During pipe installation works, a 360° excavator was being used to lift and position materials into an excavation. A Slinger/Signaller was responsible for directing the machine operator and controlling the lifting operation. ● The Slinger/Signaller was observed using a mobile phone while involved in the lifting activity. ● Several workers were positioned close to the excavation and lifting area. ● The operation required continuous attention, clear communication and awareness of personnel movements. ● Using a mobile phone created a distraction at a critical stage of the operation. A moment of distraction during lifting operations can lead to serious injuries or fatalities. What Went Wrong ● Distraction During Lifting – The Slinger/Signaller’s attention was divided between the mobile phone and the lifting activity. ● Reduced Situational Awareness – Phone use could prevent the signaller from identifying unexpected machine or load movements. ● Communication Risk – The operator may not receive timely instructions or warnings. ● Personnel Exposure – Workers positioned close to the lifting area could be exposed to swinging loads, crushing or entrapment. ● Unsafe Behaviour – Personal phone use is incompatible with actively controlling a lifting operation. Key Lessons Learned ● A Slinger/Signaller must remain focused on the lifting operation. ● Never use a personal mobile phone while actively directing lifting movements. ● Maintain continuous awareness of the load, machine and surrounding personnel. ● If attention is required elsewhere, stop the lifting operation first. ● A distracted signaller can compromise the safety of the entire lifting team. Safety Recommendations ● Prohibit personal mobile phone use while actively signalling or controlling lifting operations. ● Ensure clear communication between the machine operator and Slinger/Signaller. ● Stop lifting immediately if the signaller becomes distracted or cannot maintain control. ● Establish suitable exclusion zones around excavators and suspended loads.

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.

During a lifting operation, a load was being positioned into a restricted area. A member of the lifting team moved close to the suspended load to help guide it into its final position. As the crane continued moving, the available space between the load and the fixed structure became smaller. The person had unknowingly positioned themselves inside an entrapment/crush zone. One unexpected movement, load swing or misunderstood instruction could have resulted in a serious or fatal crushing injury. What Went Wrong - Personnel entered the potential crush zone. - Attention was focused on landing the load rather than escape routes. - The load was controlled from too close. - Clearance reduced as the load approached its final position. - Crane movement and personnel positioning were not adequately coordinated. The Entrapment Problem A suspended load does not need to move quickly to kill someone. Entrapment can occur between: Load and wall Load and column Load and vehicle Load and crane Load and another load Load and steelwork Even a small crane movement can generate forces that a person cannot physically resist. Key Lessons Learned Before approaching a load, ask: “If this load moves towards me, where do I go?” If there is no immediate escape route, do not stand there. Never use your body to stop, push or restrain a suspended load. Where appropriate, use suitable control methods such as tag lines rather than unnecessarily placing yourself next to the load. Safety Recommendations - Identify crush and entrapment zones during the lift briefing. - Maintain suitable exclusion zones. - Keep clear escape routes. - Use slow, controlled movements during final positioning. - Maintain clear Slinger/Signaller–operator communication. - Stop crane movement before personnel need to make close adjustments where the planned method requires it. - Never position yourself between a suspended load and a fixed object. Incident Source Safety-learning scenario based on common entrapment hazards during crane lifting and load positioning.

On 11 June 2023, a Lift Supervisor went to work on a large construction site in Ince, Ellesmere Port. He never came home. He was walking back to his work area from the welfare compound when an experienced telehandler operator reversed the machine and struck him. The operator reversed without using a banksman. The HSE investigation also found that the operator had been using his mobile phone while in control of the telehandler, despite having agreed to site rules prohibiting this behaviour. Lift Supervisor suffered fatal injuries. What Went Wrong Telehandler reversed without a banksman. Operator used a mobile phone while controlling the machine. Site rules were ignored. Pedestrian and plant movements were not safely separated at the critical moment. A qualified and experienced operator made an unsafe decision. Importantly, HSE found that a turning circle had been provided to reduce the need for reversing — and it was unobstructed at the time. (Construction Management) Key Lessons Learned Experience does not remove the need to follow basic controls. If reversing requires assistance, use the banksman. Mobile phones and moving plant are a dangerous combination. Lift Supervisors, slingers and other lifting personnel spend significant time around cranes, telehandlers and deliveries. They must never assume an operator has seen them. A reversing machine can kill within seconds. Court Outcome Telehandler driver pleaded guilty to breaching Section 3(2) of the Health and Safety at Work etc. Act 1974. On 11 August 2026, he received: - 12 weeks’ imprisonment, suspended for 12 months. - £800 fine. - £2,000 costs. HSE Principal Inspector highlighted that workplace transport remains a major cause of workplace deaths and warned operators against ignoring site rules or cutting corners. Safety Recommendations Separate pedestrians and moving plant.

During a busy lifting operation, the Lift Supervisor identified an unsafe condition and instructed the slinger/signaller to stop and change the lifting method. The instruction was clear. However, the slinger believed his method was acceptable and continued preparing the load rather than acting on the supervisor’s direction. A second instruction was required before the operation finally stopped. This created an unnecessary confrontation during a safety-critical activity. Experience is valuable, but experience does not give anyone permission to ignore the agreed lifting method or the person appointed to supervise the operation. What Went Wrong Clear instruction from the Lift Supervisor was ignored. The slinger continued with his preferred method. Personal judgement replaced the approved lifting arrangement. The supervisor’s authority was challenged during a live operation. Communication and teamwork broke down. The operation was not stopped immediately when concerns were raised. Key Lessons Learned A good lifting team needs leadership and discipline. The Lift Supervisor must be prepared to intervene. The slinger must be prepared to listen. If a supervisor says STOP, the immediate response should be to stop, not argue while the crane is moving. Questions and disagreements can be discussed once the operation is safe. Competence includes the ability to receive instructions, not simply give them. Most importantly, leadership is not shouting louder. Good leadership means recognising risk, communicating clearly and having the confidence to stop unsafe work. Safety Recommendations Establish the lifting team’s hierarchy during the pre-lift briefing. Make stop-work authority clear to everyone. Follow the approved lift plan and lifting methodology. Stop immediately when a safety concern is raised. Discuss disagreements with the load safely landed. Escalate repeated refusal to follow safety instructions to site management. Do not allow experience, personality or programme pressure to override the safe system of work.