Site Conditions

Ground conditions, access paths, and space availability directly impact crane type and configuration. 

  • Soft ground? Use crawler cranes with low ground pressure. 
  • Limited access? Choose Franna or city cranes. 
  • Obstructions like trees or power lines? Consider slewing radius and clearance. 

3 Formulas to Estimate Required Crane Capacity 

While professional lift plans always involve crane load charts, these formulas help provide a solid initial estimate. 

1 Calculating Load Moment  

Load moment is the turning force that the crane must resist to safely lift a load at a specific radius. It is a product of the load’s weight and the horizontal distance (lift radius) from the crane’s center of rotation to the load’s center of gravity. The greater the radius, the more torque (or tipping force) is exerted on the crane. 

Many crane manufacturers express this as ton-meters ™, a standard unit used to rate a crane’s lifting performance at different radii. Most crane load charts are based on load moment limits. If your calculated load moment exceeds what the crane can handle at that radius, the lift is unsafe. 

Formula: 

Load Moment (tm) = Load Weight (t) × Lift Radius (m) 

Example Calculation: 

  • Load Weight = 12 tons 
  • Lift Radius = 20 meters 

Load Moment = 12 × 20 = 240 ton-meters (tm) 

What this means: 
Your crane must have a rated capacity of at least 240 tm at a 20-metre radius. You would then check the crane’s load chart to confirm it can safely handle this load at that specific radius. If not, you’ll need to either reduce the radius (move the crane closer) or choose a higher-capacity crane. 

2 Required Crane Size Estimate 

To estimate the minimum crane capacity required to handle a specific load at a given radius. It uses the previously calculated load moment and divides it by an efficiency factor (E), which accounts for real-world variables like crane type, lift complexity, wind conditions, and safety margins. 

The efficiency constant typically ranges from 0.6 to 0.85: 

  • Use 0.85 for ideal conditions (short lifts, minimal obstacles). 
  • Use 0.6–0.75 for more complex lifts or conservative planning. 

Formula: 

Crane Size (t) = Load Moment (tm) / E 

Example Calculation: 

  • Load Moment = 240 tm 
  • Efficiency constant (E) = 0.75 

Crane Size = 240 / 0.75 = 320 tons 

What this means: You should consider a crane rated at least at 320 tons to lift the load safely at that radius. 

Reminder: This is a preliminary estimate, always verify with the actual crane’s load chart at the intended radius. 

3 Calculating with Boom in Crane 

This formula estimates the required crane capacity by factoring in the boom angle—which becomes critical when lifting to high elevations or in confined spaces. The boom angle (θ) affects the tension in the crane’s structure and the effective capacity at extended reach. A steeper boom angle generally means better lifting capacity, while a shallow angle increases leverage and strain. 

This method is useful when you already know your boom length and radius, and need to understand the stress placed on the crane’s structure due to geometry. 

Formulas: 

  1. Calculate boom angle:
    θ = arcsine (Radius / Boom Length) 
  2. Calculate adjusted crane capacity:
    Effective Capacity (t) = Load × Radius / sin(θ) × E   

Where: 

  • Load = lifting weight in tons 
  • Radius = lift radius in meters 
  • Boom Length = actual or planned boom extension 
  • θ = boom angle (in degrees or radians) 
  • E = efficiency constant (typically 0.6–0.85) 

Example Calculation: 

  • Load = 10 tons 
  • Radius = 22 meters 
  • Boom Length = 30 meters 
  • E = 0.75 

Step 1:  θ=arcsine(22 / 33 ) ≈ 47.7∘ 

Step 2:  sin(47.7∘)≈0.739 

Step 3:  Effective Capacity = 10×22 / 0.739×0.75 =0.554220 ≈ 397.8 tons 

What this means:
To safely lift a 10-ton load at a 22-metre radius with a 30-metre boom, the crane should be rated for approximately 398 tons under these geometry and efficiency assumptions. This accounts for the actual stress caused by the boom angle, which may not be obvious from basic load moment calculations alone. 

As always, validate this estimate using the actual crane’s load chart for the given boom configuration. 

Using Load Charts to Finalize Crane Selection 

Once you’ve estimated the required crane size using formulas, the next step is to validate your choice using the manufacturer’s load chart. Load charts provide precise information on how much weight a crane can safely lift at various boom lengths and radii. These values vary depending on the crane’s configuration, outrigger position, and boom setup. 

