Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

MEM11023A Mapping and Delivery Guide
Operate a bridge and gantry crane

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MEM11023A - Operate a bridge and gantry crane
Description This unit of competency applies to the operation of bridge and gantry cranes that are operated from a permanent cabin/control station on the crane.
Employability Skills This unit contains employability skills
Learning Outcomes and Application This unit applies to operation of a bridge and gantry crane in a manufacturing related environment, such as a factory, raw material or finished goods store. It covers safe and efficient operation of the crane and applies where the operator has responsibility to plan the work, transfer loads as well as the conduct of routine checks and shutting down and securing of the crane.This unit does not cover the bridge and gantry crane types that are controlled from a location remote to a permanent cabin/control station on the crane and that have three or less powered operations, that is hoist/raise and lower in one operation. It also does not cover the slinging or rigging of loads.While this unit applies to work covered by licensing requirements, it also includes other manufacturing related skills, such as integrating crane operations with production, jobbing, maintenance or warehouse operations.This unit is not recognised by regulators for licensing requirements. In order to satisfy licensing requirements, the imported unit TLILIC3003A Licence to operate a bridge and gantry crane will be required.Band AUnit Weight 4
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Not applicable.
Competency Field
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Plan work
  • Load transfer authorisation is obtained, including lift time and load destination
  • Potential hazards for load lift and transfer are identified
  • Hazard control measures are identified consistent with appropriate standards to ensure the safety of personnel and equipment
  • Weight (mass) of the load is estimated in consultation with associated personnel
  • Appropriate paths for the movement of loads in the work area are determined
  • Crane capacity is checked as appropriate to the load
  • Appropriate communication methods are identified with associated personnel
       
Element: Conduct routine checks
  • Appropriate hazard prevention/control measures are applied to the work area according to procedures
  • Crane is accessed in a safe manner
  • Crane is visually checked for any damage or defects
  • All signage and labels are visible and legible according to the appropriate standard
  • Routine pre-operational crane checks are carried out according to procedures
  • All controls are located and identified
  • Crane service logbook is checked for compliance
  • Crane is started according to procedures and checked for any abnormalities
  • Crane safety devices are tested according to procedures
  • Post-start operational checks are carried out according to procedures
  • All communication equipment is checked for serviceability
  • All damage and defects are reported and recorded according to procedures, and appropriate action is taken
       
Element: Transfer loads
  • Hoist block is positioned over load following directions from associated personnel
  • Test lift is carried out according to procedures
  • Loads are transferred along planned path
  • All crane movements are according to procedures and the appropriate standard
  • Communication signals are interpreted correctly according to procedures and the appropriate standard
  • Crane is operated according to procedures
  • Load movements are monitored constantly ensuring safety to personnel and load, and structural stability
  • Unplanned and/or unsafe situations are responded to in line with procedures
       
Element: Shut down and secure crane
  • Crane is parked according to procedures
  • Crane and equipment are stowed and secured according to procedures and the appropriate standard
  • All relevant motion locks and brakes are applied, where applicable
  • Crane is shut down according to procedures
  • Routine post-operational crane checks are carried out according to procedures
  • Hazard prevention/control measures are removed, where applicable
  • All damage and defects are reported and recorded according to procedures, and appropriate action is taken
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

Overview of assessment

A person who demonstrates competency in this unit must be able to operate a bridge and gantry crane to industry and enterprise standards, manufacturer specifications, and in accordance with safety regulations and procedures.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

A person who demonstrates competency in this unit must be able to provide evidence of the ability to:

comply with OHS licensing legislation

communicate and work safely with others in the work area

apply risk assessment and management procedures (particular awareness of the risks associated with overhead powerlines/electrical cables, access to cabin, other personnel and equipment in the work area, including vehicles and clear access whilst travelling)

conduct pre- and post-operational checks of the bridge and gantry crane

operate a bridge and gantry crane, including all functions to their maximum capacity in the lifting and moving of loads to the maximum rated capacity, in conjunction with other associated personnel

apply appropriate mathematical procedures for estimation of loads.

Context of and specific resources for assessment

Assessment must be undertaken either in the workplace or in a realistically simulated workplace setting.

Assessors must ensure that the assessment in the workplace is organised to ensure that all the required equipment and materials and a suitable working area is made available to suit the assessment and the workplace.

Assessment must occur under standard and authorised work practices, safety requirements and environmental constraints.

