Case Study 87: “Flip-Flop” Screening Machine. Work Ends in Fatal Crush

Incident Overview

A heavy screening machine (“flip-flop/Trisomat screen”) was being handled as part of a replacement task. The operation involved crane use and subsequent movement/handling steps. A worker was fatally crushed.

What Went Wrong

The job had multiple phases and the hazard profile changed after the initial crane movement. Planning and control did not effectively cover the full sequence and stability risks.

Key Lessons

“Phase 2” is where people drop standards

Stability and route control matter after the lift

One task can contain multiple high-risk activities

Safety Recommendations

Plan the entire job end-to-end. Re-brief after each phase. Control stability, movement routes, and stop points.

Incident source/ Reference

UK HSE-linked reporting on the fatal screening

https://constructionmanagement.co.uk

●LOLER Reg. 8 – Plan the full job, not just the first lift.

●PUWER Reg. 4 – Method must be suitable for each phase.

●PUWER Reg. 11 – Crush zones must be prevented/controlled.