For example, based on an actual load chart for an all-terrain crane

Load chart all terrain crane

The chart shows: 

  • Boom lengths along the top row (from 11.4m to 60m) 
  • Lift radius down the left column (from 3m to 56m) 
  • Rated lifting capacities in tons at each combination of boom length and radius 

Read more for a detailed guide: How to read a crane’s load chart 

Key Considerations 

  • Always allow a buffer of 10–25% over the actual load for safety and regulatory compliance. 
  • If you’re close to the limit (like lifting 9.9t with a 10t capacity), opt for a stronger configuration or shorter radius. 
  • If your lift setup involves obstructions, tight angles, or dynamic loading, increase the safety factor or choose a larger crane. 

Using the load chart ensures that you’re not just making theoretical estimates; you’re validating them against the actual performance limits of the specific crane model in your fleet or rental plan. Always consult the full chart, including notes on outrigger configuration, wind limits, and boom extension setups, before finalizing crane selection. 

5 Types of Cranes and Their Relevance to Sizing 

Different crane types suit different projects. Here’s how they compare: 

All-Terrain Cranes 

  • Versatile for urban and regional projects requiring long reach and high capacity 
  • Can travel between job sites without needing special transport logistics 
  • Ideal for multi-story structural steel installs, bridge components, and HVAC lifts 

Crawler Cranes 

  • Provide excellent lifting capacity on soft, unstable, or unsealed ground 
  • Ideal for large-scale infrastructure and industrial plants with longer setup durations. 
  • Less mobile but extremely stable with low ground pressure 

Franna Cranes (Pick & Carry) 

  • Perfect for congested, fast-moving jobs where mobility is key 
  • Commonly used for machinery relocation, pipe sections, and modular components 
  • Highly effective for plant maintenance or short transport inside yards 

Tower Cranes 

  • Stationary cranes used in high-rise construction, where frequent vertical lifts are needed 
  • Requires long-term setup and foundation but offers excellent lift repetition 
  • Suitable for inner-city developments with height restrictions on mobile cranes 

Rough Terrain Cranes 

  • Compact and capable in off-road conditions such as mines, dams, or pipeline routes 
  • Ideal for uneven or sloped terrain where crawler deployment isn’t viable 
  • Easy to set up and operate in remote civil sites 

5 Common Mistakes to Avoid When Estimating Crane Size 

  1. Ignoring Rigging Loads: Often contributes 5–15% to total load. Always include. 
  2. Underestimating Radius: Site layout changes can increase swing radius. Validate in the final lift plan. 
  3. Choosing Based on Tonnage Alone: Rated capacity applies only to specific configurations. Always verify with the load chart. 
  4. Overlooking Ground Conditions: Check allowable ground pressure and use appropriate outrigger pads. 
  5. Not Factoring Safety Margins: Critical lifts or congested sites require engineered lift plans and redundancy. 

Checklist for Accurate Crane Sizing 

  • Confirm actual load weight (including rigging) 
  • Measure true lift radius from crane base 
  • Determine vertical lift height 
  • Assess site access, terrain, and obstructions 
  • Estimate required crane capacity using formulas 
  • Consult load charts for final selection 
  • Include 10–25% safety margin 
  • Ensure compliance with Australian lifting standards 
  • Engage crane engineers for critical or tandem lifts 

Conclusion 

Crane sizing requires more than guesswork, it demands precise calculations, site awareness, and manufacturer data. Whether you’re lifting steel in the CBD or solar panels in regional NSW, accuracy ensures safety, efficiency, and WHS compliance. 

AOR Cranes offers expert crane hire services across Sydney, New South Wales, with a fleet that includes Franna, mobile, and all-terrain cranes. Backed by experienced operators and engineered lift planning, we ensure every lift is completed safely, efficiently, and on budget. 

Posted on

Why Counterweights Matter in Crane Stability and Load Capacity

How Crane Counterweight works torque diagram

When operating cranes on Australian construction or infrastructure projects, several factors influence lifting capacity and overall stability, one of the most critical being the counterweight system. Whether you’re an operator managing a 100-ton crawler crane or a project manager hiring an all-terrain model, understanding how counterweights work is essential for ensuring safety, compliance, and lifting efficiency. 

