What Causes Crane Accidents in Texas?
The Bureau of Labor Statistics' research into crane accidents found that error causes 90% of injuries. Obeying manufacturer specifications could prevent dozens of deaths a year, as 80% of accidents are caused by exceeding the crane's operational capacity. These errors aren't limited to operation; inadequate training and insufficient supervision also contribute to crane accidents. Often, operators may not receive ongoing training to keep up with equipment upgrades or changes in safety regulations. Pressure to meet deadlines can also lead to rushed decisions that compromise safety.
- Contact with Object or Equipment — 61%
- Falls — 20%
- Transportation Incidents — 10%
- Contact with Electrical Currents — 8%
Some of the most common causes of crane accidents include the following:
Electrocution
Crane booms, cables, or other parts can come into contact with a live power line while under operation.
Accidents During Crane Assembly
Crane assembly and disassembly must be done according to the manufacturer's specifications. Before operation, tests must be performed to gauge the stability of the crane. Failure to do this can cause accidents and can often be traced to a lack of proper communication among the workers involved in the procedure or human error at any point in the procedure. Crane assembly and disassembly related accidents account for about 12% of all crane accidents.
Crane Boom Collapse Accidents
Extending the crane boom beyond manufacturer's specifications can affect the crane's capacity to carry loads and lead to tremendous pressure on mechanical, hydraulic, and structural components. It can collapse, injuring operators and workers standing below. Crane boom buckling or collapse-related accidents make up about 8% of crane accidents.
Crane Tip-Over
Crane tipping occurs when there is overloading beyond the crane's capacity, or when ground conditions are unstable or uneven, causing the crane to tip over or collapse.
Inadequate Crane Operator Training
Insufficient training is both a primary and secondary cause. The operator is required to recognize when the crane has reached its maximum loading point and whether conditions on the ground are ideal.
Crane Load Accidents
Workers who are within the swing radius of an operating crane can be struck by loads causing injuries. Employers are required to barricade the area and train workers about the hazards involved in entering the area.
Fall Accidents
Wind conditions or an unstable platform can lead to a fall accident, particularly for operators of tower cranes who must climb extensive ladder systems to reach the crane operator cab. Employers are required to provide proper safety belts and harnesses and make arrangements for adequate guardrails and secured steps at the site.
- When the maximum weight is exceeded
- When a crane is improperly assembled
- When a crane has contact with overhead power lines
- When a crane is infrequently or erroneously inspected
Crane accidents need to be brought to court to address those at fault. By seeking compensation, crane accident victims can reclaim past medical expenses, provide for future medical treatment, and receive punitive damages for mental anguish or trauma. They can also help ensure that their company never allows the accident to occur again.
Addressing the root causes of crane accidents requires a mix of strict enforcement of safety protocols and continual education for crane operators and workers. Implementing technology such as real-time monitoring systems can alert crews to potential overloads or mechanical issues, thereby preventing accidents before they occur.
Common Injuries Suffered in Texas Crane Accidents
Crane accidents can lead to a wide range of catastrophic injuries, drastically affecting the victim's quality of life. Victims often face extended rehabilitation periods, possibly enduring permanent physical limitations, which can prevent them from returning to their former occupation and imposing financial setbacks due to high medical costs.
The following are potential crane accident injuries:
Crane injuries generally occur when an object strikes a worker on the crane. Those types of injuries account for nearly two-thirds of all crane injuries. Just 10% of crane injuries are suffered by the crane operator.
How Is a Crane Designed?
Understanding how a crane works reveals why crane malfunctions are so costly. Each part of the crane is dependent on the others—meaning the failure of one part can result in the catastrophic failure of the whole. This intricate design requires every component to meet exacting standards and function harmoniously with others.
- The Lever: The lever is what allows the crane to lift a heavy object without tipping over. This horizontal beam pivots around what is called a "fulcrum," or the point where one end of the lever transfers power to the other—essentially the center point of a see-saw. The heavy load goes on the shorter end, while the longer end applies force in the opposite direction. This design uses the principle of mechanical advantage. As long as the load's weight does not exceed the applied force or the other way around, the crane stays stable.
