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MOBILE PLANT OPERATIONAL STANDARD
This standard establishes minimum requirements for powered mobile plant (PMP) operations across Australian workplaces. Applies to all operations where a plant with self-propulsion is used, including earthmoving machinery, mobile cranes, elevating work platforms, concrete placement booms, telehandlers, forklifts, and drilling/piling rigs. Excludes fixed plant, tower cranes, trailers, and light/heavy vehicles (covered under separate traffic management standards).
1.0 PLANT RISK ASSESSMENT AND PROCUREMENT
Plant Risk Assessment (PRA) developed by person experienced with operation, inspection, and maintenance of plant type before PMP mobilisation.
PRA must address:
- Delivery, commissioning, operation, maintenance hazards
- Ground stability and rollover hazards (ROPS identification)
- Falling object hazards (FOPS identification)
- Operator ejection hazards
- Plant collision hazards (plant, structures, personnel)
- Access/egress hazards
- Reversing hazards
- Moving parts, rotating parts, articulated sections
- Mechanical failure, pressurised elements, hot parts, electrical contact
- Excessive noise and vibration
Operators must review and endorse PRA before operating plant (documented on PRA or electronic platform).
Purchase recommendations include:
- Health and safety specifications
- Relevant legal requirements
- Australian Standard compliance
- Local supplier preference (able to meet safety requirements)
- Plant hire agreement specifying safety requirements
2.0 PLANT REGISTRATION AND COMPLIANCE
Design Registration Requirements
| Plant Type | Registration Requirement |
| Mobile cranes >10 tonne capacity | Design registration + plant registration required |
| Work boxes suspended via cranes | Design registration required |
| Concrete placement units with booms | Design registration + plant registration required |
| Hoists with platform movement >2.4m (people) | Design registration required |
| Boom-type elevating work platforms | Design registration required |
Jurisdiction-specific: Refer Schedule 5 of Work Health and Safety Regulation (or equivalent state/territory regulation).
PMP operated on public roads must be:
- Registered
- Conditionally registered, OR
- Exempt from registration (operating within exemption conditions)
3.0 PLANT MOBILISATION AND VERIFICATION
PMP must NOT commence work until:
- Plant Risk Assessment completed
- Plant information uploaded to electronic platform (if used)
- Mobilisation checklist completed and validated
- Plant compliance sticker issued and affixed
Verification of Competence (VOC) – Internal Assessors
Internal personnel conducting VOC assessments must meet competency standard:
Minimum VOC Assessor Requirements:
- Minimum 3 years demonstrated experience operating the specific plant type being assessed
- Current high-risk work licence or equivalent qualification for plant type (where legislatively required)
- Understanding of plant-specific hazards and controls
- Ability to assess practical operation against manufacturer requirements and safe work procedures
VOC assessors verify:
- Operator holds required licence/certification (where required by legislation)
- Operator demonstrates safe pre-start inspection process
- Operator demonstrates safe operational techniques per manufacturer specifications
- Operator understands plant limitations and safety features
- Operator understands emergency procedures
Following documentation must be readily available:
- Operator/OEM manual
- Plant Risk Assessment (operator endorsed)
- Safe Work Method Statement for PMP operations
- Daily pre-start checklist (plant-specific)
- Maintenance/servicing history (current)
- Plant compliance sticker with unique ID
- Registration/certification/statutory inspection records (where applicable)
- Lifting equipment records (if crane or lift-mode earthmoving)
Plant compliance stickers re-issued minimum 12-monthly following documentation review.
ROPS (Roll-Over Protective Structures) and FOPS (Falling Object Protective Structures) required where risk of:
- Plant overturning
- Objects falling on operator
- Operator ejection from seat
Compliance:
- Certification plate/sticker on ROPS/FOPS structure
- Compliance with relevant Australian or International standard
- Verification during mobilisation process
Mandatory Operational Requirements
| Requirement | Specification |
| Mobile phone use | Prohibited while operating PMP |
| Safety equipment | Reversing alarms, amber beacons, UHF radio (earthmoving/load shifting); fitted where practicable for cranes/concrete pumps/access plant |
| Safety features | Seatbelts, guards, access steps, handholds, rails must be functional and used as intended; not disconnected/defeated |
| Riding on plant | Prohibited except in dedicated seats |
| Access to plant | Use designated steps/platforms/handrails only; no climbing where fall risk exists |
| Intended use | Operate per design, manufacturer instructions, within plant parameters/limitations |
| Operator competency | Must hold required licence and/or verified competent per legislative requirements |
Traffic management: Appropriate controls implemented where PMP operates in trafficable areas.
