During lifting operations involving an LR 1160 crawler crane, long formwork shutters were scheduled to be lifted in sustained winds of approximately 11 m/s or 25 mph. ● The crane operator raised concerns about the wind conditions and stated that he was not comfortable proceeding. ● The Lift Supervisor agreed with the operator and instructed the Lifting Coordinator to stop the operation. ● The coordinator dismissed the supervisor’s concerns and approached the operator directly, encouraging him to proceed because the Project Manager wanted the lift completed. ● During the first lift, the shutter began swinging and rotating violently, creating a serious risk of striking the crane cabin. ● The operator lowered the load to the ground in an attempt to prevent a collision. ● Afterwards, the coordinator blamed the Lift Supervisor for failing to control the operation, despite having overridden his stop instruction. What Went Wrong ● Stop Instruction Ignored – The Lift Supervisor’s decision was overridden without resolving the safety concerns. ● Management Pressure – Completing the lift was prioritised over the objections raised by the lifting team. ● Operator’s Concerns Dismissed – The operator had already identified that the conditions were unsuitable. ● Loss of Load Control – The large shutter became unstable in the wind. ● Breakdown in Supervision – The coordinator intervened directly instead of escalating the concern to the Appointed Person. ● Blame Culture – Responsibility was shifted onto the Lift Supervisor after the operation went wrong. Key Lessons Learned ● A Lift Supervisor must have the authority to stop an unsafe lifting operation. ● A coordinator or manager must not override a safety stop without a competent reassessment and safe authorisation to restart. ● Crane operating wind limits do not automatically establish safe limits for large, wind-sensitive shutters. ● The crane operator has the right to refuse a lift they consider unsafe. ● A supervisor cannot be expected to control a lifting operation when their stop instruction has been disregarded.

A mobile crane was scheduled to arrive on a busy construction site to carry out lifting operations. The lift plan had been prepared, the crane selected and the lifting accessories confirmed. However, the delivery and access arrangements had not been properly coordinated. When the crane arrived, the access route was partially blocked by parked vehicles and stored materials. There was insufficient space to manoeuvre, and the delivery trailers carrying counterweights and equipment had nowhere suitable to park. The crane was ready for work, but the site was not ready for the crane. What Went Wrong ● Site access had not been properly assessed. ● No suitable route had been confirmed for the crane and delivery trailers. ● Vehicle turning and manoeuvring space was insufficient. ● Counterweight delivery and unloading areas were not designated. ● Traffic management arrangements were unclear. ● Pedestrian routes conflicted with vehicle movements. ● Ground conditions along the access route had not been adequately assessed. ● Poor coordination between the AP, Site Manager and logistics team created unnecessary pressure. The AP’s Role in Crane Transportation The Appointed Person should ensure that the crane’s arrival, access, positioning and associated deliveries are properly considered within the lifting arrangements. This includes: ● Access Route – Confirm road widths, gradients, turning space, overhead restrictions and underground hazards. ● Ground Conditions – Check that access roads, temporary surfaces and hardstandings are suitable for the crane and transport vehicles. ● Crane Dimensions – Consider vehicle length, width, height, axle loads and any transport restrictions. ● Delivery Sequence – Coordinate the arrival of the crane, counterweights, mats, ballast and supporting equipment. ● Parking and Unloading – Identify suitable waiting, parking, assembly and unloading areas. ● Traffic Management – Coordinate with the Site Manager and logistics team to establish vehicle routes, pedestrian segregation and traffic marshal arrangements.

