A tower crane was moving a load behind a structure where the crane operator could no longer see either the load or landing area. The Slinger/Signaller was directing the operation by radio. Halfway through the movement, the radio transmission became intermittent. The operator heard: “Slew left slowly… keep…” Then silence. Instead of immediately stopping, the crane continued moving for several seconds because the operator assumed the slinger wanted the movement to continue. The load approached the structure before the operation was stopped. What Went Wrong - Communication was lost during a blind movement. - The operator continued based on an assumption. - No effective lost-communication procedure was followed. - Radio condition/coverage may not have been adequately checked. - The load was moving where the operator could not independently verify clearance. Key Lessons Learned During a blind lift, the radio can effectively become the operator’s eyes on the ground. If those instructions disappear, the operator should not guess what the next instruction would have been. The agreed principle should be simple: NO COMMUNICATION = NO MOVEMENT. The exception is any movement specifically required by an established emergency procedure to make the situation safe. Safety Recommendations - Test radios before starting. - Check communication from the actual lifting and landing positions. - Agree a lost-communication procedure. - Use clear crane and signaller call signs. - Stop movement when communication is lost or unclear. - Restore positive communication before restarting. - Consider suitable backup communication arrangements for critical blind lifts. Regulatory Mapping ● LOLER Reg. 8 – Lifting operations must be properly planned, supervised and safely carried out. ● PUWER Reg. 9 – Adequate information, instruction and training. ● BS 7121 principles – Effective communication and signalling throughout crane operations. Key Point Never think: “He probably meant keep going.”

During a blind tower crane lift, one Slinger/Signaller was controlling the load using commands by radio. As the load approached the landing area, a second slinger saw that it was getting close to an obstruction and started giving the operator instructions at the same time. The operator suddenly received: Slinger 1: “Slew right slowly.” Slinger 2: “Stop. come left!” For several seconds, the operator did not know whose instruction had priority. The operation was stopped before contact occurred. What Went Wrong - Two people attempted to control the same crane movement. - No clearly identified lead signaller. - Conflicting radio instructions were transmitted. - The operator was forced to decide which instruction to follow. - The communication arrangement had not been properly briefed. Key Lessons Learned For a crane movement, the operator should normally be receiving directions from one designated Slinger/Signaller at a time. If control needs to transfer between signallers during a blind lift, the handover must be positive and understood. For example: Slinger 1: “TC1, stop. Slinger 2 will now take control.” Operator: “TC1 stopped. Slinger 2 taking control confirmed.” Only then should the next movement begin. Emergency STOP instructions are different, a stop warning must never be ignored simply because it came from someone else. Safety Recommendations - Nominate the controlling Slinger/Signaller. - Agree call signs before lifting. - Use positive radio handovers. - Never give competing crane instructions. - Keep radio channels clear. - If instructions conflict. STOP. - Re-establish who has control before continuing. Regulatory Mapping ● LOLER Reg. 8 – Proper planning, supervision and safe execution. ● PUWER Reg. 9 – Adequate training and instruction. ● BS 7121 principles – Clear signalling and communication during lifting operations. Key Point Two voices should never fight for control of one crane. One operator. One movement. One clearly identified signaller.

A competent Slinger/Signaller does much more than simply attach lifting accessories to a load. During a lifting operation, the slinger may be responsible for selecting and attaching the correct lifting accessories, checking the load is secure, controlling the load, maintaining the exclusion zone and directing the crane operator using recognised signals or radio communication. When the operator cannot see the load or landing area, clear communication becomes even more important. Consider a tower crane carrying a heavy load to a blind landing position. The operator is relying entirely on the slinger’s radio instructions. Instead of clear commands, the radio becomes filled with conversation: “Yeah mate, keep coming… little bit… little bit… no, the other way… watch it… hold on… STOP!” By the time STOP is given, the crane may already have moved in the wrong direction. The load could strike the structure, trap an installer, enter another crane’s envelope or swing towards personnel. Radio communication during a lift is safety-critical communication, not casual conversation. What Went Wrong Unclear terminology was used. Instructions were too long. Unnecessary conversation occupied the radio channel. Direction was not clearly identified. The operator had to interpret what the slinger meant. No positive confirmation was used. Critical information became mixed with irrelevant conversation. Key Lessons Learned A Slinger/Signaller needs competence in four connected areas: •Sling the load correctly. •Check the load, lifting points, accessories, WLL, configuration and security before lifting. •Direct the crane correctly/Communicate correctly. •Position yourself where the load can be safely managed. Instructions should be short, clear and understood by the operator. If communication becomes unclear: STOP THE CRANE. Never guess what somebody meant. Example of Good Radio Communication A simple exchange could be: Slinger: “TC1, this is Slinger 1. Radio check.” Operator: “TC1 receiving you loud and clear.”

A 160-tonne crawler crane was positioned approximately 3 metres from ongoing excavation works. The crane had an established exclusion zone of around 20 metres. Without consultation with the lifting team, groundwork personnel removed sections of the crane's exclusion barriers to allow excavators and the piling team to enter the exclusion zone and continue their work. The Lift Supervisor raised concerns regarding: The proximity of the excavation works to the crawler crane. The potential effect of excavation and vibration on the crane platform. The removal of the crane exclusion zone. The absence of written engineering confirmation that the crane platform remained suitable. The concerns were discussed with the Health & Safety representative, who verbally stated that everything was safe but provided no engineering assessment or written confirmation. Afterwards, the concern was reportedly dismissed, and members of the other team laughed at the issue that had been raised. What Went Wrong? The crane exclusion zone was altered without agreement from the lifting team. Excavation activities were allowed close to a loaded crawler crane without documented engineering confirmation. Verbal reassurance replaced technical evidence. Ground stability assumptions were made without written verification. A legitimate safety concern was not treated professionally. Why This Matters Crawler cranes impose extremely high loads through their tracks. Nearby excavation, sheet piling and vibration can affect the ground supporting the crane. Removing an exclusion zone also increases the risk of collision between plant, people and lifting operations. Most importantly, when workers feel they may be ridiculed for raising concerns, hazards are less likely to be reported in the future. Key Lessons Never remove or reduce a crane exclusion zone without authorisation from the Appointed Person or responsible lifting management. Ground conditions should be confirmed by a competent engineer whenever excavation or sheet piling is undertaken near a crawler crane.

At a shipyard, an overhead gantry crane and a forklift were used together to rotate/handle a heavy item. A worker was crushed during the operation when movements were not coordinated. What Went Wrong Two operators were effectively acting as one lifting system, but without a single controller and without a safe system that prevented body positioning in pinch zones. Key Lessons ●Tandem handling needs one controlling mind ●Pinch points kill quietly and fast ●“Assumed awareness” is not communication Safety Recommendations One coordinator, one sequence, one stop command. Physical exclusion from crush zones. Clear comms and lock-step movements. Incident source/ Reference HSE press release on overhead crane + forklift crushing incident. press.hse.gov.uk ●LOLER Reg. 8 – One controlled system must exist during lifting/handling. ●PUWER Reg. 11 – Prevent crushing/striking during movement. ●PUWER Reg. 9 – Operators must be trained for coordinated operations. ●BS 7121-1 – Clear command and agreed signals are required. Key point wo machines = one plan. Wolf Lifting Dynamics – Safe Lifting UK | www.wolflifting.uk | Case Study 86