Crane rope detachment triggers safety alert for Queensland mines

By Staff Writer on August 7, 2025
Safety, Safety Training, Incident Reporting, Emergency Response, Efficiency, Equipment Maintenance, Risk, Risk Assessment, Risk Mitigation
Australia, Queensland

Resources Safety & Health Queensland (RSHQ) has issued a formal safety alert following a serious incident involving the unexpected detachment of a gantry crane rope at a mineral mine site, underscoring concerns around inadequate maintenance and inspection practices.

The incident occurred on 19 June when a worker was lowering a gantry crane hook to attach a wear plate. As the hook block neared the ground, the rope detached from the drum, causing both the rope and the heavy hook block to crash to the ground. Fortunately, no injuries were reported, but the potential for harm was significant.

An investigation by RSHQ's Mineral Mines and Quarries Inspectorate revealed critical failures in crane maintenance and safety systems. Most notably, the crane’s hook height limit switch was damaged and non-functional. Without this critical safeguard, the hook was able to descend beyond its intended lower limit, unwinding all rope from the drum.

With the load relying solely on the rope’s fasteners to the drum—an arrangement not designed to bear the full load—the fasteners ultimately failed, releasing the rope and hook.

“This incident was entirely preventable,” said Chief Inspector Hermann Fasching. “What we saw was a breakdown in basic maintenance and inspection protocols. When systems like limit switches are left inoperative, the consequences can be severe.”

Figure 1 - Hook block on the ground following the incident. Figure 2 - Fully unwound rope drum and rope fasteners. Figure 3 - Gantry crane in situ

Safety Recommendations

RSHQ has called on all mining operators to immediately review their crane safety systems. Key recommendations include:

  • Implementing a structured maintenance, inspection, and testing program under the supervision of a suitably qualified and competent person.

  • Conducting pre-operational checks to confirm cranes are safe and serviceable.

  • Ensuring that only trained and competent individuals operate gantry cranes, with clear understanding of operating limits and safety procedures.

  • Identifying potential drop zones during crane operations and enforcing exclusion zones to protect workers.

Operators are also reminded that maintenance and inspection records must be retained for the duration the crane is in use, as required by the Mining and Quarrying Safety and Health Regulation 2017.

The investigation is ongoing, and RSHQ has indicated that additional findings may be published in due course.

This alert (No. 457 V1) has been issued to raise awareness across Queensland’s mineral mines and quarries sector and reinforce the need for rigorous plant safety practices.

Further Information:

Issued by:
Resources Safety & Health Queensland
Authorised by Hermann Fasching – Chief Inspector, Mineral Mines & Quarries

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