Communication protocols: Established between operators, traffic controllers, ground workers before work commences.
Emergency instructions: Clearly displayed on or near plant.
Ground conditions assessment required for:
- Crane/boom lifts
- Concrete pumping
- Elevated work platform use
- Piling works
| Ground Type | Maximum Pressure (tonnes/m²) |
| Hard rock | 200 |
| Shale rock and sandstone | 80 |
| Compacted gravel (up to 20% sand) | 40 |
| Asphalt | 20 |
| Compacted sand | 20 |
| Stiff clay (dry) | 20 |
| Soft clay (dry) | 10 |
| Loose sand | 10 |
| Wet clay | <10 |
Table 1: Maximum Permissible Ground Bearing Pressure
Ground assessment methods:
- Visual checks – For known setups, low weight lifts, non-complex loads, favourable locations (use table above)
- Calculated assessment – Complex lifting or any doubt: formal engineering/geotechnical assessment showing allowable ground pressure exceeds PMP/crane bearing pressure (including outriggers/pads)
6.0 PLANT MOVEMENT AND TRAFFIC CONTROLS
Project risk register and SWMS must address PMP/people interface risks considering:
- Project activity scope
- Site layout, size, terrain, access methods
- Numbers/types of vehicles, PMP, people at work areas
- Proximity to public (pedestrians/motorists)
Control Hierarchy (Apply SFAIRP in Order)
- Elimination – Complete separation (time separation, restricted access)
- Separation – Dedicated zones with safety barriers (hard barriers)
- Proximity technology – Sensing/restriction systems (zone/plant-v-plant/plant-v-worker warnings and shutdowns)
- Delineation – Barrier tape/mesh, signage, traffic cones
- Rule-based – Speed limits, exclusion zones, UHF call-ups
- Administrative – Traffic controllers, spotters
- PPE – Flashing lights, reversing beepers, high-vis clothing
Implement SFAIRP:
- Dedicated separate areas: offices, light vehicle parking, laydown, storage, workshops, refuelling, construction zones
- One-way circuits to eliminate/minimise reversing
- Worker on foot exclusion from bulk earthworks/stockpile areas
- Light vehicle exclusion/minimisation from bulk earthworks/PMP areas
- Dedicated one-way haul routes
- Proximity detection/warning systems in interaction areas
- Visual/audible plant warning systems (beacons, alarms)
- Vehicle Movement Plan (VMP) signage displaying:
- Designated parking, loading/unloading, refuelling, servicing areas
- Office/amenities areas and pedestrian accessways
- ‘No go’ zones for light vehicles/pedestrians
- Communication/call-up channel details
- Directional information
- Speed limits
- Overhead/underground service locations and controls
- Weight/width/height limits
Additional controls:
- Exclusion zone demarcation per SWMS
- Designated UHF radio channels and protocols
- Clear signage at access/egress points
- Windrows or barriers adjacent to high-risk slopes/bends
- Access/egress points, haul roads, earthworks areas with adequate dimensions, slopes, sight lines
- Seatbelts and ROPS fitted to PMP
- Minimise open trenches/excavations (including depth)
- Compaction, monitoring, exclusion from embankment edges
Safety barriers (concrete, steel, water-filled) used in preference to tape/mesh/cones SFAIRP for separating plant and people (especially high frequency, longer term, static locations).
Parking and Fundamentally Stable Configuration
Parking requirements:
- Reverse park (first movement forward)
- Safe location (designated park, level surface, away from traffic flows)
- Transmission in gear (or ‘park’ for automatic)
- Engine switched off
- Park brake applied before leaving vehicle
- Heavy vehicle/trailer: all braking mechanisms applied
- Lower all ground-engaging devices (blades, tines)
Fundamentally stable configuration required:
- When used as mobile workstation
- During loading/unloading operations
- During inspections, fault finding, washing, repairs, maintenance
Fundamentally stable: Vehicle cannot roll away when in neutral with park brake off (even though park brake, shutdown, in-gear should be applied).
