13 Jul 2026
TOP CAUSES OF LIFTING EQUIPMENT FAILURE - AND HOW TO PREVENT THEM
Lifting equipment failure remains one of the most serious safety risks across construction, manufacturing, logistics, offshore operations, warehousing, and heavy industry. From damaged chain slings and failed hoists to collapsing cranes and dropped loads, lifting incidents continue to cause severe injuries, fatalities, operational downtime, and costly legal action throughout the UK.
According to the Health and Safety Executive (HSE), lifting operations involving suspended loads are responsible for a significant proportion of workplace incidents involving crushing injuries, falling objects, and structural failures.
In fact, workplace injuries involving moving or suspended objects continue to cause dozens of fatalities and tens of thousands of serious injuries across the UK every year. With over 59,000 RIDDOR-reported injuries annually and falls from height accounting for nearly 28% of all workplace deaths, lifting equipment failure remains of the most dangerous and costly risks in heavy industry.
Yet many of these incidents are entirely preventable through proper equipment selection, routine inspection, operator training, and compliance with lifting regulations.
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The reality is that lifting equipment rarely fails without warning. In most cases, failures occur because of progressive wear, overloading, corrosion, fatigue, poor maintenance, or misuse that has gone unnoticed or unresolved over time.
This guide explores the most common causes of lifting equipment failure, the warning signs businesses should never ignore. and the preventative measure required to maintain safe and compliant liftin operations.
WHY LIFTING EQUIPMENT FAILURE REMAINS A MAJOR INDUSTRY PROBLEM
Despite advances in lifting technology, lifting equipment failures remains a recurring issue across multiple industries. One of the main reasons is the increasing pressure placed on lifting operations. Equipment is often subjected to heavier workloads, more demanding environments, and longer operational cycles than ever before.
At the same time, many businesses continue operating aging lifting equipment fleets while attempting to reduce maintenance costs and minimise operational downtime. This creates a dangerous environment where damaged or deteriorating equipment remains in service longer than it should.
The HSE continues to identify the following as recurring causes of lifting-related incidents:
- Falling loads
- Equipment collapse
- Poorly planned lifting operations
- Inadequate inspection procedures
- Operator error
- Failure to maintain lifting accessories
- Use of unsuitable lifting equipment
According to industry reporting and RIDDOR data, more than 1,000 lifting-related incidents are reported annually across the UK, with many involving preventable equipment defects or procedural failures
Importantly, most lifting failures are not sudden or unpredictable events. In many cases, the warning signs were already visible through corrosion, elongation, cracking, distortion, or excessive wear before the final failure occurred.
1: OVERLOADING LIFTING EQUIPMENT
Overloading remains one of the most common causes of lifting equipment failure across all sectors.
Every lifting component - whether it is a chain sling, shackle, lever hoist, eyebolt, or wire rope assembly - is designed with a specific Working Load Limit (WLL). Exceeding this limit introduces stresses that can rapidly weaken lifting equipment and increase the likelihood of catastrophic failure.
Overloading can occur in several ways:
- Incorrect load estimation
- Dynamic loading during lifting
- Shock loading caused by sudden movement
- Uneven load distribution
- Incorrect sling angles
- Side loading of lifting accessories
Even brief overload events can permanently damage lifting equipment. Common consequences include:
- Chain elongation
- Bent hooks
- Distorted shackles
- Wire rope crushing
- Internal strand failure
- Fatigue cracking
Dynamic loading is particularly dangerous because forces generated during sudden acceleration or swinging loads can significantly exceed the equipment's rated capacity.
This is why proper lift palling is essential. Operators should always verify:
- Load weight
- Centre of gravity
- Sling angles
- Environmental conditions
- Equipment compatibility
Using properly certified and traceable lifting gear is critical. Products such as chain slings and lifting shackles should always be selected according to the intended lifting application and load requirements.
2: POOR INSPECTION & MAINTENANCE PRACTICES
A large percentage of lifting equipment failures can be traced directly to inadequate inspection procedures and poor maintenance culture.
