Question 7 of 7: Accident Case Analysis — Crane/Hoist Casting Drop

Question 7: Accident Case Analysis — Crane/Hoist Casting Drop (20 marks: 6/8/6)

Question text not reproduced: the examination questions are © Engineers and Geoscientists BC. Open the official past paper (linked at the top of this page) to read the question, then follow the worked solution below.

(i) Causes of the Accident

• Immediate cause — the hoist eyebolt (lifting) assembly failed, releasing the casting; the falling load snapped the cables, which whipped and struck the worker's head.
• Root/contributing causes (multiple-factor):
  • Equipment failure — the eyebolt/rigging was overloaded, defective, worn, wrongly rated, or improperly installed for a 3,000-lb load; possible cable/rigging weakness.
  • Inspection/maintenance — the lifting gear was not adequately inspected before use (no pre-use check of eyebolt, cables, hooks).
  • Procedure/rigging — improper rigging or load attachment; possibly no rated capacity verification or safe-load practice.
  • Work practice — the worker was positioned within reach of the load/cables (in the line of fire) rather than clear of the suspended load.
  • Training — inadequate training in safe lifting/rigging and in staying clear of suspended loads.
• The head protection performing as intended is the one positive factor that prevented a fatality—illustrating PPE as the last line of defence.

(ii) Corrective Actions

• Engineering/equipment — use correctly rated, certified lifting devices (eyebolts, slings, cables) with an adequate safety factor; replace defective components; consider secondary retention/anti-drop features.
• Inspection program — mandatory pre-use inspection and scheduled certification of all lifting gear (cranes, cables, eyebolts, hooks); remove damaged gear from service; keep records.
• Safe rigging procedures — verify load weight and gear rating; proper attachment; never exceed rated capacity.
• Keep clear of suspended loads — barricade/exclusion zone; never stand under or beside a suspended load ("line of fire"); use tag lines to guide.
• Training — for all crane/hoist operators and riggers.
• PPE — continue mandatory head protection (proved its value here).

(iii) Follow-Up

• Fully investigate and document the failure (examine the failed eyebolt/cables; root-cause analysis); report as legally required.
• Implement corrective actions; update lifting/rigging safe-work procedures and inspection schedule.
• Retrain operators and riggers; verify all lifting gear is inspected/certified through audit.
• Inspect all similar cranes/hoists in the plant for the same defect.
• Monitor for recurrence; support the injured worker's care and return to work; share lessons learned.