- The Pulley: The pulley is an axle that the cable, wire, or belt moves around. These cables are wrapped around a fixed part of the crane, while also wrapping around the block attached to the load. The winding machine then pulls the free end (not attached to the crane or object being lifted), and the principle of mechanical advantage is used to ensure the force of the load does not exceed the force of the crane.
- The Hydraulic Cylinder: The hydraulic cylinder is what powers the lift of the load. This mechanical component uses pressurized hydraulic fluid to generate force to push or pull the boom and jib, which then allows the crane to lift and move loads. One could consider the hydraulic cylinder as the “muscle” that makes a crane work. Depending on the type of crane, it may use a single-acting, double-acting, or telescopic hydraulic cylinder.
Beyond the basic components, modern cranes also integrate advanced technology, such as load sensors and computerized control systems, designed to enhance safety and precision. These innovations allow operators to manage loads more efficiently and are intended to reduce the risk of accidents caused by error or equipment overload.
Regular maintenance of all key crane components and proper training are vital to operate these complex machines safely. Ensuring that all safety mechanisms, such as emergency brakes (which are meant to keep a load from falling to the floor) and anti-collision systems, are in working order can prevent most potential crane accidents. Engaging in routine checks and proper operational practices protect both the operators and those working nearby.
Common Types of Cranes
Overhead Cranes
Overhead cranes are frequently used in factories and warehouses. They run along elevated beams attached to the ceiling, with a hook-and-line mechanism that moves horizontally. Because they can move products safely above the factory floor, they are particularly useful for large-scale manufacturing, such as steel production.
Truck-Mounted Cranes
Truck-mounted cranes are highly mobile, incorporating a crane unit on a commercial truck chassis. They typically offer lifting capacities up to around 1,300 short tons, although most models handle far less. Thanks to their road-legal design, truck-mounted cranes can travel to and from job sites quickly.
Crawler Cranes
Commonly referred to as “crawlers,” crawler cranes use track-based movement (similar to tank treads) rather than wheels. Their wide tracks allow better weight distribution, making them highly stable on soft or uneven ground. This stability can come at the cost of slower on-road travel, but it pays off when the crane must operate on tricky terrain.
Floating Cranes
Floating cranes, sometimes called “ship cranes” or “barge cranes,” are mounted on vessels designed for marine environments. They are widely used for offshore construction projects—such as bridge building over water and platform installation—and can handle heavy loads where land-based cranes are impractical.
Aerial Cranes
Aerial cranes, often helicopter-based, are employed in remote or hard-to-access locations, such as mountain rescue or remote construction sites. While they have lower lifting capacities than many land-based cranes, they offer the advantage of hovering over terrain where no safe landing zone exists.
All-Terrain Cranes
All-terrain cranes blend the off-road capability of a rough-terrain crane with the roadworthiness of a truck-mounted crane. Equipped with multiple steering axles and all-wheel drive, all-terrain cranes can traverse paved highways as well as challenging, uneven jobsites, making them a versatile option for certain projects.
Bulk-Handling Cranes
Bulk-handling cranes come with specialized grabbings or clamshell buckets to move loose materials like coal, grain, or fertilizers. They are common in ports or cargo terminals, where large volumes of goods need to be transferred quickly.
Carry Deck Cranes
Small but powerful, carry deck cranes have a 360-degree rotating boom mounted on a compact, four-wheel base. They are designed for pick-and-carry tasks in confined industrial sites, to lift and transport materials over short distances.
Deck Cranes
Mounted directly on a ship’s deck, deck cranes load and unload cargo at ports where shore-based equipment might be limited. Because they operate at sea, deck cranes must meet stringent stability and safety requirements.
Fixed Cranes
As the name implies, fixed cranes remain in one place—often anchored to the ground or a permanent foundation. Tower cranes and port gantry cranes are prime examples of fixed cranes. Although they are immobile, a fixed crane's sturdy construction allows for substantial lifting capacity and height.
