Specialist Appointed Person Services — LOLER | LEEA | BS2171 | ADOSH CoP 34
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Incident
Library
Real crane incidents from steel plant and rolling mill environments — analysed for root causes, contributing factors, and lessons learned. Every case study is a preventable event. Every lesson is an opportunity to protect your people.
Editorial note: Case studies are based on real incident types and causal patterns drawn from international investigation reports, regulatory publications, and industry safety bulletins. Specific identifying details have been generalised for educational purposes. These are presented solely as safety awareness resources.
Case Studies
Incident Reports
6 incidents shown
Overhead Bridge Crane Bridge Failure During Coil Transfer
Steel rolling mill — end carriage fracture under dynamic load
A 50-tonne overhead bridge crane suffered catastrophic end carriage fracture during a routine steel coil transfer operation. The bridge collapsed onto the mill floor, resulting in one fatality and two serious injuries. Post-incident investigation revealed the crane had not received a LOLER-compliant thorough examination in over 18 months, and fatigue cracking in the end carriage had gone undetected.
Jib Crane Overload — Pillar Fracture at Base
Rolling mill maintenance bay — SWL exceeded during roll change
A wall-mounted jib crane in a rolling mill maintenance bay was used to lift a replacement work roll estimated at 3.2 tonnes — exceeding the crane's 2.5-tonne SWL by 28%. The pillar fractured at the base mounting, and the crane arm fell across the maintenance bay. No personnel were directly struck, but the incident was classified as critical due to the proximity of two maintenance operatives.
Monorail Hoist Dropped Load — Hook Block Failure
Steel plant — hook latch failure releasing sling mid-travel
A monorail hoist hook block safety latch failed during travel, releasing a sling assembly carrying a 1.8-tonne steel section. The load fell approximately 4 metres onto the plant floor. No personnel were in the exclusion zone at the time of the drop, but the incident caused significant plant damage and a 3-day production shutdown.
Tandem Lift Loss of Control — Load Swing and Collision
Steel fabrication facility — unplanned load swing during two-crane lift
A tandem lift using two 20-tonne overhead bridge cranes to move a 32-tonne fabricated steel structure resulted in loss of load control when the cranes travelled at different speeds. The load swung and struck a structural column, causing significant damage. Three operatives in the vicinity sustained minor injuries from falling debris.
Crane Operator Struck by Swinging Load — Absence of Banksman
Steel service centre — load pendulum during deceleration
A crane operator was fatally struck by a swinging steel bundle during deceleration of an overhead bridge crane. The operator had descended from the cab to assist with load positioning — a practice that had become normalised on site. No banksman was present. The load swung on deceleration and struck the operator at head height.
Hoist Unit Collapse — Examination 3 Years Overdue
Warehouse facility — hoist drum shaft failure under load
A hoist unit drum shaft failed catastrophically during a routine lift in a warehouse facility. The hoist had not received a LOLER thorough examination in over three years. Post-incident metallurgical analysis identified progressive fatigue cracking in the drum shaft that would have been detectable at examination. The load — a 4-tonne pallet of materials — fell onto an empty pallet racking bay.
Use This in Your Safety Programme
Our Crane Incident Awareness training session uses real case studies like these to drive genuine safety culture change. Delivered on-site at your facility — available as a standalone session or as part of a wider training programme.
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Every incident in this library shares a common thread: the absence of a qualified Appointed Person. Our AP services provide the competent oversight that prevents these events from occurring in your facility.
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