Analysis of Lifting Rope Failure Accidents And Prevention Measures in Construction Operations

In construction lifting operations, wire rope failure is a highly dangerous type of heavy object drop accident. It can be classified into hoisting rope rupture and lifting sling rupture. Such accidents may result in falling loads, equipment damage, or even injuries and fatalities. Understanding the causes and implementing effective prevention measures is crucial for ensuring safe lifting operations.

1. Overview of Wire Rope Failure in Lifting Operations

Wire rope failure refers to the rupture of hoisting ropes or lifting slings, which directly causes suspended loads to fall unexpectedly. As the core load-bearing component in lifting equipment, the integrity of steel wire ropes determines the overall safety factor of hoisting operations. Any improper operation, equipment defect, or lack of maintenance significantly increases the risk of rope rupture.

2. Common Causes of Hoisting Rope Rupture

Hoisting ropes are the main load-bearing ropes of lifting equipment, responsible for vertical movement of heavy objects. Common causes of rupture include:

1. Overloading: Exceeding the rated lifting capacity is the primary cause. Some operators ignore equipment limits and attempt to lift excessive weight, instantly surpassing the rope’s tensile strength.

2. Safety device failure: Malfunctioning limit switches can allow loads to exceed safe heights, causing overwrap and excessive tension on the rope, leading to sudden rupture.

3. Improper lifting techniques: Angled or slanted lifting can distort rope arrangement, causing wires to rub, twist, or compress, damaging the rope surface and internal wires over time.

4. Lack of maintenance: Long-term exposure to sunlight, rain, corrosion, or friction without regular lubrication and inspection leads to fatigue, wear, and wire breakage.

5. Use of ropes beyond service life: Ignoring the replacement criteria for worn ropes dramatically increases rupture risk.

Case Example: On July 13, 2025, a wire rope on a tower crane in Shenzhen broke while lifting concrete, causing the load to strike a worker. Despite immediate rescue efforts, the worker later died from injuries.

3. Causes of Lifting Sling (Tie Rope) Failure

Lifting slings are used to secure loads and assist in hoisting operations. Rupture often results from:

1. Incorrect sling angle: Rope angles exceeding 120 degrees dramatically increase tension, causing instantaneous failure.

2. Improper rope selection: Using ropes that cannot support the load or employing damaged, worn ropes leads to rupture during lifting.

3. Lack of protective measures: Sharp edges or corners on loads can cut or abrade slings if protective pads or corner guards are not used, causing premature rope failure.

Case Example: On February 5, 2026, a lifting sling used at Ansteel’s plant was cut by a sharp steel beam edge during a hydraulic cylinder hoisting operation, resulting in a fatal accident.

4. Prevention Measures for Wire Rope Failure

To prevent lifting rope accidents, construction sites must implement comprehensive safety management:

1. Strict adherence to operation procedures:

   • Avoid overloading and slanted lifting

   • Maintain proper sling angles

   • Select ropes according to load specifications and rope capacity

2. Equipment maintenance and inspection:

   • Regularly check limit switches and safety devices

   • Clean, lubricate, and inspect ropes

   • Replace ropes that meet or exceed wear and breakage thresholds

3. Worker training and safety awareness:

   • Educate operators on rope failure hazards and emergency response

   • Enforce compliance with safety standards

   • Reduce human errors that contribute to rope rupture

By addressing human operation, equipment maintenance, and on-site management, lifting rope accidents can be effectively prevented, ensuring safe and smooth hoisting operations.