Many businesses continue relying solely on visual pre-use checks while neglecting preventative maintenance and statutory thorough examinations.
Under Lifting Operations and Lifting Equipment Regulations 1998 (LOLER), lifting equipment must undergo regular thorough examination by a competent person. In most cases:
- Equipment used for lifting people must be examined every 6 months
- Most other lifting equipment requires examination every 12 months
- High-risk environments may require more frequent inspection intervals
However, compliance failures remain common throughout industry.
Problems frequently identified during inspections include:
- Cracked hooks
- Excessive chain wear
- Corrosion
- Missing safety catches
- Wire rope birdcaging
- Damaged sling labels
- Deformed lifting points
- Unauthorised repairs
A common issue is the failure to quarantine damaged equipment immediately after defects are identified. Continuing to use compromised lifting gear significantly increases the risk of failure under load.
Businesses should implement a layered inspection strategy that includes:
- Pre-use checks
- Routine visual inspections
- Preventative maintenance schedules
- Thorough examinations
- Load testing where required
Professional LOLER inspection services help businesses identify developing defects before they become serious safety hazards.
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The Real Cost of Non-Compliant Equipment
3: CORROSION & ENVIRONMENTAL DAMAGE
Corrosion is one of the most destructive long-term threats to lifting equipment integrity.
Industrial lifting equipment is often exposed to harsh environments involving:
- Moisture
- Saltwater
- Chemicals
- Extreme temperatures
- UV exposure
- Abrasive contaminants
These environmental conditions gradually weaken lifting components and accelerate material degradation.
Wire ropes are particularly vulnerable because corrosion can develop internally between strands where it is difficult to detect visually. Over time, corrosion reduces the effective diameter and strength of the rope.
Chain slings, shackles, eyebolts, and hooks are also susceptible to:
- Surface pitting
- Stress corrosion cracking
- Hydrogen embrittlement
- Galvanic corrosion
Offshore lifting operations face especially high corrosion risks due to continuous saltwater exposure. These offshore sector continues to treat corrosion-related dropped object incidents as a major safety priority.
Equipment should always be selected based on environmental suitability. In corrosive or marine environments, businesses should consider:
- Galvanised components
- Stainless steel lifting equipment
- Enhanced protective coatings
- Increased inspection frequency
Proper storage is equally important. Lifting accessories should never be stored wet, contaminated, or exposed to unnecessary environmental damage.
4: FATIGUE & METAL STRESS
Metal fatigue is one of the most misunderstood causes of lifting equipment failure.
Unlike overload failures, fatigue damage develops gradually through repeated stress cycles over time. Even when loads remain below the rated capacity, repeated loading and unloading eventually creates microscopic cracks within material structure.
These cracks continues expanding until sudden points include:
- Hook necks
- Welded joints
- Chain links
- Load-bearing pins
- Wire rope terminations
- Crane structural components
One of the dangers of fatigue is that damage is often invisible during routine visual inspections. By the time visible cracking appears, the component may already be approaching failure.
Repeated sub-maximal loading can be just as dangerous as a single overload event.
Industries involving high-cycle lifting operations - including logistics, ports, manufacturing, and offshore lifting - face particularly elevated fatigue risks.
Businesses should monitor:
- Usage cycles
- Operational history
- Inspection records
- Repair frequency
- Previous overload events
Replacing aging equipment proactively is often significantly cheaper than dealing with the consequences of a major lifting failure.
5: IMPROPER STORAGE & HANDLING
Improper storage practices significantly reduce the operational lifespan of lifting equipment.
Even high-quality lifting gear can deteriorate rapidly if handled incorrectly between uses.
Common storage-related issues include:
- Chains stored in damp conditions
- Wire ropes crushed during transport
- Webbing slings dragged across abrasive surfaces
- Equipment contaminated with oils or chemicals
- Slings exposed to direct UV radiation
- Lifting accessories stacked improperly
Webbing slings are especially vulnerable to cuts and abrasion. Small cuts along the sling edge can dramatically reduce lifting capacity.