Counterweights are not just metal or concrete slabs, they’re the engineering backbone that stabilizes lifting operations, prevents tipping, and enables cranes to reach their full capacity. This article explains how counterweights contribute to crane stability and load capacity, using real-world data and standards aligned with AS 2550.1 and AS 1418.5. 

What Are Counterweights in Cranes?

A counterweight is a mass attached to the crane’s superstructure to balance the force generated by the load being lifted. In principle, the crane acts as a lever: the load on one side creates torque, which the counterweight offsets on the opposite side. 

Crane counterweights can be: 

  • Fixed (as in tower cranes) 
  • Modular (as in mobile and crawler cranes) 
  • Hydraulically variable (in Superlift systems)

Proper configuration of these weights is what makes high-capacity, long-reach lifting possible. 

How Counterweights Maintain Crane Stability

Cranes are susceptible to tipping if the center of gravity (CoG) shifts outside their base support area (defined by outriggers or track width). Counterweights keep the CoG within safe limits, even as the boom swings or radius increases. 

Without the correct counterweight: 

  • A crane becomes unstable during boom extension. 
  • Swing operations may cause rotational overload.
  • Outriggers or tracks may lift, leading to collapse. 

The Physics of Crane Stability

Cranes function as rotating levers, where the load creates a moment (torque) around the pivot point (slewing ring or chassis center), and the counterweight provides an opposing moment to balance it. 

Basic Moment Equation 

Moment = Force × Distance 

Where: 

  • Force = Load weight (in kilonewtons or tons) 
  • Distance = Horizontal distance (radius) from pivot point 
  • Moment (Nm or tons-meters) = Rotational force acting on the base 

Below is visual representation 

torque diagram of how counterweight works

Stability Principle 

A crane is in equilibrium when: 

(Load Weight × Load Radius) ≤ (Counterweight × Counterweight Radius) 

If this condition is not met: 

  • The crane rotates toward the load 
  • The tipping point is exceeded 
  • Outriggers may lift, tracks may shift, and full structural collapse can follow   

How Counterweights Enhance Load Capacity

Counterweights allow cranes to lift more weight at greater distances. For example, based on an actual load chart for an all-terrain crane: 

Load chart all terrain crane

  • At a 22.6m radius, with full counterweights: 47.5 tons 
  • At the same radius, with reduced counterweights: 36.6 tons 
  • That’s a 23% drop in capacity just from configuration 

Counterweight Configuration vs. Lifting Capacity 

Load Radius (m) Max Capacity (with full CW) Max Capacity (reduced CW)
11.4 59.2 t 50.6 t
15.9 56.3 t 41.2 t
22.5 53.0 t 36.4 t
33.0 47.6 t 33.6 t
38.5 43.6 t 33.9 t
42.1 30.9 t 30.3 t
44.6 28.6 t 29.3 t
52.2 23.6 t 23.4 t
55.9 20.2 t 16.1 t
60.0 25.3 t 8.9 t

This data reflects how critical correct counterweight configuration is for safe operation, especially at longer radii where load moment is amplified. 

4 Types of Counterweight Systems

Fixed Counterweight System

Fixed counterweights are commonly used in tower cranes and consist of precast concrete or steel blocks mounted at the rear of the counter-jib. These are non-adjustable once installed and are designed to support consistent, predictable loads throughout a project. Ideal for static, long-term construction such as high-rise buildings, they typically balance loads up to 50 tons. The simplicity of this system ensures maximum reliability with minimal configuration error. 

Modular Counterweight System

Widely used in mobile, all-terrain, and crawler cranes, modular systems consist of stackable steel slabs that can be added or removed based on lift requirements. These systems are fully adjustable and often used across changing job sites with different lifting profiles. They support up to 100+ tons of counterweight, making them suitable for infrastructure, civil works, and general construction. Their flexibility, ease of transport, and compatibility with load charts make them highly practical. 