Gantry Cranes
Gantry cranes feature a bridge-like structure supported by vertical legs. They commonly span large spaces in shipyards or rail yards, allowing the crane trolley to move along the bridge. Gantry cranes are particularly useful for lifting and moving massive loads in an open area.
Hammerhead Cranes
Hammerhead cranes are a type of fixed-jib crane, recognizable by the horizontal, hammer-like jib that extends on both sides of the supporting tower. They often operate in heavy industrial or shipyard settings, where they can rotate to shift loads without significantly changing boom angle.
Jib Cranes
Jib cranes include a rotating arm (jib) that pivots around a fixed pillar or wall attachment. They are generally used for smaller lifting tasks where rotating loads in a limited area is essential—often found in workshops or on factory floors.
Level Luffing Cranes
Level luffing cranes can move their hook horizontally—“luffing” the jib up or down—while maintaining a consistent horizontal level of the load. This precise movement is vital in shipbuilding and port operations to position bulky cargo.
Loader Cranes
Loader cranes (also called knuckle-boom cranes) are hydraulic arms attached to trailers or trucks. Loader cranes are versatile and fold in on themselves when not in use, saving space. These types of cranes are commonly used for light to moderate tasks, such as delivering building materials to a construction site.
Pick-and-Carry Cranes
Pick-and-carry cranes resemble mobile cranes but are designed to transport a load over short distances without the need for outriggers. This makes them ideal for moving materials around a site, but maintaining stability can be difficult.
Railroad Cranes
Railroad cranes are mounted on a rail car or have flanged wheels that run on train tracks. They are essential for railway maintenance, such as clearing derailments, laying tracks, or moving equipment along the rail corridor.
Self-Erecting Cranes
These are compact tower cranes that can unfold or assemble themselves on-site without the need for extensive external equipment. They are popular for smaller construction projects, particularly in urban areas where space is limited.
Sidelift Cranes (Sideloaders)
Sidelift cranes are used primarily for handling shipping containers. They attach to the side of a truck or trailer, lifting containers on and off the vehicle for transport. This lets operators work in places lacking traditional loading infrastructure.
Stacker Cranes
Stacker cranes are typically found and operate in automated warehouses, using a mast or fork-like attachments to move pallets and other materials along high racks. Staker cranes can move vertically and horizontally within narrow aisles, maximizing storage capacity and efficiency in warehouse operations.
Telescopic Cranes
Telescopic cranes feature a boom made of multiple sections that slide in and out, allowing the operator to adjust the boom length on the fly. This adaptability makes them useful across diverse applications—from moving construction materials to performing rescue operations in hard-to-reach areas.
Telescopic Handler Cranes
Also known as telehandlers, telescopic handler cranes resemble forklifts fitted with a telescopic boom. They can lift loads upwards and outwards and are common on construction sites, where they handle everything from pallets of bricks to raising work platforms.
Each crane type suits specific project conditions, including maximum lift height, load weight, required mobility, and terrain. For example, crawler cranes excel on soft ground due to their track-based stability, while all-terrain cranes can drive on public roads and maneuver over rugged surfaces. Misusing a crane—or selecting one unsuited to the environment—can lead to accidents, costly delays, or serious injuries.
Whether you’re in a shipyard, a construction zone, or a port, the correct crane type is critical to both efficiency and safety. Ultimately, the wide variety of crane designs highlights the complexity of modern heavy lifting—as well as the vital role of planning, training, and rigorous maintenance in preventing on-the-job crane accidents and injuries.
Hazards Posed by Cranes & How to Use Them Safely
Cranes provide a number of essential services in many industries such as construction, manufacturing, maritime, and transportation. Although they greatly increase efficiency, they also carry a significant danger to their operators and those nearby. In light of the high percentage of incidents in relation to the number of workers exposed to the machinery, OSHA listed crane and hoist safety as a high priority topic of discussion in 1994. This distinction has led to the development and implementation of a number of safety measures for crane operators.