Wire ropes can also suffer irreversible internal damage from:
- Kinking
- Crushing
- Improper coiling
- Excessive bending
Businesses should implement controlled storage procedures that include:
- Dry storage areas
- Proper hanging systems
- Equipment segregation
- Protective covers
- Contamination control
Correct storage is not simply about extending equipment life - it directly impacts lifting safety and legal compliance.
6: OPERATOR ERROR & POOR TRAINING
Even properly maintained lifting equipment can fail if operators use it incorrectly.
Human error remains a leading contributing factor in lifting incidents across the UK.
Common operational mistakes include:
- Incorrect rigging techniques
- Side loading hooks
- Exceeding sling angle limits
- Poor communication during lifts
- Unstable crane setup
- Inadequate lift planning
- Failure to conduct pre-use checks
Improper sling angles are particularly dangerous because they dramatically increase tension within lifting legs. Many operators underestimate how quickly load forces rise as sling angles decrease.
Poorly controlled loads can also create:
- Swing hazards
- Shock loading
- Collision risks
- Structural instability
The HSE repeatedly identifies inadequate planning and insufficient competence as recurring causes of lifting accidents.
Every lifting operation should involve:
- Competent operators
- Properly trained slingers/signallers
- Documented lift plans
- Clear communication systems
- Environmental risk assessment
Training should never be treated as a one-time exercise. Refresher training is essential, particularly when introducing new equipment or lifting procedures.
7: USING THE WRONG EQUIPMENT FOR THE APPLICATION
Selecting unsuitable lifting equipment is a major cause of avoidable failures,
Not all lifting accessories are designed for the same operational conditions. Using the wrong equipment can compromise both lifting performance and structural integrity.
Examples include:
- Using standard webbing slings around sharp edges
- Selecting undersized shackles
- Using lifting chains in corrosive chemical environments
- Exceeding temperature limits
- Mixing incompatible lifting components
LOLER requires lifting equipment to be suitable for its intended purpose.
This means businesses must consider:
- Load type
- Environmental conditions
- Load geometry
- Temperature exposure
- Chemical exposure
- Dynamic loading factors
Incorrect equipment selection often results in:
- Premature wear
- Structural deformation
- Reduced load stability
- Unexpected failure
Using properly certified lifting accessories from reputable suppliers helps reduce the risk of compatibility and performance issues.
Businesses should ensure all lifting gear includes:
- Traceable certification
- WLL markings
- Manufacturer documentation
- Inspection records
8: WEAR, ABRASION, & MECHANICAL DAMAGE
All lifting equipment experiences gradual wear during normal operation.
However, excessive wear or mechanical damage significantly increases the risk of failure.
Common forms of lifting equipment wear include:
- Chain link thinning
- Hook throat opening
- Surface gouging
- Bearing wear
- Wire rope abrasion
- Flattened chain sections
- Distorted lifting eyes
Mechanical damage often develops through repeated contact with:
- Sharp edges
- Abrasive surfaces
- Impact loading
- Poor handling practices
Wire rope assemblies are particularly vulnerable to abrasion and internal strand breakage. Birdcaging, broken wires, and diameter reduction are all serious indicators that replacement may be necessary.
Hook deformation is another critical warning sign. A widened hook throat often indicates previous overloading and should never be ignored.
Routine inspection procedures should include:
- Dimensional measurement
- Crack detection
- Wear monitoring
- Lubrication assessment
- Functional testing
Any equipment showing excessive wear should be removed from service immediately.
9: COUNTERFEIT OR LOW-QUALITY LIFTING EQUIPMENT
The growth of low-quality imported lifting equipment has introduced serious safety concerns across the lifting industry.
Counterfeit or poorly manufactured lifting accessories may appear compliant while lacking:
- Proper material certification
- Heat treatment verification
- Traceability
- Independent testing
- Accurate WLL ratings
In some cases, counterfeit lifting gear carries fake CE or UKCA markings despite failing to meet required safety standards.
