Uncontrolled release of monopile causes damage

A fabrication crew was asked to work unplanned overtime to complete urgent tasks at the end of their scheduled shift.

During the shift, incorrect rigging was used to move a heavy cylindrical structure, deviating from the approved procedure.

Instead of using steel cradle supports, wooden wedges were used to temporarily secure the structure.

After multiple failed attempts to land the structure, the wedges slipped or were not replaced, causing it to roll and fall approximately 1 metre (3.3 feet).

Several pieces of equipment were damaged, and four personnel were in the immediate area but avoided injury.

The incident had the potential for serious harm due to the mass and movement of the structure.

The use of wooden wedges instead of cradle supports had become common practice, despite not being part of the approved method.

The approved procedure was either not known or not effectively communicated to the team.

The rigging selected for the lift was too high, contributing to difficulties during positioning.

A supervisor knowingly allowed deviation from the correct procedure and did not enforce the documented method.

The team was operating well beyond their scheduled working hours, increasing fatigue and reducing situational awareness.

The failure to replace the wedges was likely due to mental fatigue and distraction late into the extended shift.

Deviation from approved methods has been normalised, often due to convenience or pressure to complete tasks quickly.

Informal training and on-the-job learning have led to poor understanding of correct procedures.

Oversight gaps have allowed unsafe practices to go unchallenged over time.

Excessive working hours and unexpected overtime increase the likelihood of human error and lapses in safety-critical tasks.

All teams require re-training on proper handling and rigging methods, supported by effective supervision.

Management must reinforce a safety-first culture by actively monitoring work practices and addressing unsafe behaviours.

How confident are we that everyone knows and follows the approved methods for high-risk tasks?

What systems do we have in place to prevent unsafe practices from becoming the norm?

How are we managing fatigue and decision-making during overtime or unexpected work?

Are team leaders/managers consistently reinforcing safety over schedule or output, and how do we know?

What would we do differently if this situation occurred in our work area?