What makes a lift critical under AS 2550?

AS 2550 Section 8 defines special lifting applications that require additional planning. A lift is typically classified as critical when the load exceeds 80% of the crane rated capacity at the planned radius, involves two or more cranes (tandem lift), passes over occupied buildings or public areas, is near live overhead power lines, uses a load without certified lifting points, or involves personnel riding on the load or hook block. Individual organisations may apply additional criteria based on their risk appetite.

Who can sign off on a critical lift plan?

A critical lift plan requires sign-off from a qualified engineer (typically a mechanical or structural engineer with crane lifting experience), the crane supervisor on site, the site manager and, where applicable, the principal contractor. The engineer sign-off covers the calculations and structural adequacy. The crane supervisor verifies the operational feasibility. The site manager and principal contractor confirm site readiness and authorise the activity.

How is a tandem lift plan different from a single-crane critical lift plan?

A tandem lift plan must include load share calculations for each crane expressed as both a percentage and an absolute tonnage. It must define the maximum permissible out-of-level angle during the lift, the synchronisation method (visual, radio command, electronic), and the communication protocol between the two crane operators and the lift supervisor. It also requires a step-by-step sequence showing the exact order of crane movements, hold points and the contingency plan if one crane experiences a fault during the lift.

What are abort criteria and why are they mandatory?

Abort criteria are pre-defined conditions that require the lift to be stopped immediately. They are mandatory because critical lifts operate with tighter margins and the consequences of failure are more severe. Typical abort criteria include wind speed exceeding the stated limit, load spinning or swinging beyond a defined tolerance, ground settlement or outrigger pad sinking observed, crane alarm activation, communication failure between key personnel, or any unauthorised person entering the exclusion zone.

Do I need a critical lift plan for every lift over 80% of crane capacity?

Yes. Under AS 2550 and industry best practice, any lift that loads the crane to more than 80% of its rated capacity at the planned radius is classified as a critical lift and requires a full critical lift plan with engineering calculations, dual approvals and a specific risk assessment. Some organisations set their threshold lower, at 75%, as an additional safety margin.

Can a standard lifting plan be upgraded to a critical lift plan?

A standard lifting plan can form the starting basis, but a critical lift plan requires additional sections that are not present in a standard plan. These include engineering calculations, engineer sign-off, abort criteria, contingency planning, detailed step-by-step sequencing with hold points, and tandem lift data if applicable. It is better to use a dedicated critical lift plan template to ensure no required section is missed.

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Free critical lift plan template (PDF-ready) per AS 2550 Section 8. Engineering calcs, tandem lifts, dual approvals and risk controls. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a critical lift plan template?

A critical lift plan is a detailed engineering and safety document required for crane lifts that carry elevated risk beyond a standard lifting operation. Under AS 2550 Section 8, a lift is classified as critical when it involves any of the following: the load exceeds 80% of the crane rated capacity at the required radius, the lift is a tandem or multi-crane operation, the load is lifted over occupied buildings or public areas, the lift is performed near live power lines or other critical infrastructure, the load is an engineered or non-standard item without certified lifting points, or the lift involves personnel riding on the load or hook block.

The critical lift plan goes well beyond a standard lifting plan. It requires detailed engineering calculations for crane stability, rigging loads, ground bearing pressures and load distribution. It typically needs sign-off from a qualified engineer as well as the crane supervisor, site manager and the principal contractor. A risk assessment specific to the critical lift must be completed and attached to the plan. The plan must include a detailed sequence of operations, step-by-step communication protocols, abort criteria and a contingency plan if the lift cannot be completed as planned. Under Australian WHS legislation, cranes are high-risk plant and critical lifts represent the highest-risk subset of crane operations. Failure to plan a critical lift properly has been a contributing factor in multiple fatal incidents investigated by Australian WHS regulators.

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Benefits of using this critical lift plan template

Engineering rigour: require formal calculations for crane stability, rigging loads and ground bearing, reducing the risk of overload or structural failure.
Regulatory compliance: satisfy AS 2550 Section 8 and WHS Regulation requirements for special or high-risk lifting operations.
Dual approvals: mandate sign-off from a qualified engineer and the crane supervisor before the lift proceeds, adding an independent verification layer.
Tandem lift coordination: provide a structured framework for multi-crane lifts, including load sharing calculations, communication protocols and synchronised sequencing.
Abort criteria: define clear conditions under which the lift must be stopped, preventing pressure to continue when conditions deteriorate.
Incident prevention: address the specific risk factors that have contributed to fatal crane incidents in Australia, including overloading, inadequate ground preparation and poor communication.

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What to include in a critical lift plan template

This critical lift plan template covers 12 key areas:

Critical lift classification: the specific criteria that make this lift critical (over 80% capacity, tandem lift, lift over occupied area, near power lines, etc.).
Lift identification: plan number, project, site, date, planned sequence start and finish times.
Load details: description, verified weight, dimensions, centre of gravity, lifting point certification, loose component securing.
Crane details (per crane for tandem lifts): type, make, model, SWL/WLL at required radius, boom length, configuration, capacity chart reference.
Engineering calculations: crane stability check, rigging load calculations, sling angle factors, ground bearing pressure analysis, outrigger reaction forces.
Tandem lift data (if applicable): load share per crane (expressed as percentage and tonnage), maximum out-of-level tolerance, synchronisation method.
Rigging plan: detailed rigging arrangement drawing, component schedule with tag numbers and WLL, spreader bar design certification if purpose-built.
Lift sequence: step-by-step procedure from initial hook-on through lift, travel, set-down and unhook, with hold points for verification.
Risk assessment: specific risk assessment for the critical lift, including hazard identification, consequence analysis and control measures.
Abort criteria: defined wind speed, load behaviour, ground movement or equipment alarm conditions that require the lift to be stopped immediately.
Communication plan: radio channels, hand signal conventions, call signs, challenge-and-response protocol for critical steps.
Approvals: prepared by, engineer review and sign-off, crane supervisor approval, site manager authorisation, principal contractor consent, crane operator acknowledgement.