Hydraulic Superlift Counterweight System

The hydraulic Superlift system is found in large crawler cranes handling ultra-heavy and long-radius lifts. It uses a hydraulically extendable tray or wagon that increases the distance from the crane’s pivot, improving leverage. This system allows for real-time adjustability and is commonly used in wind turbine installation, bridge lifting, and industrial plant construction. It can accommodate 200-300+ tons of counterweight, helping maintain balance during complex or high-risk operations. 

Ballast Tank (Fluid-Based) Counterweight System

Ballast tank systems are used in floating cranes or marine barge-mounted lifting platforms, especially for offshore and port operations. Instead of solid weights, they use fluid-filled tanks, usually water, that can be pumped between compartments to dynamically balance the crane in real time. These systems are continuously adjustable and support over 1,000 tons of compensating ballast, depending on vessel size. Their adaptability to wave motion and platform tilt makes them essential in maritime environments.  

Impact on Structural Engineering and Ground Pressure

  • Counterweight Influence: Counterweights increase total crane mass, resulting in higher ground pressure through outriggers or tracks. A 100-ton crawler crane with full counterweights can exert 250-350 kPa at each contact point. 
  • Ground Pressure Management: Exceeds safe bearing capacity of typical construction soil (often <150 kPa). Requires use of load-distribution systems: steel pads, timber mats, or engineered platforms. 
  • Soil and Site Assessment: Ground must be tested via geotechnical surveys for:
    1. CBR (California Bearing Ratio) 
    2. Moisture content 
    3. Compaction level 

Governed by AS 3798 (site prep) and AS 2550.1 Clause 7.4.1 (crane setup). 

  • Load Spreading Techniques: Common mat sizes: 1.2m-1.5m square steel pads for mobile cranes. Cribbing is used under crawler shoes to distribute force over uneven terrain. 
  • Risks of Poor Ground Prep: Sinking, outrigger uplift, crane tilt or collapse, even if within rated capacity. Structural engineers must validate all base conditions prior to lift. 

Cranes That Require Counterweights

Here’s a classification table of common cranes and their counterweight usage: 

Crane Type Needs Counterweight Placement Why It Matters
Tower Crane Yes Rear counter-jib Balances boom moments; essential for high-altitude stability
Mobile Crane Yes Rear of frame Enables lifting on long booms with compact footprint
Crawler Crane Yes Rear frame + Superlift Handles extremely heavy loads with wide track support
Overhead Crane No Not applicable Load is supported symmetrically on bridge rails
Floating Crane Yes Ballast tanks Maintains vessel stability amid wave motion
Knuckle Boom (truck-mounted) Sometimes Rear chassis Needed for heavy lifting or extended articulation

Counterweight Checklist: Crane Operation Best Practices

Before any lift involving counterweights:

  • Confirm crane configuration matches load chart. 
  • Verify counterweight slabs are properly installed and secured. 
  • Check ground conditions and use appropriate mats or steel plates. 
  • Use only qualified personnel to configure or modify counterweights. 
  • Document weight and configuration in the lift plan. 
  • Follow AS 2550.1 and crane manufacturer’s safety guidelines. 

Safety and Compliance: Risk of Misconfiguration 

Misconfigured counterweights are among the top 3 causes of crane-related incidents. Risks include 

  • Crane tipping or collapsing under load 
  • Overloading the slewing ring or boom pivot 
  • Breach of AS 2550.1 or AS 1418.5, leading to liability 

Conclusion

Counterweights are far more than just heavy attachments, they are a critical part of a crane’s structural balance and lifting capability. From placing a precast wall panel at 10 metres to installing a turbine blade at 60 metres, the right counterweight setup determines whether a lift is safe, successful, and compliant with Australian standards. 

At AOR Cranes, our team specializes in tailored crane hire solutions with precisely configured counterweight systems for every job. Whether you’re managing a high-rise build in Sydney or a remote infrastructure project across NSW, we ensure your lifts are engineered for maximum safety and performance every time. 

Posted on

Crane Lift Plan: Key Elements and Mistakes to Avoid

AOR

In high-risk environments like construction and infrastructure development, lifting operations involving cranes demand meticulous preparation. A single miscalculation in crane setup, load capacity, or environmental conditions can lead to catastrophic consequences. According to Safe Work Australia, crane-related incidents accounted for over 240 serious injury claims in the construction industry in a recent five-year period. To mitigate such risks, a crane lift plan serves as the operational blueprint that ensures each lift is executed safely, efficiently, and in compliance with national regulations.

