The Hidden Risk in Telco Tower Lifts Most Crews Miss – And How We Planned Around It

1. Fall-Arrest Loads Must Be Engineered into the Lift Plan—Not Just the Structure

Most tower designs comply with AS/NZS 1891.3, which defines fall-arrest loads (~20.3kN for 4 persons).
But if you lift a tower pre-rigged with fall-arrest hardware, that load rating must be verified during lift planning—especially if the tower is entered while suspended or immediately post-lift.
Lesson: Treat the fall-arrest system as a live structural load, not a passive feature.

2. Lift Radius Dictates Safety Margins—Not Just Load Charts

A common mistake is to treat the crane’s lift capacity as fixed.
In reality, even a slight increase in boom length or radius (e.g., from 8m to 9.5m) can dramatically reduce capacity and safety margin—especially for dual lifts or long towers.
Lesson: Always simulate worst-case radius drift due to rigging swing, wind sway, or operator offset.

3. Ground Pressure Checks Are Critical When the Tower is Tall and the Access is Tight

Telco tower sites often involve confined rear access or soft ground.
Even a correctly rated crane can cause failure if outrigger loads exceed ground-bearing capacity.
Lesson: Use lift planning software or geotech input to confirm outrigger load zones—especially near trenches or underground services.

4. Wind Is the Silent Saboteur of Tall, Light Structures

TECO towers are tall and slender, making them susceptible to wind drift, especially when lifted fully assembled.
Australian Standards require lifts to stop if wind exceeds certain thresholds (typically 7–10 m/s for non-enclosed loads).
Lesson: Incorporate wind monitoring, define stop triggers, and consider temporary bracing/taglines during lift.

5. Australian Standards Define the Baseline—But Your Risk Appetite Defines the Real Plan

Compliance with AS/NZS 1418 (Cranes), AS/NZS 1891 (Fall-Arrest), and AS 2550 ensures legal coverage.
But real safety comes from planning for site-specific risks: unknown underground services, fatigued crew, poor visibility, conflicting subcontractors, etc.
Lesson: Use the standards as a floor, not a ceiling. Your planning process should go further.

6. Communication Protocols Save Lives When Lifting Vertical Structures

When visibility is obstructed (e.g., rear of building, nighttime work), even experienced crews can miscommunicate.
Having clear stop signals, dual-channel radios, and pre-lift briefings for every crew member is essential.
Lesson: Assume miscommunication will happen—and design around it with repeatable SOPs.

When it comes to erecting a TECO tower, especially on constrained or live sites, there is no room for improvisation. Every meter of elevation brings not just height, but risk. At Midland’s latest installation, our team executed the lift of a prefabricated TECO tower using a mobile crane under tight spatial and environmental conditions.

The lift involved:

Erecting a TECO tower designed to accommodate a 4-person fall-arrest system.
Utilizing a single mobile crane, strategically placed to ensure optimal reach and minimal ground impact.
Fall-arrest equipment installed in accordance with AS/NZS 1891.3 and manufacturer specifications .

Challenges Faced

Confined Access
The rear access via Lloyd Street allowed limited setup area for the mobile crane. Every outrigger placement had to be millimetre-perfect to avoid underground services and unstable terrain.
Tower Stability During Lift
The tower’s height and surface area made it susceptible to wind sway. The team conducted wind speed monitoring and used taglines to stabilize the lift during positioning.
Safety at Height
With workers expected to access the tower during final alignment and bolting, the structure’s integrated fall-arrest anchor points needed to comply with Australian standards and be operational immediately upon erection.

Risk Mitigation Through Planning

Lift study modeling simulated crane setup, boom angle, load radius, and clearance to overhead hazards.
Engineering review confirmed that the crane’s ground pressure and setup were compliant with site limits.
Communication protocols were established between riggers, crane operator, and spotters with predefined stop signals.
AS/NZS compliance was ensured across rigging hardware, personnel protection systems, and lifting sequences.

Conclusion

What could be a risky vertical installation became a smooth and safe lift thanks to detailed planning and execution. In today’s high-stakes construction environment, risk isn’t eliminated on the day—it’s designed out weeks before the crane even arrives.

If you’re planning a complex lift like this, make safety and certainty your first load—get a tailored lift study that aligns with Australian standards and site constraints.