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Workplace incident: serious injury by crane load

In January 2026, a worker sustained serious foot injuries after it was crushed by a load weighing approximately 4.5 tonnes.

Initial inquiries indicate the load was being moved using an overhead crane with the worker assisting. As the load was being lowered into position, it struck the worker’s foot.

Investigations are continuing.

Safety issues

Overhead travelling cranes (sometimes known as bridge cranes), are used to handle heavy loads and can create the potential for serious injury or death.

Typical hazards found in managing risks associated with a bridge crane include:

  • worn or damaged mechanical components
  • background noise causing problems with communication
  • lighting
  • collision of crane with runway end stops and other cranes on the same runway
  • inappropriate or damaged lifting gear such as slings and shackles
  • collision or crushing between load and obstacles when operating crane in crowded environment.
  • unintentional crane movements or collisions from improper direction of crane movement resulting from unfamiliarity of directions on pendant and orientation of operator
  • collisions resulting from swinging loads due to rapid direction changes or accelerations.

Workers and others may be exposed to proximity hazards in the work area including but not limited to load clearance associated with nearby obstructions.

Handling and positioning heavy suspended loads using overhead cranes presents significant risks to workers, particularly where workers are required to work in proximity to the suspended load while it’s in motion.

Managing the risk

Effective risk management starts with a commitment to health and safety from those who manage the business. If an incident occurs, you'll need to show the regulator that you’ve used an effective risk management process. This responsibility is covered by your primary duty of care in the Work Health and Safety Act 2011.

Use the hierarchy of controls to help decide how to eliminate and reduce risks in your place of work. The hierarchy of controls ranks types of control methods from the highest level of protection and reliability to the lowest. It’s a step-by-step approach to eliminating or reducing risks. You must work through the hierarchy of controls when managing risks, with the aim of eliminating the hazard, which is the most effective control.

Further information about the hierarchy of controls and managing risks can be found at managing risks

Possible control measures to prevent similar incidents

The Work Health and Safety Regulation 2011 includes specific duties for a PCBU with management or control of plant, including plant that lifts or suspends loads.

Extreme care should be exercised when lifting loads in the vicinity of other persons, including other workers and members of the public.

Planning and coordinating crane operations

Planning for bridge crane operations should start as early as possible. This includes but is not limited to:

  • consultation with everyone engaged in the work within the working area of the crane prior to the work occurring
  • identifying and developing effective exclusion zones around the crane and adjoining areas to prevent people from entering the area (the size of the exclusion zone should be based on a written risk assessment).

Crane operator

Bridge crane operators must have a comprehensive knowledge of the operating capabilities of the crane and be competent to carry out the lifting operation. It is a must for crane operators to:

  • know the particular model of crane to be operated, its characteristics, functions and limitations as well as information in the crane’s operating manual
  • ensure loads are evenly balanced and well secured
  • ensure the lifting gear (slings, shackles and hooks) are not damaged, have a load rating in excess of the load to be lifted and are suitable for the purpose (e.g. soft slings on steel edges can fail)
  • hold the appropriate high-risk work licence (if applicable) for the type of crane being operated, and complete refresher training as required. A CB class high-risk work licence includes bridge and gantry cranes that are controlled from a permanent cabin or control station on the crane or remotely controlled with more than three powered operations
  • know proper inspection and maintenance procedures to be followed in accordance with the guidelines of the manufacturer
  • complete a pre-operational visual inspection and operational check of the crane’s structure and components before each work shift, including inspecting and testing.

Lifting materials

Crane-lifted loads should be slung and secured so the load (or any part of it) cannot fall. To ensure the safe lifting of loads:

  • use lifting hooks with operable safety latches
  • use tag lines to control loads
  • if the person responsible for slinging a load is required to exercise judgement in relation to the suitability and condition of lifting gear and the method of attaching the sling (including sling accessories) to the load or crane, then this person must hold a dogging licence or be training to be dogger and be supervised by a licensed dogger
  • note: there are limited circumstances where a person without a high-risk work dogging licence can safely sling a load.

Safe system of work

A safe system of work should be implemented to manage the risks associated with lifting loads in the vicinity of other persons. This could include, but is not limited to the following:

  • implementing and enforcing clearly marked exclusion zones to ensure those involved in the lifting process do not get under a suspended or partially lifted load. Workers should remain outside the crush zone while a load is being lifted and lowered.
  • maintaining sufficient clearances with other plant and structures. Also, understanding the load’s landing area, ensuring sufficient room around the load for workers to move safely and keep clear.
  • control of the load should be maintained through the use of tag lines or similar methods. Where pendant controls are being used, consider that the operator may have to move with and be reasonably close to the load.
  • a reliable method of signalling between the crane operator, dogger and any other workers assisting is essential for safe crane operation. Where radio communication is not or cannot be used, other forms of communication, such as hand signals, verbal communication or whistle signals should be used.
  • providing workers, and others with clear instructions, training and supervision on safe work procedures and processes.
  • ensuring worker training, experience and competency aligns with the requirements and complexity of the task.

You must minimise any remaining risk with suitable personal protective equipment, such as hard hats, protective footwear, eye protection, safety vests.

Administrative control measures and PPE rely on human behaviour and supervision. If used on their own, they are least effective in minimising risks.

The control measures you put in place should be reviewed regularly to ensure they are effective.

More Information

If this information has caused distress, there are services to help:

  • Lifeline – 24/7 crisis support service, including phone, texting and chat services.
  • Beyond Blue – information and support for anxiety, depression and suicide prevention for everyone in Australia.
  • Black Dog Institute – research and resources on mental health in the workplace.
  • SANE – helpline service, as well as resources on mental health.

Have you been affected by a workplace fatality, illness or serious injury?

For advice and support:

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Last updated 27 October 2026