Top 10 LOLER Failures | Common Lifting Equipment Defects

Top 10 Most Common LOLER Failures – What Inspectors Look For

If your business uses lifting equipment, a LOLER Thorough Examination is an essential part of keeping your workplace safe and compliant.

But what happens when your lifting equipment doesn't pass its examination?

From worn chains and damaged lifting accessories to missing identification and structural defects, there are a number of common issues that can be identified during a LOLER inspection.

In this guide, we'll look at the 10 most common LOLER failures and defects, what causes them, and what businesses can do to reduce the risk of problems during their next Thorough Examination.

What is a LOLER Thorough Examination?

A LOLER Thorough Examination is a systematic and detailed examination of lifting equipment and its safety-critical components.

It must be carried out by a competent person with the appropriate practical and theoretical knowledge and experience of the equipment being examined.

The purpose is to identify defects or weaknesses that could affect the safe continued use of the equipment.

It is important to understand that a LOLER Thorough Examination is not the same as routine maintenance or servicing. Equipment still needs to be properly maintained between examinations.

What Does a LOLER Failure Mean?

There isn't simply a "pass or fail" sticker for every LOLER examination.

A Thorough Examination may identify defects that require action within a specified period, while serious defects that are or could become a danger to people may require the equipment to be taken out of service immediately.

The competent person records significant defects in the examination report and advises the dutyholder on the action required.

That's why regular maintenance, pre-use checks and timely LOLER examinations are so important.

1. Worn or Damaged Lifting Chains

Lifting chains are exposed to significant loads and repeated use, making wear and damage an important area for inspection.

An inspector may look for:

• Excessive wear

• Elongation

• Corrosion

• Cracked or damaged links

• Distortion

• Heat damage

• Evidence of inappropriate use

A damaged chain can compromise the safety of an entire lifting operation.

How to reduce the risk

Operators should carry out appropriate pre-use checks and report damaged chains immediately.

Chains should also be stored correctly and maintained in accordance with the manufacturer's recommendations.

2. Damaged Webbing Slings

Webbing slings are widely used across construction, manufacturing, engineering, warehousing and many other industries.

Because they are flexible and lightweight, they can also be susceptible to damage.

Common problems include:

• Cuts

• Tears

• Fraying

• Broken stitching

• Abrasion

• Heat damage

• Chemical damage

• Missing or illegible identification labels

A sling that has suffered significant damage should not simply be put back into service.

How to reduce the risk

Store slings away from damaging conditions and carry out suitable checks before use.

Never use a lifting accessory if you are unsure whether it remains safe.

3. Damaged or Distorted Hooks

Hooks are critical load-bearing components of lifting equipment.

During a LOLER Thorough Examination, an inspector may identify:

• Cracks

• Excessive wear

• Distortion

• Damaged safety catches

• Corrosion

• Incorrect hook opening

• Other signs of deterioration

A damaged hook can present a serious risk because it may affect the secure attachment of the load.

How to reduce the risk

Never exceed the equipment's rated capacity and report damaged or distorted hooks immediately.

4. Excessive Corrosion

Corrosion can gradually weaken lifting equipment, particularly where equipment is used outdoors or in wet, humid, chemical or otherwise harsh environments.

Corrosion may affect:

• Chains

• Hooks

• Beams

• Frames

• Wire ropes

• Fixings

• Structural components

The important issue isn't simply whether rust is present — it is whether deterioration could affect the safe operation or structural integrity of the equipment.

How to reduce the risk

Regularly clean and maintain equipment and pay particular attention to equipment operating in harsh environments.

5. Structural Damage, Cracks or Deformation

Structural integrity is a major consideration during a Thorough Examination.

Inspectors may identify:

• Cracked welds

• Bent components

• Deformation

• Damaged lifting points

• Structural corrosion

• Damaged frames or supports

These defects can potentially affect the equipment's ability to safely support its intended load.

How to reduce the risk

Any suspected structural damage should be reported immediately and the equipment assessed by an appropriately competent person.

Do not attempt to hide or ignore damage simply because the equipment still appears to operate normally.

6. Faulty Safety Devices

Modern lifting equipment can incorporate a range of safety devices designed to prevent dangerous situations.

Depending on the equipment, these may include:

• Limit switches

• Overload protection

• Safety catches

• Interlocks

• Braking systems

• Emergency stop systems

A defect affecting a safety-critical device can significantly increase the risk associated with using the equipment.

How to reduce the risk

Safety devices should be maintained and tested as appropriate for the equipment.

Any suspected fault should be investigated before the equipment continues to be used.

7. Missing or Illegible SWL Markings

Safe Working Load (SWL) information is extremely important.

Operators need to know the capacity of lifting equipment so that loads can be planned and carried out safely.

HSE guidance states that lifting equipment should be suitably marked with information such as its safe working load where appropriate.

Problems can arise when:

• Identification plates are missing

• SWL markings are damaged

• Labels are illegible

• Equipment configuration changes its lifting capacity

• Operators cannot clearly determine the safe capacity

How to reduce the risk

Regularly check identification plates, markings and labels.

If information is missing or unclear, seek competent advice before using the equipment.

8. Poor Maintenance and Unresolved Defects

A LOLER Thorough Examination is not a replacement for routine maintenance.

