On the 22 April 2010, a rigger had a lucky escape as the crane he was working on became unbalanced, subsequently throwing him off the crane. He was left hanging over the side of the crane below the counterweights some 40 metres up in the air.

His knowledge and skill to safely and securely connect his harness to the crane saved him from any serious injury or death.

During the erection of a Potain Luffing tower crane, Model 415 H24, which was brand new and the first of its kind in Victoria, the counterweights of the crane shifted in an uncontrolled movement, believed to be caused by overloading the temporary rigging components, due to the assembly and installation of the components being performed outside the sequence required and recommended by the manufacturer to maintain the stability of the crane during the erection sequence. 

In plain English, there were too many counterweights put in before the luffing winch rope was connected to the jib.

When the counterweights shifted, a rigger was thrown off the crane. Luckily, he had enough knowledge and skill to safely and correctly secure himself to the crane, via his safety harness, which was connected to the counterweight cradle.  He was left hanging over the side of the crane below the counterweights some 40 metres up in the air.  When he went over, the mobile crane operator, who was part of the erection crew, heard a large “BANG”, and looked up to see the rigger swinging in the breeze.

The driver quickly slewed around and the rigger managed to get his foot into the lifting chains hanging off the mobile crane jib, and he was safely lifted back onto the tower crane with no serious injuries.  His harness was the type that ‘cradled’ him in a seating type position, rather than the more common ‘hanging’ type position which would normally result in serious injury to a workers’ groin area in such circumstances.

This should be a warning to all riggers and other workers involved in the setting up and erecting of tower cranes that :

1. Any new model or type of crane being erected, especially for the first time, the company must provide authorised and correct sequences of erection, for the specific type and model of crane in the form of an approved and agreed Safe Work Method Statement (SWMS), and must ensure all workers are fully and comprehensively trained in and understand the SWMS.
2. The person, who is assigned to be in charge and supervise both the erection and the rigging crew, must be fully conversant with and trained in the erection procedures of that particular make and model crane.
3. The importance of all riggers and others being safely and securely harnessed, in the correct type of harness when working at heights, to an approved and agreed fixing point during the erection procedures. 
4. A fully comprehensive and detailed rescue plan must be approved and able to be immediately implemented when using a harness and whenever erecting a tower crane.
5. All those requiring the use of a harness must have undergone specific and approved training in the correct use and the correct selection of harnesses before their use.

A prohibition notice of the erection of this particular tower crane was issued by WorkSafe Victoria, on the basis of providing an approved and agreed (by all the parties) safe system of work to erect the crane, in full and total compliance with the requirements and recommendations of the manufacturer. The prohibiton notice has since been lifted due to compliance by company.