Assessment is to comply with relevant appropriate standard requirements.

Applicants must have access to:

personal protective equipment for the purpose of the Performance Assessment

appropriate bridge and gantry crane and associated equipment in safe condition

suitable loads as specified by the endorsed Assessment Instrument

communication equipment (e.g. two-way radios and whistles)

other associated personnel to sling and direct the loads.

Method of assessment

The use of ‘simulators’ in the assessment of this unit of competency is not acceptable.

Assessment may be in conjunction with the assessment of other units of competency.

Assessment methods must confirm consistency and accuracy of performance together with application of underpinning knowledge.

Assessment must confirm a reasonable inference that competency is not only able to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Guidance information for assessment

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Required knowledge includes:

appropriate mathematical procedures for estimation of loads

bridge and gantry crane characteristics

federal, state or territory occupational health and safety (OHS) legislation, standards and codes of practice relevant to the full range of processes for the crane class

emergency procedures, including escape routes

the hierarchy of hazard identification and control

organisational and workplace standards, requirements, policies and procedures for conducting operations for the crane class

typical hazards in manufacturing related environments, including:

process areas that must be avoided, ceased or special procedures adopted before load transfers occur, including welding, machining, melting and casting

transfers across areas frequented by personnel, including workstations and walkways

hazardous loads, including hot or liquid metals, chemicals, heavy and non-standard shaped loads

procedures for the recording, reporting and maintenance of workplace records and information

typical routine problems encountered in the operation of the crane and equipment and adjustments required for correction

Required skills include:

accurately recording and maintaining information relating to bridge and gantry crane operations

using communication techniques in the workplace, including hand signals, whistles and two-way radios

using interpersonal and communication skills at a level sufficient to communicate with other site personnel

operating a bridge and gantry crane, including all functions to their maximum for the lifting and moving of loads to the maximum rated capacity, in conjunction with other associated personnel

applying risk assessment and hazard control strategies, including hierarchy of control, as applied to the safe operation of the crane (particular awareness of the risks associated with the workplace, including location of utilities, such as overhead powerlines, other electrical cables, water and compressed air lines, access to cabin, location of equipment, fixtures and workstations, vehicles and clear access whilst travelling)

planning load transfer paths for safety and efficiency in a manufacturing related environment

using and interpreting crane manufacturer specifications and data, including maximum load information, to ensure the crane is not overloaded

identifying problems and equipment faults and demonstrating appropriate response procedures

reading and comprehending manufacturer instructions, procedures and safety signs

Hazards

Hazards may include, but are not limited to:

ground stability (e.g. ground condition or slopes for load placement)

overhead hazards (e.g. powerlines and service pipes)

insufficient lighting

traffic (e.g. pedestrians, vehicles and plant)

environmental conditions (e.g. dust, wind, lightning and storms)

other specific hazards (e.g. dangerous materials)

Hazard control measures

Hazard control measures refer to the systematic process of eliminating or reducing the risk to personnel and property through the application of controls.

It includes the application of the hierarchy of control, the six-step preference of control measures to manage and control risk:

elimination

substitution

isolation

engineering control measures

using safe work practices

personal protective equipment

Appropriate standards

Appropriate standards may include, but are not limited to:

codes of practice

legislation

Australian standards

crane manufacturer specifications

industry and workplace standards, where applicable

Appropriate paths

Appropriate paths are paths that:

ensure clearances of fixed machinery, equipment, fixtures and work in progress

minimise transfers across workstations and walkways

minimise disruption to work unrelated to the load transfer

minimise transfer time and distance subject to safety and disruption assessments

Associated personnel

Associated personnel may include, but are not limited to:

riggers

doggers

supervisory and expert personnel to advise on any special features of the load or transfer

Crane

Crane may include:

bridge crane, a bridge beam mounted at each end to an end carriage, capable of travelling along elevated runways and having one or more hoisting mechanisms arranged to traverse across the bridge

gantry crane, a bridge beam, supported at each end by legs mounted on end carriages, capable of travelling on supported surfaces or deck levels, whether fixed or not and which has a crab with one or more hoisting units arranged to travel across the bridge

Bridge and gantry:

excluded are cranes of the type that are controlled from a location remote to a permanent cabin/control station on the crane and that have three or less powered operations, that is hoist raise and lower is one operation