How to use this critical lift plan template

Classify the lift and confirm it meets the critical lift threshold.: Review the lift parameters against AS 2550 Section 8 criteria. If the load exceeds 80% of the crane rated capacity at the planned radius, involves tandem cranes, passes over occupied areas, is near live overhead power lines, or uses non-standard lifting points, it must be treated as a critical lift. Document the specific classification criteria on the plan.
Complete engineering calculations and obtain engineer sign-off.: Calculate crane stability, outrigger reaction forces, ground bearing pressures, rigging loads at the planned sling angles and load distribution for tandem lifts. These calculations must be reviewed and signed by a qualified engineer. For tandem lifts, calculate the load share for each crane and the maximum permissible out-of-level tolerance during the lift.
Prepare the detailed lift sequence and risk assessment.: Write a step-by-step lift procedure covering hook-on, initial lift-off, travel path, slew, set-down and unhook. Identify hold points where the lift supervisor must verify conditions before proceeding. Complete a risk assessment specific to this lift, addressing each critical hazard and the controls in place.
Define abort criteria and the contingency plan.: Specify the exact conditions that require the lift to be stopped: wind speed exceeding the limit, load spinning or swinging beyond tolerance, ground settlement observed, crane alarm activation, communication failure, or any person entering the exclusion zone. Document what happens if the lift is aborted mid-sequence, including how the load will be safely lowered or secured.
Conduct a pre-lift briefing with all personnel.: Hold a formal briefing covering the full lift sequence, roles, communication channels, hand signals, hold points, abort criteria and emergency procedures. Every person with a role in the lift must attend and sign the briefing register. Verify all licences, crane inspections and rigging inspections are current.
Obtain all required approvals before the lift commences.: The plan must be signed by the preparing engineer, reviewed by the crane supervisor, approved by the site manager and consented to by the principal contractor. Each crane operator must acknowledge the plan. No element of the lift may proceed until all sign-offs are obtained and filed.

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How often should you complete this plan?

A critical lift plan is required every time a lift meets any of the critical lift criteria defined in AS 2550 Section 8. There is no standing or recurring critical lift plan; each critical lift must have its own dedicated plan because the specific parameters, site conditions and hazards are unique to that operation. If conditions change after the plan is approved (wind, ground conditions, crane availability, load weight revision), the plan must be revised, re-calculated and re-approved before the lift proceeds. Organisations that perform critical lifts regularly should maintain a register of all critical lift plans for audit purposes. In MapTrack, you can flag lifts as critical, link the engineering sign-off documentation to the asset record and set mandatory approval workflows that prevent the lift from being recorded as commenced until all approvals are captured digitally.

Frequently asked questions

What makes a lift critical under AS 2550?: AS 2550 Section 8 defines special lifting applications that require additional planning. A lift is typically classified as critical when the load exceeds 80% of the crane rated capacity at the planned radius, involves two or more cranes (tandem lift), passes over occupied buildings or public areas, is near live overhead power lines, uses a load without certified lifting points, or involves personnel riding on the load or hook block. Individual organisations may apply additional criteria based on their risk appetite.
Who can sign off on a critical lift plan?: A critical lift plan requires sign-off from a qualified engineer (typically a mechanical or structural engineer with crane lifting experience), the crane supervisor on site, the site manager and, where applicable, the principal contractor. The engineer sign-off covers the calculations and structural adequacy. The crane supervisor verifies the operational feasibility. The site manager and principal contractor confirm site readiness and authorise the activity.
How is a tandem lift plan different from a single-crane critical lift plan?: A tandem lift plan must include load share calculations for each crane expressed as both a percentage and an absolute tonnage. It must define the maximum permissible out-of-level angle during the lift, the synchronisation method (visual, radio command, electronic), and the communication protocol between the two crane operators and the lift supervisor. It also requires a step-by-step sequence showing the exact order of crane movements, hold points and the contingency plan if one crane experiences a fault during the lift.
What are abort criteria and why are they mandatory?: Abort criteria are pre-defined conditions that require the lift to be stopped immediately. They are mandatory because critical lifts operate with tighter margins and the consequences of failure are more severe. Typical abort criteria include wind speed exceeding the stated limit, load spinning or swinging beyond a defined tolerance, ground settlement or outrigger pad sinking observed, crane alarm activation, communication failure between key personnel, or any unauthorised person entering the exclusion zone.
Do I need a critical lift plan for every lift over 80% of crane capacity?: Yes. Under AS 2550 and industry best practice, any lift that loads the crane to more than 80% of its rated capacity at the planned radius is classified as a critical lift and requires a full critical lift plan with engineering calculations, dual approvals and a specific risk assessment. Some organisations set their threshold lower, at 75%, as an additional safety margin.
Can a standard lifting plan be upgraded to a critical lift plan?: A standard lifting plan can form the starting basis, but a critical lift plan requires additional sections that are not present in a standard plan. These include engineering calculations, engineer sign-off, abort criteria, contingency planning, detailed step-by-step sequencing with hold points, and tandem lift data if applicable. It is better to use a dedicated critical lift plan template to ensure no required section is missed.

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS 2550 Section 8 - Special lifting applications
AS 2550 - Cranes, hoists and winches (safe use)
BS 7121-1 - Code of practice for safe use of cranes (general)
AS 1418 - Cranes, hoists and winches (design)
WHS Regulations Chapter 5 Part 5.1 - High risk work licences
WHS Regulations Chapter 5 Part 5.3 - Construction work

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