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Flood light dropped to deck – corrosion

A floodlight weighing about 6kg was found on the deck, near to the scaffolding storage area, underneath the main crane boom rest.  The flood light affixed to the main crane boom rest dislodged from its frame and dropped to deck, a distance of 4.5m. The electrical supply to the flood light fitting was immediately isolated.

At the time of the incident there were no personnel in the area.

Dropped floodlight
Flood light mounting frame

What went wrong?

  • Hidden corrosion: The flood light mounting frame which remained affixed to the main crane boom rest, showed excessive wear and tear, and had completely corroded, leading to the flood light detaching from its mounting frame;
  • There was no secondary retention;
  • The flood light had not been identified as a potential dropped object;
  • The advanced deterioration of the mounting frame was obscured by the paint work;
  • Environmental conditions including vibration, humidity, wind loading, and sea salt corrosion may have impacted the mounting frame materials.


  • Think carefully about what could become a dropped object – perform dropped object surveys
    • Consider cross-departmental “hazard hunts” for drop hazards – get some “fresh eyes” in to spot what you may have missed;
  • Ensure that everyone knows who is responsible for doing dropped object inspections;
  • Make use of secondary retention where appropriate.

Members may wish to review:

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