Communication methods

Communication methods may include, but are not limited to:

verbal and non-verbal language

written instructions

signage

hand signals

listening

questioning to confirm understanding

appropriate worksite protocol

Signage and labels

Signage and labels may include, but are not limited to:

crane data plates/labels

load charts

crane decals

control labels

Procedures

Procedures may include, but are not limited to:

manufacturer guidelines (instructions, specifications or checklists)

industry operating procedures

workplace procedures (work instructions, operating procedures and checklists)

Controls

Controls may include, but are not limited to:

long travel levers

cross travel levers

hoisting and lowering levers

rotating hook levers, where applicable

Service logbook

Service logbbook may include, but is not limited to:

any logbook

service book

history record system where the service and maintenance history is kept

Safety devices

Safety devices may include, but are not limited to:

horns/sirens

audible and visual motion devices

operator restraint devices, where applicable

lights

Communication equipment

Communication equipment may include, but is not limited to:

two-way radios

whistles

bells

buzzers

Hazard prevention/control measures

Hazard prevention/control measures may include, but are not limited to:

safety tags on electrical switches/isolators

insulated powerlines

safety observer used inside exclusion zone

disconnected power

traffic barricades and controls

pedestrian controls

movement of obstructions

personal protective equipment

adequate illumination

Test lift

Test lift means the load is lifted just clear of the lifting plane to allow for checks to be safely made in consultation with associated personnel to ensure that:

near capacity loads do not overload the crane

loads of unusual shape or weight distribution are correctly slung

load measuring equipment can be used to verify the calculated weight of the load

all crane equipment is functioning properly

adjustments to the slinging can be made in a safe manner

Relevant crane movements

Relevant crane movements may include, but are not limited to:

hoisting (raise and lower)

traversing (moving hoisting mechanisms along bridge)

travelling (at minimum speed, gentle acceleration and braking, to minimise load swing)

Communication signals

Communication signals may include, but are not limited to:

stop - hand

stop - whistle

hoist up - hand

hoist up - whistle

hoist down - hand

hoist down - whistle

traverse - hand

travel - hand

creep - hand

Unplanned and/or unsafe situations

Unplanned and/or unsafe situations may include, but are not limited to:

failure/loss of control (e.g. brakes and steering)

failure of equipment (e.g. hydraulic system)

environmental conditions (e.g. wind, lightning and storms)

Shutdown

Shutdown may include, but is not limited to:

retracting hoist rope and hook block

travelling crane to park position

removing key from control panel, where applicable

locking and securing cabin, where applicable

isolating power to crane

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Load transfer authorisation is obtained, including lift time and load destination 
Potential hazards for load lift and transfer are identified 
Hazard control measures are identified consistent with appropriate standards to ensure the safety of personnel and equipment 
Weight (mass) of the load is estimated in consultation with associated personnel 
Appropriate paths for the movement of loads in the work area are determined 
Crane capacity is checked as appropriate to the load 
Appropriate communication methods are identified with associated personnel 
Appropriate hazard prevention/control measures are applied to the work area according to procedures 
Crane is accessed in a safe manner 
Crane is visually checked for any damage or defects 
All signage and labels are visible and legible according to the appropriate standard 
Routine pre-operational crane checks are carried out according to procedures 
All controls are located and identified 
Crane service logbook is checked for compliance 
Crane is started according to procedures and checked for any abnormalities 
Crane safety devices are tested according to procedures 
Post-start operational checks are carried out according to procedures 
All communication equipment is checked for serviceability 
All damage and defects are reported and recorded according to procedures, and appropriate action is taken 
Hoist block is positioned over load following directions from associated personnel 
Test lift is carried out according to procedures 
Loads are transferred along planned path 
All crane movements are according to procedures and the appropriate standard 
Communication signals are interpreted correctly according to procedures and the appropriate standard 
Crane is operated according to procedures 
Load movements are monitored constantly ensuring safety to personnel and load, and structural stability 
Unplanned and/or unsafe situations are responded to in line with procedures 
Crane is parked according to procedures 
Crane and equipment are stowed and secured according to procedures and the appropriate standard 
All relevant motion locks and brakes are applied, where applicable 
Crane is shut down according to procedures 
Routine post-operational crane checks are carried out according to procedures 
Hazard prevention/control measures are removed, where applicable 
All damage and defects are reported and recorded according to procedures, and appropriate action is taken 

Forms

Assessment Cover Sheet

MEM11023A - Operate a bridge and gantry crane
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

MEM11023A - Operate a bridge and gantry crane

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: