In lifting and rigging operations, equipment failure can be just as deadly and disruptive as operator error. At CERTEX, we believe learning from these events is essential to building safer operations across the industry.
This article examines a rigging hardware failure and offers practical steps to prevent similar tragedies.
Incident Case Study: Tower Crane Section Collapse – Fort Lauderdale, Florida (April 4, 2024)
On April 4, 2024, during the erection of a tower crane at a high-rise residential site in downtown Fort Lauderdale, a catastrophic failure occurred. A platform dislodged from the climbing frame of the crane, sending a worker more than 30 stories down and causing a major crane section to fall onto a busy bridge below1.
Investigators determined that corroded and cracked pins, bolts, and improperly applied end-connections in the crane’s climbing mechanism were the root cause2. The Occupational Safety and Health Administration (OSHA) cited both the erector and the crane rental company for serious violations relating to inspection and maintenance3. Proposed penalties totaled over $61,0001.
What Went Wrong
- The failure was hardware-related rather than simple operator error. Damaged pins and bolts, as well as poorly installed end-connections, gave way during crane assembly2.
- A support cable failure triggered the platform displacement and subsequent fall4.
- Pre-use inspections were inadequate: the corroded and cracked hardware went undetected3.
- Because the event occurred during the crane-erection phase, one of the most critical rigging operations, the consequences were severe — a fatal fall, a dropped crane section, and public exposure1.
Likely Root Causes
- Hardware integrity and maintenance – Corroded and cracked components indicate inadequate inspection and replacement2.
- Inspection and qualified personnel – Shift inspections were either skipped or insufficiently thorough3.
- Planning and risk assessment – Hardware condition was not properly addressed in the erection plan4.
- Worksite and environmental factors – Operating in an urban area increased the potential for collateral damage1.
- Safety culture and lifecycle management – Hardware lifecycle tracking and replacement criteria were likely weak2.
Consequences
- One worker killed1.
- Two bystanders injured5.
- Significant property damage and risk to the public1.
- OSHA citations and penalties for multiple firms3.
- Long-term reputational impact for the companies involved4.
Key Takeaways & Practical Tips from CERTEX
1. Rigging Hardware — Selection, Maintenance & Lifecycle
- Specify and maintain all pins, bolts, shackles, thimbles, wire ropes, and fittings for actual service conditions.
- Track hardware use, inspections, and replacements through a documented lifecycle program.
- Inspect for corrosion, cracks, or deformation before every critical lift.
- Replace components on a time-based or condition-based schedule rather than waiting for visible failure.
2. Inspection & Qualified Personnel
- Require competent personnel to inspect every critical component at the start of each shift.
- For high-risk lifts (tower-crane erection, bridge work, offshore lifts), involve a qualified person for a formal pre-use inspection.
- Use checklists that cover torque verification, corrosion, cracks, and correct installation of thimbles, clamps, and pins.
3. Inspection & Qualified Personnel
- Include hardware condition as a dedicated item in the lift plan.
- Define exclusion zones for areas beneath crane sections and platforms.
- Apply redundancy where practical—secondary pins or backup supports during erection
- Conduct a coordinated pre-lift meeting with riggers, engineers, and safety staff.
4. Environmental & Site-Specific Considerations
- Account for corrosion due to salt air, humidity, or pollutants.
- Evaluate the potential impact radius in urban environments.
- Keep all non-essential personnel clear of suspended or supported sections during erection.
5. Safety Culture, Training & Communication
- Reinforce a mindset that hardware condition is safety-critical.
- Train crews to recognize corrosion, cracks, and improper end-connections.
- Encourage workers to stop operations if any hardware seems questionable.
- Maintain complete inspection and torque records to prove compliance and accountability.
Positioning CERTEX as Your Rigging & Hardware Safety Partner
At CERTEX, we don’t just supply rigging gear — we partner with you to ensure it’s safe, traceable, and properly maintained.
- Certified, traceable hardware meeting or exceeding ASME / OSHA standards.
- Training and consultation on rigging inspection and lifecycle programs.
- Support for engineered lift plans, risk reviews, and hardware condition audits.
By studying failures like the Fort Lauderdale incident, we strengthen our shared commitment to a safety-first culture — because every hardware failure is preventable.
Final Thoughts
The Fort Lauderdale crane collapse is a stark reminder that a single defective pin or bolt can bring down an entire system. Rigging hardware integrity is not a minor detail — it is the foundation of lifting safety.
At CERTEX, we build safety into every product and every plan. If your team needs help with inspection programs, rigging lifecycle tracking, or lift planning, we’re ready to partner with you. Together, let’s raise the standard for rigging safety.
Contact your local CERTEX representative to learn more about our rigging products, testing services, and safety training.
References
- U.S. Department of Labor, Occupational Safety & Health Administration. “Inspection No. 1739734 – Phoenix Rigging & Erecting LLC; Maxim Crane Works LP (Fort Lauderdale, FL)”. Citation and Notification of Penalty. Issuance Date Oct 2, 2024. DOL+1
- “Crane companies fined $61K after fatal crane collapse in Florida.” Equipment World. Nov 7, 2024. Equipment World
- “Investigation finds high-rise contractors failed to protect rigger from fatal 30-story fall at Fort Lauderdale high-rise.” ISHN. ISHN
- “OSHA cites contractors over fatal crane collapse at Fort Lauderdale high-rise.” Occupational Health & Safety Online. Oct 31, 2024. Occupational Health & Safety
- “Florida construction crane segment collapses onto downtown bridge killing 1 worker, hospitalizing 2 others” April 4, 2024 Fox News
Images: Fort Lauderdale Fire Rescue Facebook.
