Failure of a lifting cross connection can result in dropped loads, presenting a serious pinch, crush, or impact hazard to workers
What happened?
A crew was pouring a concrete floor using a shotcrete machine and 1,000 kg bulk bags of concrete. While lifting a bag, the connection between the lifting jib and the lifting cross failed, and the load was dropped. No injuries occurred.
Why did it happen?
Preliminary investigation revealed that the hoist ring on the lifting cross failed. A retaining pin was missing, and the hoist ring was heavily worn, contributing to the equipment failing. The incident is currently under investigation, and the exact cause of the failure has yet to be determined.
How to reduce the risk
Employers and workers should implement the following practices to safely manage suspended loads and prevent equipment failures or dropped-load incidents:
- Maintain consistent inspection, maintenance, and repair records for equipment.
- Establish a preventive maintenance program outlining what components to inspect, how often, and how to document results.
- Develop inspection criteria for equipment returned from site to ensure staff are trained to identify damage or wear.
- Clean equipment before inspection - cement or debris buildup can prevent proper examination and hide defects.
- Train and verify competency of all workers involved in hoisting and rigging activities.
- Require operator pre-use checks of lifting devices before each task.
- Develop and communicate emergency procedures to respond quickly and safely to equipment failures or dropped-load incidents.
For more information on preventing injuries from suspended loads, contact your local health and safety specialist.