What is a Crane Lift Plan?

A crane lift plan is a comprehensive strategy that outlines how a crane will be used to safely lift, move, and place a load. It serves as a safety and coordination document that considers all the variables involved in the lift, including site conditions, weather, equipment, personnel, and load characteristics.

According to Australian standards, particularly AS 2550.5 and Work Health and Safety Regulation 2011, lift plans are mandatory for high-risk operations. These plans should not be treated as one-size-fits-all templates. Instead, they must be tailored to the site and the complexity of the lift.

Scenarios requiring a crane lift plan include:

  • Lifts exceeding 75% of rated crane capacity.
  • Lifts performed near active traffic, overhead powerlines, or public zones.
  • Tandem or multiple crane lifts.
  • Lifts involving personnel hoisting or non-routine load configurations.

Creating a lift plan in these scenarios ensures that everyone on site, from supervisors to riggers, is aware of their responsibilities, the sequence of operations, and emergency protocols.

8 Key Elements of a Crane Lift Plan

A well-structured crane lift plan isn’t just a formality; it’s a proactive risk management tool. Each component of the plan plays a distinct role in reducing hazards, streamlining communication, and ensuring regulatory compliance. Below is a detailed breakdown of what must be included and why each element matters.

1. Load Characteristics

Before any crane even starts its engine, you need a full understanding of the load to be lifted. That means:

  • Accurate weight calculation: Use certified documentation or load cells if unknown. Misjudging weight can lead to boom failure or tipping.
  • Load geometry: Irregular shapes require customized rigging solutions.
  • Center of gravity (CoG): If the CoG isn’t centered beneath the hook, the load may swing, rotate, or shift mid-air.

Example: Lifting a steel tank that’s wider at the base demands precise identification of the CoG to avoid tilting.

Pre-Lift Load Characteristics Checklist

  1. Use this if you’re hiring a crane or preparing a lift plan.
  2. Is the total load weight known and verified?
  3. Have load dimensions (L × W × H) been measured and documented?
  4. Has the center of gravity been identified or estimated?
  5. Is the shape regular or does it require special rigging?
  6. Are lift points clearly marked and structurally sound?
  7. Is the load rigid, flexible, or likely to deform in the air?
  8. Does the load require surface protection (e.g., padding, spreaders)?
  9. Have you shared drawings or photos of the load with your crane provider?

2. Crane Specifications

Not all cranes are created equal, and using the wrong crane type for a lift can be disastrous.

  • Crane type: Mobile, tower, or crawler? Each has different mobility, capacity, and setup needs.
  • Load chart reference: Always consult the crane’s load chart for boom length and radius combinations.
  • Setup parameters: Include outrigger placement, counterweights, slewing limitations, and tail swing clearance.

Quick Guide: Choosing the Right Crane for Your Lift

Selecting the wrong crane can delay your project or compromise safety. Here’s a simplified breakdown to help you match crane type to your site needs:

  • Mobile Slew Cranes
    Fast to set up, road-legal, and ideal for general construction lifts with good access.
    Best for: Rooftop HVAC, steel beams.
  • Crawler Cranes
    Great for heavy lifts on soft or uneven ground. Requires more setup space.
    Best for: Bridge work, remote infrastructure.
  • Tower Cranes
    Fixed to site, perfect for vertical lifting on high-rise projects.
    Best for: Apartments, commercial buildings.
  • Rough Terrain Cranes
    4WD and stabilizers make them ideal for off-road, uneven job sites.
    Best for: Wind farms, pipeline work.
  • Pick and Carry (Franna)
    Compact, mobile, great for quick shifts of light loads.
    Best for: Onsite equipment moves.

Read more for a detailed guide on selecting right crane for every job .

3. Rigging Configuration

This is often where plans go wrong. Inadequate rigging is a leading cause of dropped loads.

  • Rigging gear selection: Ensure WLL (Working Load Limit) is suitable. Slings, shackles, hooks, and spreader bars must be matched to the load.
  • Sling angles: Sharper angles increase tension on slings. Calculations must factor this in.
  • Inspection logs: All rigging gear should be inspected and tagged before the lift.

