Top seven common failures found during LOLER inspections

THE LIFTING Operations and Lifting Equipment Regulations (LOLER) remain a cornerstone of workplace safety across the UK. Whether used in construction, manufacturing, warehousing or heavy engineering, lifting equipment must undergo regular thorough examinations to ensure it remains safe for use. 

When these checks are ignored, the consequences can be severe. As highlighted in HSM Search’s report on a construction firm prosecuted following a fatal incident, failures involving lifting equipment rarely end without significant harm.

Despite LOLER being well established, many of the same issues arise repeatedly during examinations. Understanding these common failures and how to prevent them helps duty-holders maintain compliance and protect both staff and equipment.

1. Worn or damaged wire ropes

Wire ropes are among the most critical components in lifting equipment. Signs such as broken strands, corrosion, bird-caging, kinks or flattening significantly weaken the rope’s structural integrity. These faults are often progressive, going unnoticed until the rope is close to failure.

Prevention:

• Conduct interim inspections between formal LOLER examinations
• Lubricate ropes regularly
• Store wire ropes in dry, controlled conditions
• Replace ropes at the first sign of deterioration

The HSE’s official guidance on LOLER sets out clear criteria for rope retirement.

2. Defective chain slings, hooks and shackles

Lifting accessories frequently fail LOLER checks due to stretching, cracks, excessive wear or damaged safety latches. Even small defects can significantly reduce safe working load capacity and increase the risk of sudden failure.

Prevention:

• Ensure accessories are certificated and traceable
• Remove worn or distorted components from service immediately
• Train operators to recognise common defects
• Store chains off the floor to reduce corrosion risk

3. Brake, clutch or safety pawl failures

Hoists, cranes and chain blocks rely on effective braking systems and safety pawls to hold loads securely. Contamination, mechanical wear and ignored warning signs all contribute to failures.

Prevention:

• Follow manufacturer service intervals
• Conduct functional tests as part of daily pre-use checks
• Address unusual noises or slipping immediately
• Keep mechanical components clean and lubricated

4. Missing, incorrect or invalid certification

A large number of LOLER failures relate not to equipment condition but to incomplete records. Missing certificates, expired examinations, unclear asset identification or out-of-date paperwork can all result in non-compliance.

Prevention:

• Implement a centralised LOLER record system
• Tag equipment clearly with asset numbers
• Check new or repaired equipment always includes certification
• Appoint a responsible person to manage documentation

5. Overloading and incorrect use of rated capacity

Exceeding a lifting accessory’s safe working load (WLL) is still a common issue. Problems arise when operators estimate weights, use incompatible accessories or fail to account for load angles and distribution.

Prevention:

• Clearly label WLLs on all lifting equipment
• Use load cells or test weights where necessary
• Match accessories to the load and lifting configuration
• Provide training on load distribution and angular forces

6. Structural damage or fatigue

Cranes, gantries, lifting beams and mobile frames often display signs of structural fatigue during examinations, including cracked welds, bent sections, deformities or corrosion. Many of these issues originate from past collisions or from lifting beyond design limits.

Prevention:

• Perform routine visual checks
• Do not ignore impact damage, even if minor
• Ensure lifting structures are installed correctly
• Follow manufacturer guidance for safe working ranges

7. Poor maintenance and lack of interim inspections

Equipment that is used heavily but maintained infrequently is far more likely to fail a LOLER examination. Missed lubrication, worn consumables, contaminated components and unrecorded repairs all contribute to avoidable failures.

Prevention:

• Maintain a structured inspection and maintenance programme
• Document all repairs and part replacements
• Encourage operators to report concerns immediately
• Ensure service parts and lubricants are readily available

Insights from industry: what inspectors are seeing across the UK

To understand how these failures appear in real workplaces, it’s worth looking at what competent examiners encounter daily. Lloyds Beal, who deliver LOLER inspection services nationwide, report several recurring patterns across warehouses, factories, construction sites and engineering facilities.

One of the most common findings is lifting accessories operating far beyond their intended lifespan. Chain slings with stretched links, shackles with worn pins and textile slings showing UV degradation feature frequently in examinations. These defects often begin subtly and go unnoticed during rushed pre-use checks.

Another frequent issue is the mixing of components from different manufacturers. While a hook may physically fit a chain from another system, small differences in metallurgy, sizing or design philosophy can invalidate its certification and compromise load integrity. Lloyds Beal’s engineers report seeing this regularly on sites attempting to “make do” with available spares.

A more concerning trend is unapproved on-site modification, such as welded repairs, ground-down hooks, non-standard bolts or improvised lifting points. Although usually carried out with good intentions, these changes can alter stress paths, invalidate CE markings and introduce hidden weaknesses.

Lloyds Beal also often encounter traceability issues: accessories with missing tags, equipment with incorrect asset numbers, no record of repairs, or expired examination certificates. In some cases, lifting accessories are used with no supporting documentation at all.

Finally, misuse remains a consistent theme, such as forklift attachments without rated capacity charts, jib arms extended beyond their safe range or cranes used on misaligned rails. These issues highlight the importance of user training and competent planning.

The clear conclusion from their nationwide experience is this: most LOLER failures are avoidable, and regular examination, combined with proactive day-to-day checks, prevents minor wear from developing into high-risk defects.

Conclusion

LOLER examinations are fundamental to ensuring safe lifting operations. The issues identified, from worn ropes to poor record-keeping and unapproved modifications are entirely avoidable with the right systems in place. By following HSE guidance, using competent inspectors and embedding proper maintenance practices, organisations can significantly reduce risk and protect their workforce.