Lifting equipment should be maintained so that it remains safe to use.

Common maintenance-related problems can include:

• Worn components

• Loose fixings

• Damaged hydraulic hoses

• Oil leaks

• Deteriorated electrical components

• Missing parts

• Previously identified defects that have not been repaired

HSE guidance makes clear that thorough examination and routine maintenance are separate responsibilities.

How to reduce the risk

Don't wait for your next LOLER examination to deal with obvious defects.

Implement a planned maintenance programme and keep appropriate records of repairs and maintenance.

9. Incomplete or Missing LOLER Records

The physical condition of lifting equipment isn't the only consideration.

Businesses also need to keep appropriate records of Thorough Examinations.

A LOLER Thorough Examination report should contain specific information, including the examination date, the date when the next examination is due, and details of defects that are or could become a danger to people.

Poor record keeping can make it difficult to demonstrate that your inspection programme is being properly managed.

How to reduce the risk

Keep your LOLER reports organised and make sure you know:

• What equipment you have

• When each item was last examined

• When the next examination is due

• What defects have been identified

• Whether corrective actions have been completed

  
  

10. Overdue LOLER Thorough Examinations

One of the simplest problems to prevent is allowing an examination to become overdue.

For equipment subject to the standard LOLER intervals, Thorough Examinations are generally required:

Every 6 months for:

• Lifting accessories

• Equipment used for lifting people

Every 12 months for:

• Other lifting equipment used for lifting loads

However, a competent person can establish different examination intervals through a suitable examination scheme where appropriate. Additional examinations may also be required following certain events or changes affecting the equipment.

How to reduce the risk

Don't wait until the certificate is about to expire.

Maintain an equipment register and schedule your next examination in advance.

What Should You Do If Your Equipment Has a LOLER Defect?

If a Thorough Examination identifies a defect, the action required depends on its nature and severity.

Where a defect is considered to be, or could become, a danger to people, the dutyholder should be informed immediately and effective action taken to prevent the equipment being used until the defect has been remedied.

This is why it is important to take inspection findings seriously.

A LOLER report isn't simply a certificate to file away — it provides important information about the condition and safety of your lifting equipment.

How Can You Reduce LOLER Failures?

The best way to reduce the likelihood of defects is to take a proactive approach to lifting equipment safety.

1. Carry Out Pre-Use Checks

Operators should carry out appropriate checks before using lifting equipment.

2. Maintain Equipment Properly

Follow manufacturer recommendations and address defects promptly.

3. Train Your Employees

Make sure people using lifting equipment understand how to operate it safely and identify obvious defects.

4. Keep Accurate Records

Maintain your LOLER reports, maintenance records and equipment register.

5. Schedule Thorough Examinations on Time

Don't wait until an examination is overdue.

6. Use a Competent Inspection Company

Your Thorough Examination needs to be carried out by a competent person with suitable knowledge and experience of the equipment being examined.

Is Your Lifting Equipment Due a LOLER Inspection?

Whether your business operates cranes, hoists, MEWPs, goods lifts, forklift attachments, lifting beams, chains, slings or other lifting equipment, keeping your Thorough Examinations up to date is essential.

At Mechanical Inspection Services, we provide professional LOLER Thorough Examinations for businesses across Berkshire, Surrey, Hampshire, Heathrow, the South East and throughout the UK.

Our experienced inspection engineers can help you identify potential issues, maintain accurate inspection records and keep your lifting equipment compliant.

Don't Wait for a Failure to Find the Problem

A LOLER inspection shouldn't be something you think about only when an inspection date is approaching.

Regular examinations, proper maintenance and good record keeping can help identify problems before they become more serious.

Frequently Asked Questions About LOLER Failures

What is the most common LOLER failure?

There isn't one single defect that applies to every type of lifting equipment. Common issues can include wear, damage, corrosion, defective safety components, damaged lifting accessories and inadequate identification or records.

What happens if lifting equipment fails a LOLER inspection?

The competent person will report the defect and specify the action required. Where a defect is, or could become, dangerous to people, the equipment should not be used until the defect has been appropriately addressed.

How often does lifting equipment need a LOLER inspection?

The standard intervals are generally six months for lifting accessories and equipment used to lift people, and 12 months for other lifting equipment, unless a competent person's examination scheme specifies different intervals.

Does LOLER inspection replace maintenance?

No. A Thorough Examination and routine maintenance are separate requirements. Lifting equipment must continue to be maintained so that it remains safe to use.

Who can carry out a LOLER Thorough Examination?

It must be carried out by a competent person with appropriate practical and theoretical knowledge and experience of the lifting equipment being examined. HSE guidance also emphasises the importance of sufficient independence and impartiality.

Need a LOLER Inspection?

If your business uses lifting equipment, regular LOLER inspections are essential to maintain compliance and workplace safety.

Our experienced engineers provide professional LOLER inspections for businesses across multiple industries, helping companies keep equipment safe, compliant, and fully operational.

📩 Get in Touch

Contact us today to arrange your LOLER inspection or discuss your compliance requirements.

👉 Contact us today to arrange your LOLER inspection and keep your business running safely and efficiently. 📧 info@mechinspect.co.uk 📲 0330 043 3448