As shown in the image below, sling angles significantly affect load distribution. Therefore, selecting the correct angle is crucial for a safe and stable lift.

sling angles affect on load distribution

4. Ground and Environmental Assessment

A crane’s lifting capacity depends on several factors, including weather and ground conditions.

  • Soil bearing capacity: Must be verified to prevent sinkage or instability.
  • Underground services: Always locate utilities before setup, contact Dial Before You Dig in Australia.
  • Weather considerations: Wind speed affects the lifting capacity of cranes with high boom lengths. Lifts should be rescheduled if wind speeds exceed crane-specific limits (typically 36 km/h for mobile cranes). Also consider lightning, heavy rain, or poor visibility.

5. Lifting Path and Movement

It’s not just about going up and down, lateral movement introduces complexity and additional hazards.

  • Load path planning: Map the full travel route of the load to avoid contact with obstacles like scaffolding, overhead cables, or nearby structures.
  • Crane swing radius: Define and mark the area around the crane’s rotation zone to prevent personnel from entering dangerous zones during operation.
  • Emergency drop zones: Pre-designate safe areas where the load can be lowered quickly in case of equipment failure or sudden environmental hazards.

6. Personnel and Supervision

People are the most critical part of any lift.

  • Named personnel: Every lift plan must list the crane operator, dogman, rigger, lift supervisor, and spotters.
  • Competency verification: All must hold valid High Risk Work (HRW) licences per Safe Work Australia.
  • Toolbox talks: Conduct a pre-lift briefing to review responsibilities and site hazards.

7. Communication Plan

Clear, fail-safe communication is vital, especially when visibility is limited or when lifting in noisy environments.

  • Primary system: Most sites use two-way radios with a designated channel.
  • Secondary system: Hand signals, standardized under AS 2550.1, serve as backup.
  • Spotters and signalers: Should be clearly identified in PPE and remain in direct line-of-sight or radio contact.

8. Emergency Protocols

Things go wrong, even with perfect planning.

  • Wind shutdown procedures: Know your crane’s wind limits and stick to them.
  • Mechanical failure response: Have trained personnel ready to engage emergency brakes or drop loads safely.
  • Evacuation plans: Include routes, assembly points, and contact numbers in the lift plan.

Standard vs. Critical Lifts

Not all lifts are created equal. Some crane operations are straightforward and occur in controlled environments, while others involve complex load dynamics, tight working spaces, or high-consequence environments. This is where understanding the difference between standard and critical lifts becomes essential.

A standard lift typically involves known loads under controlled conditions, using a single crane well within its capacity. These lifts follow routine procedures and generally don’t require engineering review beyond basic compliance checks.

In contrast, a critical lift involves elevated risks, whether it’s lifting close to the crane’s capacity, working over live plants or public spaces, performing tandem crane operations, or involving expensive or irreplaceable loads. Critical lifts require additional scrutiny, including peer-reviewed lift calculations and constant supervision by experienced personnel.

Here’s a side-by-side comparison for clarity:

Criteria Standard Lift Critical Lift
Capacity Usage ≤ 75% of crane rating ≥ 90% or multi-crane coordination
Load Type Known and simple Complex, large, sensitive, or unknown loads
Risk Environment Controlled, clear zone Crowded site, near public or utilities
Documentation Basic lift plan Full engineered lift plan with supporting calculations
Supervision Lift supervisor recommended Mandatory full-time lift supervisor with sign-off authority

Safety and Legal Importance

Lift plans are not just internal guidelines, they are enforceable documents that demonstrate duty of care under Australian law. Failure to implement a crane lift plan that meets WHS regulations can result in fines, project delays, or worse, fatal incidents.

  • They also provide an audit trail for:
  • Site inspectors and project auditors
  • Insurance claims following incidents
  • Root cause analysis in case of mechanical failure or human error

A documented lift plan also protects crane operators from liability when procedures are followed correctly. According to WorkSafe NSW, several serious crane accidents could have been prevented if documented lift procedures had been followed.

5 Common Mistakes to Avoid

Some frequently overlooked errors in crane lift planning include:

  • No lift plan for routine lifts: Every lift involving non-trivial weights or public risk should be documented.
  • Improper rigging assumptions: Using slings that are improperly angled or worn out drastically increases failure probability.
  • Missing wind monitoring protocol: Even moderate winds can destabilize long boom lifts.
  • Untrained spotters: Spotters must be trained in crane movement and hand signal standards.
  • No trial lift or dry run: Testing the lift with a partial load or empty hook can expose issues before the full load is handled.

