When is a crane lift plan required under OSHA and AS 2550?

OSHA 29 CFR 1926.1400 requires employers to ensure crane operations are performed safely and that loads do not exceed rated capacity. While OSHA does not prescribe a specific lift plan document for every lift, a documented lift plan is considered best practice and is required for critical lifts. AS 2550 requires a lift plan for all lifts beyond routine operations, and critical lifts must have an engineered plan reviewed by a competent person. Most crane companies and principal contractors require a lift plan as a minimum for all lifts.

What makes a crane lift a critical lift?

A critical lift is typically defined as a lift that exceeds 75 to 80 percent of the crane rated capacity at the working radius, a lift over personnel, a tandem or multi-crane lift, a lift involving complex rigging (spreader bars, equaliser beams), a lift near overhead power lines, or any lift where the consequences of failure are severe. Definitions vary by company, regulator and standard. Critical lifts require a detailed engineering lift plan reviewed and approved by a qualified engineer.

How often should a lift plan be reviewed?

A lift plan should be reviewed and re-signed at the start of each day or shift for routine standing lift plans. For one-off lifts, the plan should be completed before each individual lift. If conditions change during a lift (such as wind exceeding the planned limit, ground conditions deteriorating or the crane configuration being altered), the plan must be revised and re-approved before the lift continues.

What is the difference between a lift plan and a rigging plan?

A lift plan covers the entire crane operation including crane selection, ground assessment, load weight, capacity calculations, hazard assessment, exclusion zones, personnel and communication. A rigging plan is a subset of the lift plan that focuses specifically on the rigging arrangement, including sling types and capacities, shackle sizes, attachment points, centre of gravity and rigging geometry. Both are essential for a safe lift, and the rigging plan is typically included as a section within the lift plan.

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Free crane lift plan template (PDF-ready). Covers OSHA 29 CFR 1926.1400 and AS 2550 lift planning, load charts and rigging. Download free.

Last updated: 2026-04-20

Jarrod Milford

Commercial Director

Updated 20 April 2026

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What is a crane lift plan template?

A crane lift plan template is a pre-lift planning document used to ensure that every crane lift is engineered, reviewed and authorised before the load leaves the ground. Under OSHA 29 CFR 1926.1400 (Cranes and Derricks in Construction), employers must ensure that crane operations are conducted safely and that loads do not exceed the crane rated capacity. AS 2550 (Cranes, hoists and winches - Safe use) requires a documented lift plan for all lifts beyond routine operations. The lift plan captures the crane make, model and configuration, boom length and radius, rated capacity at the planned radius, gross and net load weight (including rigging, block and hook), rigging arrangement (slings, shackles, spreader bars), ground conditions and outrigger setup, overhead and underground hazards, exclusion zones, wind limits, communication plan and personnel roles. For critical lifts (typically defined as lifts exceeding 75 to 80 percent of the crane rated capacity, lifts over personnel, tandem lifts or lifts involving complex rigging), a detailed engineering lift plan reviewed by a qualified engineer is required. Using a standardised lift plan template ensures that every relevant factor is assessed before the crane begins the lift, reducing the risk of overloading, structural failure or contact with overhead power lines.

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Benefits of using this crane lift plan template

Overload prevention: documenting load weight, rigging weight and crane capacity at the planned radius ensures the crane is never loaded beyond its rating.
Regulatory compliance: meet OSHA 29 CFR 1926.1400 and AS 2550 requirements for pre-lift planning and documentation.
Hazard identification: the planning process forces consideration of overhead power lines, underground services, ground bearing, wind and exclusion zones before the lift.
Communication clarity: defined roles (crane operator, rigger, dogger, signal person, lift supervisor) and a communication plan reduce misunderstandings during the lift.
Audit trail: a signed lift plan provides documented evidence for regulatory inspections, insurance claims and incident investigations.
Repeatability: a standardised template ensures every lift is planned with the same rigour, regardless of the crane operator, rigger or site, reducing variability and human error.

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What to include in a crane lift plan template

This crane lift plan template covers 10 key areas:

Lift details: project name, location, date, lift description, lift classification (routine, standard, critical).
Crane details: make, model, serial number, configuration (boom length, jib, counterweight), capacity chart reference.
Load details: item description, gross weight, centre of gravity, rigging weight, total suspended load.
Rigging plan: sling types and capacities, shackles, hooks, spreader bars, equaliser beams, rigging arrangement diagram.
Crane setup: ground bearing assessment, outrigger setup, mat placement, crane level check, swing radius.
Radius and capacity: pick radius, set radius, boom angle, rated capacity at each radius, percentage of rated capacity.
Hazard assessment: overhead power lines, underground services, adjacent structures, wind limits, exclusion zones, pedestrian and traffic management.
Personnel: crane operator, rigger, dogger, signal person, lift supervisor, engineer (for critical lifts).
Communication plan: radio channels, hand signals, stop-work authority.
Approvals and sign-off: lift supervisor, crane operator, site manager, engineer (if critical lift).