Methods to achieve:
- Move to more suitable location (designated park or level surface)
- Park against bank/berm with wheels turned into bank/berm
- Park across grade with front wheels facing uphill
- Use suitable chocks downhill against wheels
- Lower ground-engaging devices
Loading/Unloading Exclusion Zone (LUEZ) Protocol
LUEZ sequence (strictly followed):
- Heavy vehicle driver: Park with parking brake on, keys removed from ignition
- Heavy vehicle driver: Delineate LUEZ with barrier tape/traffic cones
- Heavy vehicle driver: Remove load restraints, prepare vehicle
- Heavy vehicle driver: Move to safe location outside LUEZ
- Heavy vehicle driver: Provide positive visual confirmation to material handling equipment operator (permission to enter LUEZ)
- Material handling operator: Enter and control LUEZ, load/unload with no personnel or driver on foot in LUEZ
- Material handling operator: Hand back LUEZ control via positive visual confirmation, remain outside LUEZ
- Heavy vehicle driver: Apply load restraints, complete inspections
- Heavy vehicle driver: Remove LUEZ delineation and exit
Laydown Area Requirements (SFAIRP)
- Separated from high traffic/pedestrian areas
- One-way traffic flow
- Separated heavy vehicle and light vehicle areas
- Level and stable surface
- Defined light vehicle parking clear of activities
- Defined truck queuing areas clear of work/roadways
- Defined pedestrian routes around work areas
- Restricted to loading/unloading personnel only
- Material storage positioned for ease of equipment movement
- Material storage protected from traffic/plant impacts
- Worker facilities positioned to minimise crossing traffic routes
7.0 INSPECTION AND MAINTENANCE
Requirements:
- Pre-start inspection completed daily before PMP use
- Checklist specific to plant type
- Covers safety critical controls (minimum)
- Typically undertaken by operator
- Records retained with plant or on electronic platform
- Must include method for recording inspections and faults identified
- Must prompt defect isolation and repair process
| Inspection Type | Frequency | Responsibility |
| Plant mobilisation | Before first use on site | Safety/supervisor + verification person |
| Pre-start inspection | Daily before operation | Operator |
| Statutory/periodic inspections | Per manufacturer/legislative requirements | Maintenance/qualified person |
| Plant compliance review | Minimum annually | Safety/supervisor |
- PMP maintained in “fit for use” condition
- Manufacturer/statutory/periodic maintenance records uploaded to electronic platform
- Maintenance records retained for period item is owned (or per subcontractor systems)
- Modifications avoided wherever practicable
- Non-OEM parts/consumables avoided wherever practicable
Where PMP modification considered:
- Detailed risk assessment required
- Design drawings required
- Engineering certification of design required
- OEM recommendations followed
- Competent person (or engineer with appropriate qualifications) assesses modification
- Registrable plant may require re-registration post-modification
- All modification documentation kept for life of plant
8.0 QUALIFICATIONS AND COMPETENCIES
Following plant types require operator to hold current high-risk work licence (where legislatively required):
| Plant Type | Licence Class |
| Boom-type elevating work platform (EWP) | WP licence |
| Mobile crane >3 tonnes capacity | Crane licence (appropriate class) |
| Forklift | LF licence |
| Order picking forklift | LO licence |
| Reach truck | Reach truck (RT) endorsed LF |
| Non-slewing mobile crane >3 tonnes | CN licence |
| Vehicle loading crane >10 metre-tonnes capacity | CV licence |
Operators without legislatively required licence must be verified competent by:
- Person with minimum 3 years experience operating specific plant type, AND
- Person holding current qualification for plant type (where qualification exists)
Verification includes:
- Pre-start inspection demonstration
- Safe operational techniques demonstration
- Understanding of plant limitations and safety features
- Understanding of emergency procedures
All PMP operators receive:
- Site induction (including site-specific PMP hazards)
- Plant-specific training (pre-start, operational techniques, limitations)
- Emergency response training
- SWMS briefing for activities involving PMP
9.0 ROLES AND RESPONSIBILITIES