- Automatic alarm if a fire is detected
- Automatic crane shutdown if a fire is detected
- Boom tip camera to increase visibility and minimize blind spots
- Brake redundancy, with an extra brake in place in the case that one should fail
- Fail-safe brakes which automatically brake if the control system fails
- Hands-off communication system to keep both hands on controls
- Hydraulic system which enables maintenance of hydraulic refilling
- Load holding valves which protect against movement if a hose should rupture
- Manual emergency stop command which overrides all other commands
- Two-way communication systems
- Assessing all construction sites for the potential for a crane incident to occur
- Establishing a crane safety plan for each lift
- Assigning a competent person to oversee crane operations
- Utilizing qualified operators, signalpersons, and riggers
- Training ancillary workers in safe crane operation
Training and communication are key to maintaining a safe environment around a working crane. Workers must be able to communicate any issues, plans for executing work, and hazards that may arise. Signage is also important to warn other employees of any areas inside the danger zone of an operating crane. Blind spots and low visibility can make it difficult for operators to see other workers, so it is imperative that all workers understand the risks involved with cranes, even if they are not operators themselves.
Creating a culture of safety involves regular safety drills and workshops to reinforce correct operational procedures and response strategies. By simulating potential emergency scenarios, employers can prepare workers to become better prepared to handle unexpected situations, mitigating risks before they result in real-world accidents.
Arnold & Itkin's Experience with Crane Accidents
One of Arnold & Itkin's most notable crane-related cases involved a man who was injured in a crane accident, requiring amputation of his leg above the knee. Our client was standing more than 100 feet away from a crane that was being used to drill auger cast pilings. The drill became stuck, but the foreman demanded that the crane operator continue attempting to drill, despite the operator's requests to stop.
The operator asked the foreman if he could stop the crane five times total. As a result of the foreman's reckless attempt to value his deadline above the safety of his employees, the crane collapsed, pinning our client underneath heavy equipment. Our firm successfully fought on his behalf, securing a $44 million verdict—the largest amputee verdict in the nation.
Results like these are what we aim for with every accident case: securing our clients' futures while ensuring they'll get high-quality care. With so much on the line, you deserve an attorney who is fighting for the best result.
After a Houston Crane Accidents: Next Steps & How a Lawyer Can Help
The initial moments after a crane accident are crucial for both health and potential legal claims. First, seek medical attention for anyone injured, even if injuries appear minor. Contact emergency services so they can provide immediate care and document the incident. Simultaneously, report the accident to your employer or site supervisor. Take photographs of the scene, the crane, any damaged property, and hazardous conditions, if possible. Witness statements are invaluable; gather contact information from anyone who saw the accident happen. Lastly, it is crucial to refrain from making any statements about fault or accepting any initial settlement offers from insurance companies until consulting with a knowledgeable crane accident lawyer in Texas.
Legal representation in the aftermath of a crane accident is invaluable for protecting your rights. A lawyer experienced in crane accidents can investigate the cause, whether it was due to operator error, mechanical failure, or regulatory non-compliance. They can ensure that all evidence is properly documented and preserved and take legal action on your behalf to seek the compensation you need to rebuild.
Determining liability in crane accidents often involves multiple parties. Potentially responsible parties include the crane operator, the contractor or construction company, and sometimes the crane manufacturer if mechanical defects were involved. Subcontractors or third-party maintenance crews could also bear responsibility if improper setup or maintenance led to the accident. Our crane collapse attorneys in Houston conduct thorough investigations to pinpoint negligence and ensure the responsible parties are held accountable. Access to industry experts and thorough knowledge of local and federal safety regulations are instrumental in establishing negligence and liability.
Schedule a Free Consultation with Our Texas Crane Accident Law Firm
If you have been injured or a loved one has been killed in a crane accident, you should consult with a Houston construction accident lawyer as soon as possible. In many crane accidents, several different parties could potentially be held liable for your injuries. At Arnold & Itkin, our team of top-rated lawyers has the knowledge and experience to prosecute even the most complex crane accident cases. We have helped dockworkers, mariners, and other workers across the U.S. to recover from serious incidents and seek full and fair compensation.
Call Arnold & Itkin at (888) 493-1629 to get a free consultation. We can lay out your options and help you make the choice that's best for you.