How to use this crane lift plan template

Determine the load weight, dimensions and centre of gravity. Include the weight of all rigging equipment in the total suspended load.: Obtain the verified weight of the load from the manufacturer data plate, shipping documentation or by weighing the item. If the weight cannot be confirmed, have it calculated by a qualified engineer. Add the weight of all rigging gear, including slings, shackles, spreader bars, the hook block and headache ball, to arrive at the total suspended load. Identify the centre of gravity and mark the lift points on the load. An incorrect weight or centre of gravity is the most common cause of crane overloading and load swing incidents.
Select the crane configuration and verify the rated capacity at the planned pick and set radii using the manufacturer load chart.: Choose the crane make and model, boom length, jib extension (if applicable), counterweight configuration and outrigger setup that provides adequate capacity at the planned working radii. Read the manufacturer load chart for the specific configuration and confirm the rated capacity at both the pick radius (where the load is lifted) and the set radius (where the load is placed). The total suspended load must not exceed the rated capacity at either radius. Calculate the percentage of rated capacity; if it exceeds 75 to 80 percent, classify the lift as critical and require engineering review.
Assess the ground conditions, outrigger setup, overhead hazards, underground services, wind limits and exclusion zones. Document findings on the lift plan.: Inspect the ground where the crane will be positioned. Confirm the ground bearing capacity can support the outrigger loads, and place mats or pads under each outrigger to distribute the load. Check for overhead power lines and maintain the minimum safe approach distance (at least 6.1 metres for voltages up to 33 kV under AS 2550, or per the OSHA voltage-distance table). Identify underground services using Dial Before You Dig or 811 plans. Set a maximum wind speed limit for the lift, typically 20 to 40 km/h depending on the load sail area. Define and barricade the exclusion zone beneath and around the lift path.
Define personnel roles, communication methods and the stop-work protocol. Brief all personnel involved in the lift.: Assign the crane operator, rigger(s), dogger (signal person), lift supervisor and any observers. Establish the communication method: radio channels, hand signals per AS 2550 or OSHA signals, and a clear stop-work authority for any person who identifies a hazard. Conduct a pre-lift briefing (toolbox talk) with all personnel covering the lift sequence, load weight, swing path, set location, exclusion zone boundaries, wind limits and the emergency stop procedure. Confirm every person understands their role before the lift begins.
For critical lifts, have the plan reviewed and signed by a qualified engineer before the lift proceeds.: A critical lift, typically any lift exceeding 75 to 80 percent of rated capacity, a tandem lift, a lift over personnel, or a lift near overhead power lines, requires a detailed engineering lift plan reviewed and signed by a qualified structural or mechanical engineer. The engineer verifies the load calculations, crane capacity, rigging design, ground bearing assessment and lift geometry. Do not proceed with a critical lift until the engineer has signed the plan and a copy is available on site. Some jurisdictions and principal contractors require the engineer to be present during the lift.
Obtain all required sign-offs. Retain the completed lift plan for the project file.: The lift supervisor, crane operator and site manager sign the completed lift plan before the lift begins. For critical lifts, the engineer sign-off must also be on the plan. File the signed lift plan in the project crane compliance folder and upload a digital copy to MapTrack so the record is linked to the crane asset. Retain lift plans for the life of the project and at least as long as required by your contract, insurance and regulatory obligations. The plan is a key document in any incident investigation involving a crane lift.

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How often should you complete this plan?

A lift plan must be completed before every crane lift that is not a routine repetitive operation. For routine lifts (same crane, same load, same location, same conditions), a standing lift plan may be used provided it is reviewed and re-signed at the start of each day or shift. Critical lifts always require an individual lift plan reviewed by a qualified engineer. If conditions change during the lift (wind increases, ground conditions deteriorate, crane configuration changes), the existing lift plan must be revised and re-approved before the lift continues. In MapTrack, lift plans can be attached to the crane asset, completed on mobile and automatically retained as part of the crane compliance record.

Frequently asked questions

When is a crane lift plan required under OSHA and AS 2550?: OSHA 29 CFR 1926.1400 requires employers to ensure crane operations are performed safely and that loads do not exceed rated capacity. While OSHA does not prescribe a specific lift plan document for every lift, a documented lift plan is considered best practice and is required for critical lifts. AS 2550 requires a lift plan for all lifts beyond routine operations, and critical lifts must have an engineered plan reviewed by a competent person. Most crane companies and principal contractors require a lift plan as a minimum for all lifts.
What makes a crane lift a critical lift?: A critical lift is typically defined as a lift that exceeds 75 to 80 percent of the crane rated capacity at the working radius, a lift over personnel, a tandem or multi-crane lift, a lift involving complex rigging (spreader bars, equaliser beams), a lift near overhead power lines, or any lift where the consequences of failure are severe. Definitions vary by company, regulator and standard. Critical lifts require a detailed engineering lift plan reviewed and approved by a qualified engineer.
How often should a lift plan be reviewed?: A lift plan should be reviewed and re-signed at the start of each day or shift for routine standing lift plans. For one-off lifts, the plan should be completed before each individual lift. If conditions change during a lift (such as wind exceeding the planned limit, ground conditions deteriorating or the crane configuration being altered), the plan must be revised and re-approved before the lift continues.
What is the difference between a lift plan and a rigging plan?: A lift plan covers the entire crane operation including crane selection, ground assessment, load weight, capacity calculations, hazard assessment, exclusion zones, personnel and communication. A rigging plan is a subset of the lift plan that focuses specifically on the rigging arrangement, including sling types and capacities, shackle sizes, attachment points, centre of gravity and rigging geometry. Both are essential for a safe lift, and the rigging plan is typically included as a section within the lift plan.

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