Fly-by-Night Crane Operators and the Cost of Negligence

[MikePhua]

The Rise and Risk of Boom Trucks
Boom trucks, a hybrid between mobile cranes and flatbed trucks, became popular in the 1980s for their versatility in lifting and transporting materials. Manufacturers like Manitex, National Crane, and Terex produced thousands annually, targeting construction, utility, and marine sectors. While their compact design and mobility made them ideal for tight job sites, their operation required strict adherence to safety protocols. Unfortunately, not all operators followed best practices, leading to a rise in accidents involving overturned cranes and damaged booms.
A Real-World Incident and Its Implications
One evening, a local crane operator was called to assist a boom truck company whose vehicle had overturned near a tidal zone. The truck had rolled while attempting a lift, and the tide was threatening to swamp the skiff it was supporting. The assisting crane, a rough terrain model, lacked the capacity to fully recover the truck but managed to stabilize the situation enough to prevent further damage. The boom had buckled—again. This was not the first time the same company had suffered such a failure, raising concerns about their operational standards.
Understanding Boom Buckling and Load Limits
Boom buckling occurs when a crane’s boom is subjected to compressive forces beyond its design limits. This can result from:

• Overloading beyond rated capacity
  
• Improper boom angle during lift
  
• Unstable ground conditions under outriggers
  
• Sudden dynamic loads or shock loading
  

Modern cranes are equipped with limit switches and load moment indicators (LMIs) that prevent unsafe operations. These systems monitor boom angle, extension, and load weight, automatically restricting movement when thresholds are exceeded. However, older or poorly maintained equipment may lack these safeguards, or operators may override them.
Ground Stability and Outrigger Support
A critical factor in crane safety is the stability of the ground beneath the outriggers. In this case, the passenger-side outrigger was positioned on unstable material, contributing to the rollover. Best practices dictate the use of reinforcement pads or cribbing under each outrigger to distribute load and prevent sinking. These pads can be made from:

• High-density plastic
  
• Layered timber (e.g., 2x4s in two layers)
  
• Steel plates for heavy cranes
  

Operators should inspect the ground for hidden hazards like buried pipes or voids. A Norwegian production manager recalled a crane overturning when its leg collapsed into a buried pipe trench—an avoidable disaster had proper reinforcement been used.
Operator Training and Safety Culture
Repeated incidents with the same company suggest a lack of training or disregard for safety. Proper crane operation requires:

• Certification and licensing
  
• Routine safety briefings
  
• Adherence to manufacturer guidelines
  
• Use of spotters and load charts
  

In quarry operations, experienced operators often warn newcomers to stay clear of suspended loads and to respect ground conditions. Yet, some contractors ignore these warnings, relying on oversized rigging without considering soil bearing capacity—a dangerous oversight.
Lessons from the Field
One operator shared that he always carries custom-made outrigger pads with handles fashioned from old securing straps. These pads vary in size depending on the crane, ensuring proper support regardless of terrain. Another technician emphasized the importance of visual cues—if a crane begins to lean or outriggers shift, the lift must be aborted immediately.
Conclusion
Fly-by-night crane operations pose serious risks to personnel, equipment, and public safety. The repeated failure of a boom truck due to poor ground support and overloading highlights the consequences of negligence. With proper training, equipment maintenance, and adherence to safety protocols, such incidents are entirely preventable. The industry must continue to promote a culture of accountability, where every lift is treated with the respect it demands.