3D Model — Orbit & Inspect
Anatomy of a Safety Cage
Steel Floor Plate
Non-slip steel base plate provides a stable standing surface. Must be free of holes, corrosion, and excessive wear. Supports all personnel and equipment weight.
Guard Rails
1100mm high top rails around the full perimeter. Primary fall prevention barrier. Must be rigid with no bends or loose connections.
Mid-Rails
Horizontal rails at approximately half the guard rail height. Prevents personnel from slipping between the top rail and floor plate.
Toe Boards
Minimum 100mm high kick plates at floor level around the perimeter. Prevents tools and materials from sliding off the platform.
Self-Closing Gate
Access gate with self-closing latch mechanism. Must close automatically when released. Gate must open inward only.
Lifting Lugs
4-point crane attachment. Engineered lifting points at each corner. Must be inspected for cracks and wear before every use.
Harness Anchor Points
Rated anchor points inside the cage for attaching personnel harness lanyards. Must be load-rated and certified. Located above shoulder height.
Purpose — Last Resort Only
A safety cage (also called a man cage or work platform) allows personnel to be lifted by crane to work at height.
Last Resort Requirement
- A crane-lifted personnel cage is a LAST RESORT — only permitted when no other access method is practicable
- You must demonstrate that EWPs (boom lifts, scissor lifts), scaffolding, and other means of access are not feasible before using a safety cage
- A specific risk assessment and Safe Work Method Statement (SWMS) must be prepared for every use
Hierarchy of Access (Try First)
Only use a safety cage when ALL other methods are impracticable.
Critical Operating Rules
These rules are non-negotiable and apply every time a safety cage is used:
Mandatory Requirements
- Harness required: ALL personnel in the cage MUST wear a full-body harness with lanyard attached to the cage’s rated anchor point
- Crane must be static: the crane must NOT travel, slew, or luff while personnel are in the cage (except for the lift itself)
- Dedicated dogger/rigger: a competent dogger or rigger must supervise the entire operation from the ground
- Specific SWMS required: a Safe Work Method Statement must be prepared specifically for this lift
- Crane operator must remain at controls: the operator must never leave the crane cabin while personnel are elevated
- No sudden movements: all crane movements must be slow and controlled — no free-fall lowering
WLL & Capacity
| Specification | Typical Value |
|---|---|
| Working Load Limit (WLL) | 500 kg |
| Includes | Personnel + tools + materials combined |
| Typical max persons | 2 – 4 persons |
| Guard rail height | 1,100 mm |
| Toe board height | ≥ 100 mm |
Always check the cage rating plate. WLL varies between manufacturers. The total weight of all personnel, tools, and materials must not exceed the rated WLL.
Weight Calculation
- Assume 100 kg per person (including harness, tools on person, PPE)
- Weigh all tools and materials separately
- Total must be under WLL at all times
Pre-Use Checks
A trial lift without personnel must be performed first. Raise the empty cage to working height, hold for stability check, then lower before personnel enter.
Pre-Use Inspection Checklist
- All structural welds inspected — no cracks
- Guard rails, mid-rails, and toe boards secure
- Gate latch self-closes positively
- Floor plate intact, non-slip surface present
- Harness anchor points rated and undamaged
- Lifting lugs inspected — no wear or elongation
- Rating plate legible and current
- Trial lift completed successfully (no tilt, no sway)
- Communication method confirmed (radio/hand signals)
- SWMS reviewed and signed by all personnel
Inspection & Rejection Criteria
Inspect the safety cage before every use. A defective personnel cage is an immediate danger to life.
Reject Immediately If
- Cracked welds: ANY visible crack in structural welds — zero tolerance
- Bent rails: guard rails or mid-rails deformed or loose
- Damaged floor: holes, corrosion, or deformation in the floor plate
- Gate latch failure: gate does not self-close or latch does not engage
- Damaged anchor points: harness attachment points bent, cracked, or missing
- Missing/damaged toe boards: tools could fall on workers below
- Missing rating plate: no identification = no use
- Failed trial lift: cage tilts, rotates, or sways excessively
Standards & Legislation
| Reference | Requirement |
|---|---|
| AS 1418.17 | Design and construction of platforms for lifting persons by cranes |
| NSW WHS Reg 2017 Cl. 214 | Specific requirements for crane-lifted work platforms |
| AS 2550 | Cranes, hoists and winches — Safe use (general crane operations) |
| AS/NZS 1891 | Industrial fall-arrest systems and devices (harness requirements) |
The principal contractor and crane operator share responsibility for compliance. The dogger must verify all requirements are met before personnel enter the cage.
Remember
All four conditions must be satisfied before any personnel lift proceeds.