Final Thoughts

Crane lift planning is about more than compliance, it’s about foresight, collaboration, and accountability. Every successful lift begins long before the crane is on site, with a well-researched, site-specific plan that anticipates the unexpected.

When in doubt, consult a certified lift planner or engage crane hire specialists with engineering capabilities. Proper documentation and preparation today can prevent disaster tomorrow.

For reliable, fully compliant crane lift planning and execution, explore how AOR Cranes supports complex lifting projects across Sydney, NSW.

Posted on

How Weather Conditions Affect Crane Operation and Lifting

crane lifting operations

While weather is one of the key variables, it’s important to remember that multiple factors influence a crane’s lifting performance, including boom angle, radius, and ground stability. Because crane operations are heavily reliant on the weather, erratic weather patterns can present significant safety hazards as well as operational delays. Whether lifting in high-rise zones or regional infrastructure sites, understanding how weather specifically impacts different crane types is critical to ensuring safety and regulatory compliance.

Weather Conditions & Crane-Specific Effects

Each crane type behaves differently under environmental stress. This section breaks down how six key weather conditions impact cranes used across NSW (New South Wales), along with targeted safety actions.

High Winds

Impact:

Wind introduces dynamic loading, where side gusts cause swinging, instability, or uncontrolled boom movement. Wind speed affects the lifting capacity of cranes with high boom lengths. This becomes especially dangerous during long or high lifts.

  • Tower Cranes: Their elevation makes them extremely wind-sensitive. Gusts above 54 km/h (15 m/s) typically require a full stop.
  • Mobile Slewing Cranes: Boom sway and sail area increase with height; lifting capacity must be reduced by 50% or more at 40 km/h.
  • Franna Cranes: Shorter reach, but still vulnerable when using long boom extensions or lifting with load sail area.
  • Crawler Cranes: More stable at base, but vulnerable at full boom height or when lifting large surface-area loads.

Safety Protocols:

  • Install anemometers at both crane height and ground level.
  • Use manufacturer wind derating charts and load charts to recalculate safe load.
  • Implement wind-triggered lift shutdowns using real-time monitoring.
  • Conduct toolbox talks on sail area awareness, especially for large panels, frames, or precast concrete lifts.

Heavy Rain & Storms

Impact:

Rain affects surface traction, electrical systems, and visibility, and increases the risk of ground saturation. Storms add lightning and wind risk.

  • Franna Cranes: Struggle with traction on wet roads or grass, especially during tight urban lifts.
  • Crawler Cranes: While designed for rough terrain, wet clay or sand can bog tracks and compromise base stability.
  • All-Terrain Cranes: Better equipped for varied terrain but still require dry, stable pads.
  • Tower Cranes: Limited risk from water, but operations must pause during lightning due to elevated structure.

Safety Protocols:

  • Conduct site drainage checks before deploying heavy equipment.
  • Use anti-slip access paths, bog mats, or steel plates under outriggers.
  • Implement a pre-lift lightning assessment during storm forecasts (BOM).
  • Provide clear visibility PPE and flashing beacon lights for spotters during reduced visibility periods.

Extreme Heat

Impact:

Prolonged heat affects operator performance, hydraulic fluid viscosity and can cause thermal expansion in structural components.

  • Crawler Cranes: Extended cycles in direct sun can overheat hydraulics and cab interiors.
  • Tower Cranes: Operators may experience heat exhaustion in glass cabs. Cabin temps can exceed 50°C if unventilated.
  • Franna and Mobile Cranes: Engines and electronics may fail without adequate cooling.

Safety Protocols:

  • Use reflective insulation inside crane cabins.
  • Schedule early morning or night shifts to avoid midday extremes.
  • Enforce hydration and rest protocols: 15-min break per hour in 35°C+.
  • Monitor hydraulic oil temperatures and apply cooldown periods.

Fog, Smoke, and Low Visibility

Impact:

Crane operations rely heavily on line-of-sight. Fog and bushfire smoke can completely obscure visual cues and signalers.

