Gold Coast, Queensland

October 2019 Gold Coast, Queensland

Project Cranes The Outcome Key Learning

Installation of tilt-up panels

100t crawler crane • No injuries but high potential incident • Extensive damage to concrete panel • Lifting clutch links must be regularly and thoroughly inspected • Consider going beyond current regulatory requirements by carrying out Non-Destructive Testing at inspections in addition to when manufactured • A back-up lifting system is critical for lifting precast concrete panels

A 100t crawler crane was lifting a 16-tonne concrete wall panel on a tilt-up construction site on the Gold Coast in Queensland, Australia when the lifting clutch link on a 5-tonne lifting clutch failed, sending the panel crashing onto the casting stack below. Thankfully no one was injured in the incident, but the concrete panel was severely damaged.

The concrete panel had four face lifting inserts with equalising sheaves each fitted between two inserts. When the lifting clutch failed, two of the lifting points became ineffective resulting in the dropped panel.

It was identified that the lifting clutch link had a crack through the cross-section.

Despite inspection and proof testing from a third-party lifting gear organisation six months prior, the crack went undetected as it was on the inside of the lifting clutch link and not clearly visible on a visual inspection.

Key learnings from this incident

While this incident fortunately did not result in any injuries, it did have the potential to cause major injury or death to nearby workers. It highlights several key areas to consider in concrete panel erection: As outlined in Section 13.2 of the Tilt-up and pre-cast concrete construction Code of Practice 2003, back up lifting systems are critical for lifting precast concrete. Be sure to check your relevant local regulations and guidelines.

Rigorous and frequent inspection and testing programs are necessary for lifting clutches. Consider going beyond the current requirements outlined in AS3850 and carry out Non-Destructive Testing (NDT) at annual inspection and testing. AS3850 currently specifies Non-Destructive Testing is required at manufacture but not during subsequent inspection and testing.

Maintain comprehensive inspection and testing records on all rigging equipment including lifting clutches.

Ensure visual inspections of lifting gear are carried out prior to any lift execution.