Training Requirements for Gantry Crane Operators in New Zealand

The operation of gantry cranes comes with significant risks if not performed correctly. To ensure workplace safety and compliance with New Zealand regulations, proper training is essential for all gantry crane operators.

Regulatory Framework

In New Zealand, the operation of gantry cranes is governed by the Health and Safety at Work Act 2015 which sits above the Approved Code of Practice for Cranes. These regulations establish the responsibilities of both employers and employees regarding the safe operation of cranes, and providing gantry crane training.

Because the HSWA2015 sit above the ACOP, it means that you can choose to follow the ACOP, or achieve the same result in an equal or better way.

According to the Regulations, the controller of a crane (typically the owner or the person with management or control of the crane) must ensure that the crane is operated safely, within its design limits, and maintained in a safe condition. This responsibility includes ensuring that operators are adequately trained and competent.

Minimum Training Requirements

The Approved Code of Practice for Cranes, developed by the Ministry of Business, Innovation and Employment (MBIE), outlines the specific training requirements for gantry crane operators in New Zealand. Table 4.1 of the code states that operators of different types of gantry cranes must hold specific Unit Standards as a minimum qualification.

For pendant or remote-controlled overhead travelling crane operation, operators must hold Unit Standard 3800. For cab-controlled overhead travelling crane operation, operators must hold Unit Standard 3790.

It is worth noting that since the development of the Approved Code of Practice in 2009, there have been updates to the Unit Standard training requirements. According to the Crane Association of New Zealand, it is now a prerequisite of NZQA Unit Standard 3800 V6 that NZQA Unit Standard 30072 is achieved first. Unit Standard 30072 covers demonstrating and applying knowledge of slinging regular loads safely.

However, because the HSWA2015 sits above the ACOP (i.e. the HSWA is legislation versus the ACOP being simply a non-binding guide), a PCBU can choose an equal or better way to train and demonstrate competence other than a unit standard.

Why would you avoid doing unit standards for gantry crane operation?

Unit standards are rigid qualifications where the trainee is assessed according to the ‘performance criteria’ stated in the unit standard. This is inflexible. Assessors are not permitted to ‘over-assess’. If your business has specific requirements, a unit standard qualification may not meet the requirements that you must (by law) abide by according to the HSWA (those requirements are to ensure that trainees are trained and competent on plant and machinery for the exact purpose it is used for).

If your trainees already have the unit standard, they don’t need to do the unit standard training again; a refresher course will suffice (see below).

You may not have a person available to you who can train your operators in the appropriate unit standards – that person (or course) may provide equal or better training that is not a unit standard.

Ultimately, the PCBU can choose to train its crane operators in a way that is justifiably equal or better than a unit standard.

Training Pathways

The Crane Association of New Zealand recommends that all operators of gantry cranes undertake New Zealand Certificate qualifications training. This includes both technical and theoretical information competency assessment, as well as familiarisation training with practical demonstrations conducted under supervision.

For those who already have relevant experience in the industry but have not yet undertaken formal qualification, there is an alternative pathway. Employees who can demonstrate prior knowledge and experience in slinging and rigging loads, either through employer attestation or recorded experience in a logbook, may be able to proceed directly to Unit Standard 3800 without completing Unit Standard 30072.

Training Content

Training for gantry crane operators typically covers several key areas:

Pre-operational safety checks are a critical component, teaching operators how to identify potential issues before they become serious problems. This includes inspection of structural components, rails and wheels, hoisting mechanisms, electrical components, and control systems.

Understanding crane controls is another essential area, covering bridge travel, trolley travel, hoisting functions, emergency stop procedures, and proper shut-down protocols. Operators must also learn to interpret load charts and understand crane capacity calculations, including maximum capacity, lift height, and working load limits.

Safe operational techniques form a significant part of the training, emphasising smooth movements, load control, and the importance of maintaining clear visibility. Trainees learn how to manage various conditions, including weather effects, proximity to power lines, and the proper use of safety devices and features.

Load handling is covered extensively, focusing on positioning the hook directly over the load’s centre of gravity, performing trial lifts, and using techniques to control load swing or rotation. Training also addresses specialised lifting situations and emergency scenarios.

Refresher Training

Regular refresher training is important to ensure licensed crane operators maintain the competencies gained during their initial training and stay updated with any changes in equipment or safety procedures. The Approved Code of Practice states that “refresher training should be conducted as often as necessary to ensure the crane crew continues to work safely.”

This is typically vague by these types of documents. We would recommend refresher training at least every three years, which matches that suggested by the forklift ACOP for the forklift operator’s certificate, but you may need to provide other training at more frequent intervals if you notice poor operational practice, or there’s an incident.

The Crane Association of New Zealand recommends periodic refresher courses to keep skills sharp and knowledge current. This continuous professional development helps to maintain safety standards and reduce the risk of accidents.

Practical Assessment

Beyond theoretical knowledge, practical assessment is a crucial component of gantry crane operator training. Operators must demonstrate their ability to perform tasks safely and competently under various conditions. This hands-on evaluation ensures that operators can apply their knowledge in real-world situations.

Practical assessments typically include pre-operation inspections, crane movements, load handling, and emergency response procedures. Assessors look for smooth control operation, proper communication, adherence to safety protocols, and effective load management.

Documentation and Record Keeping

Employers are required to maintain records of operator training and competency assessments. These records should include details of the training provided, the date of completion, and the specific type of crane for which the operator has been trained. This documentation is important for demonstrating compliance with health and safety regulations and may be requested during workplace inspections.

Conclusion

Proper training for gantry crane operators is not just a regulatory requirement in New Zealand; it is a fundamental aspect of workplace safety. By ensuring that operators hold the appropriate qualifications and receive ongoing training, employers can significantly reduce the risk of accidents and create a safer working environment.

The combination of theoretical knowledge and practical skills development, along with regular refresher training, equips operators to handle gantry cranes safely and efficiently. This comprehensive approach to training aligns with New Zealand’s commitment to maintaining high standards of workplace health and safety across all industries.

Check out our gantry crane certificate to see if it matches your requirements for training.