  • Tower Cranes: Signalers and dogmen may be invisible from cab height.
  • Franna Cranes: Limited maneuvering space becomes riskier when ground crew can’t be seen clearly.
  • All Mobile Cranes: Swing paths, landing spots, and surrounding structures can’t be judged accurately.

Safety Protocols:

  • Pause all critical lifts when visibility drops below 100 meters.
  • Equip crews with two-way radios and establish verbal/automated signal protocols.
  • Deploy high-vis PPE with retroreflective strips and LED signal flags or strobes.
  • Establish exclusion zones where visibility is <50% of standard lift distance.

Frost, Ice, and Cold Snaps

Impact:

While rare in NSW lowlands, frost is common in highland and alpine zones. Cold weather affects hydraulics, steel components, and surface friction.

  • Crawler Cranes: Hydraulic oil thickens, slowing boom response and risking cavitation.
  • Tower Cranes: Ice on cables or booms can lead to jerky movements or failure to hold load tension.
  • All Types: Frosted outriggers may slip or misalign on icy pads.

Safety Protocols:

  • Conduct early morning frost inspections on metal surfaces and hydraulic lines.
  • Use low-temperature-rated oils and lubricants during winter months.
  • Apply non-slip pads or rubber mats over frozen concrete or gravel.
  • Delay operations until ambient temp exceeds 5°C to allow safe hydraulic activation.

Muddy Ground Conditions

Impact:

Soft or saturated soil reduces ground-bearing capacity and increases the risk of crane tip-over.

  • Crawler Cranes: Most at risk of becoming bogged, especially in clay-heavy terrain.
  • Franna Cranes: Wheels may sink on grass or dirt access ways.
  • All-Terrain Cranes: May appear stable but can shift without proper outrigger pads.

Safety Protocols:

  • Conduct soil compaction and bearing pressure tests before lift.
  • Use spreader plates, steel mats, or bog mats under all contact points.
  • Avoid parking or lifting near trench edges or unreinforced embankments.
  • Assign a spotter for outrigger placement and movement checks.

Region-Wise Weather Impact on Crane Operation in NSW

NSW Region Common Weather Risks Cranes Most Affected Key Precautions
Sydney Metro Gusts, fog, thunderstorms Tower, slewing cranes Wind derating, lightning pauses, visibility control
Newcastle & Hunter Coastal winds, heavy rain Mobile, tower cranes Rain shutdown protocols, gust monitoring
Western Sydney Heat, muddy soil post-rain Franna, crawler cranes Hydration enforcement, bog mat use
South Coast Flooding, unstable ground All-terrain, Franna Drainage prep, storm delay planning
Snowy Mountains Frost, cold winds, fog Tower, crawler cranes Cold start checks, anti-slip pads

9 Weather Safety Protocols for Crane Operations

  1. Check live weather forecasts from reliable sources (e.g., BOM) before each shift.
  2. Monitor on-site conditions continuously, especially wind speed and visibility.
  3. Verify ground stability and soil condition before setup, especially after rainfall.
  4. Confirm crane configuration matches weather tolerance, including load limits and boom angles.
  5. Suspend operations when any condition exceeds the crane’s manufacturer-rated limits.
  6. Equip the crew with proper communication tools (e.g., radios, signal systems) for low-visibility environments.
  7. Conduct pre-start inspections focused on hydraulics, outriggers, and cab conditions relevant to the weather.
  8. Train all personnel on emergency response and shutdown procedures related to weather hazards.
  9. Document weather-related decisions in lift plans and daily reports for compliance and risk management.

Plan Lifts with Weather in Mind

Every crane has a weather limit. Ignoring environmental conditions not only compromises safety but can delay projects and violate compliance standards. Whether operating in Sydney’s storm-prone urban zones or on regional NSW construction sites, crane operations must be tailored to local weather risks and supported by structured planning.

Following best practices, such as those aligned with AS 2550.1 and Safe Work NSW guidelines, ensures that both personnel and project timelines are protected.

At AOR Cranes, we bring decades of experience managing crane hire operations across Sydney in various weather conditions. Our team applies rigorous safety protocols, uses manufacturer-approved load derating practices, and monitors real-time weather data to ensure your lift is not just possible but professionally executed.