Low-quality equipment may suffer from:
- Inconsistent metallurgy
- Inferior weld quality
- Reduced fatigue resistance
- Poor dimensional tolerances
This significantly increases the likelihood of premature failure.
Businesses should only purchase lifting equipment from reputable suppliers capable of providing:
- Certification
- Traceability
- Manufacturer documentation
- Inspection support
- Technical guidance
Safety-critical lifting operations should never rely on undocumented or unverified lifting gear.
10: FAILURE TO FOLLOW LOLER & PUWER REQUIREMENTS
Non-compliance with lifting regulations remains a major contributor to workplace incidents.
Under LOLER & PUWER, employers have a legal responsibility to ensure lifting equipment remains safe throughout its operational life.
This includes:
- Proper equipment selection
- Thorough examination
- Maintenance
- Operator competence
- Safe lifting procedures
- Record keeping
Where dangerous defects are identified during inspection, they must be reported to the appropriate enforcing authority.
failure to comply with lifting regulations can result in:
- Improvement notices
- Prohibition notices
- Unlimited fines
- Criminal prosecution
- Imprisonment in severe cases
More importantly, regulatory failures place workers at serious risk.
Compliance should not be viewed purely as a legal obligation. Effective compliance systems reduce accidents, minimise downtime, improve operational reliability, and protect long-term business reputation.
WARNING SIGNS OF IMPENDING LIFTING EQUIPMENT FAILURE
Many lifting failures are preceded by visible warning signs.
Operators and inspectors should immediately remove equipment from service if they identify:
- Chain elongation
- Cracked welds
- Bent hooks
- Missing safety catches
- Corrosion pitting
- Wire rope birdcaging
- Frayed webbing slings
- Seized bearings
- Unusual noises during operation
- Distorted shackles
- Missing identification tags
- Excessive wear marks
Ignoring these indicators significantly increases the risk of catastrophic failure during lifting operations.
Businesses should also encourage proactive reporting cultures where operators feel confident raising safety concerns without pressure to continue using questionable equipment.
HOW PROPER INSPECTION PREVENTS LIFTING EQUIPMENT FAILURE
Effective inspections systems are the single most important defence against lifting equipment failure.
A comprehensive inspection programme should include:
PRE-USE CHECKS
Quick operator inspections before each lift.
ROUTINE INSPECTIONS
Scheduled visual and functional assessments.
PREVENTATIVE MAINTENANCE
Lubrication, adjustment, and component replacement.
THOROUGH EXAMINATIONS
Formal statutory inspection carried out by a competent person.
Modern inspection systems increasingly use:
- Digital inspection records
- RFID asset tracking
- Defect categorisation software
- Predictive maintenance systems
These technologies improve traceability and help businesses identify developing trends before failures occur.
Most importantly, inspections must lead to action. Identifying defects is only effective if damaged equipment is removed from service promptly and replaced appropriately.
CONCLUSION
Lifting equipment failures rarely occur without warning.
In most cases, the root causes involve preventable issues such as overloading, corrosion, fatigue, poor maintenance, operator error, or inadequate inspection procedures.
Businesses that prioritise:
- preventative maintenance
- proper training
- compliant inspections
- equipment traceability
- safe lifting procedures
dramatically reduce the likelihood of serious incidents.
Compliance with LOLER and PUWER should not simply be viewed as a regulatory requirement. It is a critical part of protecting workers, maintaining operational reliability, and reducing long-term business risk.
By investing in high-quality lifting equipment, professional inspection services, and ongoing operator competence, organisations can create safer lifting operations while extending the lifespan of their lifting assets.
For businesses looking to improve lifting safety and compliance, LES - Lifting Equipment Store provides certified lifting equipment, inspection services, and technical guidance across a wide range of industrial lifting applications.
IMPROVE YOUR LIFTING COMPLIANCE STRATEGY
If you’re reviewing:
- lifting inspections
- supplier standards
- equipment lifecycle planning
- compliance procedures
- operational risk reduction
download the full executive report:
