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Safety Alert - Electro-Hydraulic Lifts

Lapse in Appropriations

For workplace safety and health, please call 800-321-6742; for mine safety and health, please call 800-746-1553; for Job Corps, please call 800-733-5627 and for Wage and Hour, please call 1-866-487-9243 (1 866-4-US-WAGE).  This website is currently not being updated due to the suspension of Federal government services. The last update to the site was 10/1/2025.  Updates to the site will start again when the Federal government resumes operations.

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Use qualified welders. Inspect welds and metal components. Train users.

Damaged or defective welds on aerial lifts have caused several fatalities in the mining industry.

  • A mechanic died while being lowered in an electro-hydraulic aerial lift. A weld splice fractured on a recently repaired arm of the lift, causing the arm to strike the victim in the head (Figure 1). The weld failed because of poor weld quality from an improper repair.
  • A welder died while being lowered in an electro-hydraulic aerial lift when the lift arm catastrophically fractured at a critical weld connecting the arm support to its lift cylinder (Figure 2). Undetected cracks existed in the weld and the surrounding metal prior to failure.
Best Practices

Best Practices to Prevent the Mechanical Failure of Welded Connections

Prevent accidents by following proper welding procedures and performing regular inspections for damages or defects.
Best Practices for Welding and Inspections
  • Only qualified welders should perform all welding.
  • Determine the service/fatigue life of mechanical systems or parts by consulting with the manufacturer.
  • Inspect welds following installation and repairs, and periodically during service life.
  • Train users in the proper operation of lifts – including not exceeding their design capacity.
  • Routinely examine metal components for signs of weakness, corrosion, fatigue cracks, bends, buckling, deflection, missing connectors, etc.
  • Use nondestructive test methods to detect cracks that may be indistinguishable to the eye.
  • Take cracked mechanical components out of service immediately. Small cracks can quickly grow and lead to catastrophic fracture.