During a machinery relocation operation, workers used a forklift to lift a 4.5-tonne machine so that skates could be positioned underneath it. The lifting arrangement was improvised, and the machine had already slipped from the forklift forks on two previous occasions. During another attempt, a worker positioned themselves underneath the suspended machine to secure a wheel. The machine slipped again, striking the worker and causing life-changing injuries. What Went Wrong The lifting operation was not properly planned. An unsuitable lifting arrangement was used. The machine had no dedicated lifting points. The load's stability and centre of gravity were not adequately assessed. Previous warning incidents were ignored. A worker entered the danger zone beneath the suspended load. The lifting method was not changed despite repeated failures. Key Lessons Learned Never position yourself in the line of fire. A suspended load can fall, rotate, slide or move unexpectedly. If a load slips once, the lifting operation must be stopped and reassessed. A near miss is a warning, not permission to try again. Safety Recommendations Ensure every lifting operation is properly planned. Use suitable lifting equipment and approved lifting arrangements. Confirm load weight, centre of gravity and stability. Establish effective exclusion zones. Never allow workers underneath an inadequately supported suspended load. Stop and investigate unexpected load movements. Use engineered methods to position skates or supports without exposing workers to crushing hazards. Ensure competent supervision throughout the operation. Incident Source Real UK lifting incident investigated by the HSE. The incident occurred in October 2023, and the prosecution outcome was published in January 2026. The company was fined £433,333, plus a victim surcharge, following breaches of LOLER Regulation 8. Regulatory Mapping ● LOLER Reg. 8 – Lifting operations must be properly planned, appropriately supervised and carried out safely.

A crane was unloading a bundle of reinforcement mesh directly from a lorry positioned on a roadway. The photograph raises several serious concerns. There is no obvious segregated loading/unloading zone, a car is immediately alongside the operation, and a worker is positioned on the edge of the lorry bed while the load is suspended (ready to fall). There is also no clearly identifiable designated Slinger/Signaller visible controlling the lifting operation. In UK practice, this combination would require careful lifting, logistics, traffic and work-at-height controls. HSE guidance says loading/unloading should generally take place away from passing traffic, pedestrians and people not involved in the operation. What Went Wrong? The photograph suggests several potential failures: - No obvious segregated loading/unloading area. - Road traffic appears extremely close to the lifting operation. - No clearly identifiable Slinger/Signaller controlling the crane. - A worker is positioned at the edge of the lorry bed. - No visible collective fall protection around the working position. - Suspended reinforcement mesh is close to personnel. - No obvious exclusion/drop zone around the load. - The lifting operation and road traffic appear to be occupying the same space. HSE states that signallers directing cranes should be trained and competent and should work from a protected position. The Lorry Bed Is a Work-at-Height Risk One of the strongest lessons from this photograph isn’t actually the crane. Look at the worker. They appear to be sitting or slipping towards the edge of the vehicle while the load is being lifted. If workers must access a lorry bed, the risk of falling must be controlled. HSE recommends eliminating the need to climb onto vehicles where possible and, where access remains necessary, considering suitable access, walkways, guardrails or other appropriate safeguards depending on the operation. So the answer isn’t automatically “every lorry must have handrails.”

A load of scaffold tubes was prepared for lifting from one side of a building, travelling up, across the structure and down to another area. The load was slung and sent by the Slinger/Signaller. However, one small scaffold component with a double fitting/coupler attached was loose and unsecured within the load. The video taken afterwards demonstrated how easily the loose component could simply be pulled out by hand. That means it potentially could also have worked free while the load was travelling. HSE guidance specifically says measures should be taken to prevent the load, or part of it, disintegrating while being lifted, and that loads should be securely bound where necessary to prevent items slipping or falling. What Went Wrong The main problem happened before the crane moved. The final load check was inadequate. The Slinger/Signaller should have confirmed that: - All scaffold components were contained and secured. - Nothing could slide longitudinally from the bundle. - No loose fittings or couplers were present. - The lifting arrangement properly restrained the complete load. - The load remained secure when tension was applied. Instead, a small loose item travelled with the load. “It’s Only a Small Piece” This is exactly what makes this type of incident dangerous. The crane doesn’t need to drop the complete load to kill somebody. A scaffold fitting or short steel component falling from height can become a serious falling-object hazard. And because this load travelled across the building, the potential drop zone could extend far beyond the original lifting point. HSE identifies falling loads as one of the principal hazards associated with crane operations and requires practical measures to prevent people being struck. The Slinger’s Final Check Before giving the operator permission to hoist: LOOK. TOUCH. CHECK. TENSION. CHECK AGAIN. LIFT Don’t only inspect the slings. Inspect the load itself. Where appropriate and safe, physically check potentially loose components rather than assuming everything within the bundle is secure.