Crane heavy-lifting — real accidents & risk assessment

Real Crane heavy-lifting accident cases (AI-cleaned) plus example risk assessment, JSA and TBM. Free, no sign-up.

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Sample for: Crane heavy-lifting

Hazards

Unit tasks

Related laws

Criminal 4

Full risk assessment

Unit task	Hazard / Cause	Current controls	Risk (F×S)	Controls	After	Legal
Lift plan & pre-lift inspection	Crane overload due to underestimated load weight — structural failure No accurate load weight calculated; rated capacity not verified Falling Objects	Visual capacity placard	8· Medium 4×2	EngineeringInstall load cell (rated capacity limiter) that prevents lift if weight exceeds 90% SWL AdministrativeMandatory lift plan with load weight certification for all critical lifts (>75% SWL)	4· Medium	제168조 변형되어 있는 훅ㆍ샤클 등의 사용금지 등 Criminal
Lift plan & pre-lift inspection	Crane wire rope failure — load drops on workers Wire rope worn beyond retirement criteria; no pre-shift inspection Struck-by / Impact	Annual crane inspection certificate	8· Medium 2×4	EngineeringReplace wire rope at 10% broken wires per lay length; use synthetic slings where appropriate AdministrativePre-shift visual inspection of all wire ropes by crane operator before use; document and record	3· Low	제146조 크레인 작업 시의 조치 Criminal
Rigging & load securing	Musculoskeletal injury during manual rigging attachment to heavy load Awkward posture and heavy sling weight when rigging in confined area Musculoskeletal Disorder	General manual-handling guidance	12· High 3×4	EngineeringProvide rigging aids (hook positioners, magnetic attachment aids) to reduce manual effort AdministrativeTwo-person rigging team for loads over 25 kg; ergonomic task briefing before rigging	3· Low	제146조 크레인 작업 시의 조치 Criminal
Rigging & load securing	Load falls during initial lift due to inadequate rigging Sling angle too acute; single sling point for off-centre load; sling damaged Falling Objects	Rigger competency training	10· High 2×5	AdministrativeInspect all slings before use; use rated slings at correct angle (>60°); load-test rig before full lift EngineeringRequire certified rigger to sign rigging plan for all critical lifts	4· Medium	제134조 방호장치의 조정 Criminal
Lift, swing & travel	Swinging load strikes worker or structure during crane travel Load pendulum effect from sudden travel or swing; no tag lines; no exclusion zone Struck-by / Impact	Operator experience	6· Medium 3×2	EngineeringInstall anti-sway system on crane; use tag lines (minimum 2) for all loads AdministrativeEstablish and enforce exclusion zone equal to load height + 1 m radius; signal person controls all movements	2· Low	Art. 171 전도 등의 방지 Criminal
Lift, swing & travel	Crane boom or wire rope contacts overhead power line Crane working near overhead lines; no minimum clearance maintained Electrical Shock	Awareness of overhead lines	10· High 2×5	EngineeringInstall proximity warning device that alerts operator when within 3 m of power lines AdministrativeContact utility company to de-energise or re-route lines; maintain 3 m minimum clearance	4· Medium	Art. 171 전도 등의 방지 Criminal
Load lowering & placement	Load swings or tips during lowering and falls on worker Load off-balance when lowered; ground worker in load zone Falling Objects	Signal person guiding load	9· High 3×3	AdministrativeAll workers out of load swing zone during lowering; ground workers use tag lines from safe distance EngineeringControlled-lowering device limits descent speed; load must be balanced before lowering begins	2· Low	제134조 방호장치의 조정 Criminal
Rigging removal & post-lift	Sling or rigging accessory falls from height when detached Rigger releases sling without securing it first; sling falls from hook Falling Objects	Verbal warning	6· Medium 3×2	AdministrativeAttach securing line to sling before releasing from load; never release above unprotected workers EngineeringUse latch-type hooks that retain rigging until manually released by rigger	2· Low	제134조 방호장치의 조정 Criminal

Legal compliance (OSH rules)

Art. 132Crane Inspection Requirements

CriminalMust-check

Art. 133Rated Capacity Limiter

CriminalMust-check

Art. 134Signal Person Requirements

CriminalMust-check

Art. 135Exclusion Zone During Lifts

CriminalMust-check

Art. 93PPE Provision

Must-check

Art. 136Lift Plan Requirements

Art. 137Wire Rope Maintenance

Grounding real accidents

Crane boom contacted a 154 kV overhead power line during a lift; operator received severe electrical burns.

⚠ Crane boom contacts energised overhead line

Load swung out of control when crane operator slewed too quickly; load struck and fatally injured a worker.

⚠ Uncontrolled load pendulum strikes worker

Wire rope parted during lift — post-incident inspection found 23% of wires broken in one lay length.

⚠ Wire rope overdue for retirement — in-service failure

Overloaded mobile crane tipped over; counterweight crushed two workers on the ground.

⚠ Crane overload and tip-over

Actual AI output. Get it for your work in seconds.

Other tasks

Forklift material unloading Scaffold assembly/dismantling at height Confined-space pipe welding Press die change

Crane heavy-lifting — real accidents & risk assessment

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