13d (edited) • Supervision & Control Failures
Tower Crane Lifting 7 Tonne Bags in One Lift
Incident Overview
During lifting operations on a construction site, a tower crane was used to lift 7 tonne bags simultaneously approximately 25 metres above ground level using a single 4-leg chain configuration.
The tonne bags were grouped together and lifted as one suspended load despite the bags being designed for individual lifting operations. No one checked the bag label!
The lift created an unstable and unpredictable load configuration with multiple suspended points moving independently during the operation. Workers remained active below and around the lifting area while the lift was taking place.
What Went Wrong
Multiple tonne bags lifted together without approved lifting methodology
4-leg chains used on unstable grouped loads
Load centre of gravity not properly controlled
Individual bags free to move and shift independently
Risk of bag collision and uneven loading during lift
No evidence of engineered lifting frame or spreader beam
Workers exposed below suspended load
Lift created excessive dynamic movement at height
Lift supervisor did not stop the lift operation as advised.
Key Lessons Learned
Tonne bags are generally designed for individual lifting only
Grouping multiple suspended bags creates unpredictable load behaviour
Chain angles and unequal loading can overload lifting accessories
Dynamic movement increases dramatically when loads move independently
Suspended loads above live work areas create severe risk exposure
Safety Recommendations
Lift tonne bags individually unless a designed lifting arrangement is approved.
Use engineered lifting frames or spreader beams for grouped loads.
Verify total load weight and individual load distribution.
Establish and enforce exclusion zones beneath suspended loads.
Ensure lifting methodology is clearly detailed within the lift plan.
Stop lifting operations if load stability cannot be guaranteed.
Incident Source
Real construction site observation – UK lifting operation (2026).
Tower crane observed lifting multiple tonne bags simultaneously using 4-leg chains at approximately 25 metres height.
Regulatory Mapping
● LOLER Reg. 4 – Lifting accessories and loads must remain stable and secure.
● LOLER Reg. 8 – Lifting operations must be properly planned and supervised.
● LOLER Reg. 9 – Planning must be carried out by a competent person.
● PUWER Reg. 4 – Equipment and lifting arrangements must be suitable for use.
● PUWER Reg. 11 – Risks from falling or unstable loads must be prevented.
● BS 7121-1 – Loads must be attached and controlled using safe lifting methods.
Key Point
Just because a crane can lift the weight doesn’t mean the load is safe to lift.
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Tower Crane Lifting 7 Tonne Bags in One Lift
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