| Role | Key Responsibilities |
| Principal Contractor/Site Manager | Ensure PMP compliance with standard; approve plant mobilisation; ensure competent operators; ensure inspection/maintenance systems implemented; approve SWMS; ensure traffic management controls implemented |
| Safety Advisor/Coordinator | Coordinate PRA development; verify plant documentation during mobilisation; issue plant compliance stickers; conduct periodic compliance audits; maintain plant registers; coordinate VOC process |
| Supervisor | Verify operator competency; ensure daily pre-starts completed; ensure SWMS followed; monitor traffic controls; report defects/hazards; isolate defective plant; ensure exclusion zones maintained |
| Plant Operator | Hold required licence/competency; complete daily pre-start inspections; operate per manufacturer instructions; operate within plant limitations; follow SWMS; report defects immediately; comply with traffic management controls; maintain communication protocols |
| Maintenance Personnel | Conduct statutory/periodic inspections per schedule; maintain plant in fit-for-use condition; document all maintenance/repairs; ensure defect rectification; calibrate monitoring equipment; assess modification requirements |
Mandatory Records (Minimum Retention 7 Years)
- Plant Risk Assessments
- Plant mobilisation checklists
- Operator competency records (licences, VOC assessments)
- Daily pre-start inspection records
- Maintenance and servicing records
- Statutory inspection records (design registration, plant registration, periodic inspections)
- Plant compliance sticker issue register
- Defect reports and rectification records
- Incident investigation reports (permanent retention if notifiable)
- Training records
11.0 LEGAL REFERENCES AND STANDARDS
Commonwealth and State Legislation
- Work Health and Safety Act 2011 (Cth, NSW, QLD, SA, ACT)
- Work Health and Safety Regulations 2011/2017 (jurisdiction-specific)
- Occupational Health and Safety Act 2004 (VIC)
- Occupational Health and Safety Regulations 2017 (VIC)
- Work Health and Safety Act 2020 (WA)
- Work Health and Safety Regulations 2022 (WA)
- AS 1418 series – Cranes, hoists and winches
- AS 2550 series – Cranes, hoists and winches – Safe use
- AS 2359 series – Powered industrial trucks
- AS 1576 series – Scaffolding
- AS 2549 – Concrete pumps
- AS 2294 series – Earth-moving machinery
- AS 1170 series – Structural design actions (ground bearing pressure)
- Managing the Risk of Powered Mobile Plant (Safe Work Australia)
- How to Safely Remove Asbestos Code of Practice
- Managing Noise and Preventing Hearing Loss at Work Code of Practice
- Managing the Risk of Falls at Workplaces Code of Practice
DOWNLOAD YOUR MOBILE PLANT RESOURCES
HSE Direct provides practical mobile plant management templates aligned with WHS Regulations and Safe Work Australia guidance.
Available Resources:
- Plant Risk Assessment template (customisable for all plant types)
- Plant mobilisation checklists (earthmoving, height access, cranes, general plant)
- Daily pre-start inspection checklists (plant-specific)
- Operator competency verification (VOC) template
- Plant register and compliance tracking spreadsheet
- SWMS templates for mobile plant operations
- LUEZ protocol signage and procedure
- Traffic management plan template
- Ground bearing pressure calculator
- Plant defect register
These resources are designed for construction, civil, mining, and industrial operations across all Australian jurisdictions.
About HSE Direct: We develop practical WHS compliance solutions for high-risk industries across Australia. Our mobile plant management resources are authored by experienced safety professionals and plant specialists with direct operational and compliance experience.
Visit www.hsedirect.com.au to download your mobile plant management templates and guidance.
This standard is copyright-free under Creative Commons CC0 1.0 Universal.
You may freely use, share, adapt, and distribute this document with your team, industry peers, and the broader WHS community. All we ask is that you credit HSE Direct (www.hsedirect.com.au) when you reference, share, or adapt this standard.
HSE Direct | Workplace Health & Safety Consulting
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- Email: contact@hsedirect.com.au
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