Once upon a time, a wire rope broke on an overhead crane and the block came crashing down. Thankfully no one was hurt, the wire rope was replaced and everyone got back to work. Three days later it broke again…and the block came crashing down.
What? How could this be? It was a new rope. Did anyone stop to ask “Why?” Was the rope installed properly? Maybe there is an issue with the crane? Maybe an issue with the operator? Maybe it was a bad rope? An investigation took place but they could not determine what happened. The rope was replaced and operations resumed—but this time with a surveillance camera on the crane.
We wish we could tell you that the story ended there, but it did not. Two days later the rope broke a third time, but this time it was caught on video. So what would cause a brand new wire rope to break? The “Why?” was due to the crane operator’s improper operation.
How Cranes Lift
Overhead cranes are meant to lift loads vertically. Their hoists are made to spool the rope in such a way to protect the rope from crushing itself. However the operator was using the crane to drag the load instead of lift the load. So the horizontal side pull was causing the wire rope not to spool properly. As a result the wires and strands were getting damaged and after a few days of heavy use the rope broke.
In the U.S. we have a saying, the “third times a charm” meaning the third time is usually lucky. I think in this case we can agree that it was… while it did take three failures, the company was able to determine the root of the issue and re-train the operator on proper usage. So what can we learn from this story? Don’t rely on luck. When accidents happen, it is important to stop and take the time to fully investigate the circumstances. Crane Tech can provide or assist in providing a full investigation. Another good course of action might be to conduct re-fresher training while the crane is being repaired.
Remember, Safety through Education is more than just our motto, it is our guiding principle. Teaching operators how to properly operate equipment is one of the best investments you can make in the safety of your operations. Call 800-290-0007 or email us today to find out about our Open Enrollment or On-Site Training offerings.
Want more Accident to Education articles? Check out these previous Hooked On Crane Tech posts:
Accident to Education: Small Loads Can Cause Tipping
Accident to Education: Plate Clamp Safety
*Please note the photo used above was for illustrative purposes. It was not from the crane described in the post.