Even in the most precisely engineered lifting systems, gravity remains the one variable that never forgives mistakes.

A falling load – whether due to component failure, misuse, or fatigue – can cause catastrophic injury, halt operations, and damage valuable infrastructure. Preventing such incidents is not just about compliance; it’s about engineering redundancy and resilience into every lift.

Beyond Overload Protection

Most lifting professionals are familiar with overload protection – systems that prevent a crane or hoist from lifting more than its rated capacity. These devices stop a hazardous lift before it happens.

But dropped load prevention addresses a different risk: what happens if a mechanical or structural failure occurs while a load is already suspended?

That’s where load arrest systems, also known as secondary load protection devices or load arrestors, come into play.

What a Load Arrest System Does

A load arrest system acts as a secondary safety mechanism, designed to catch and hold a load if the primary hoist or lifting gear fails.

Typically installed above the load path, a load arrestor uses an independent, retractable cable attached to a secure anchor point. If a sudden descent is detected, the device instantly locks — stopping the load from falling.

These systems are common in high-risk or high-value lifting environments:

• maintenance work above production areas,
• lifting near personnel or sensitive equipment,
• multi-hoist or synchronised lifts,
• or where operational continuity is critical.

In short, they serve as the last line of defence when every other layer of safety has already been tested.

Engineering Safety in Layers

In overhead crane design, safety is not achieved through a single device but through layered engineering:

1. Design safety – appropriate load ratings, correct factor of safety, and adherence to standards like SANS, ISO, and FEM.

2. Operational safety – overload limiters, inspections, and operator competence.

3. Redundant safety – systems like load arrestors that protect people and assets when the unexpected happens.

Manufacturers and system integrators who work with advanced equipment suppliers — such as Planeta or Demag — recognise that true safety comes from integrating these layers into the design itself, not adding them as afterthoughts.

A Shared Responsibility

Regulations in both South Africa (OHS Act and Driven Machinery Regulations) and the UK (LOLER, PUWER, HSE Dropped Objects Guidance) reinforce one principle: the person responsible for lifting operations must ensure no unsafe load is ever suspended overhead.

Load arrest systems contribute directly to meeting this responsibility, particularly in operations where risk cannot be engineered out entirely.

Looking Ahead

As the industry moves toward smarter, connected lifting systems, the same philosophy applies: prevention through design, and protection through redundancy. Modern cranes increasingly integrate intelligent overload detection, fatigue monitoring, and secondary safety features that alert operators before a hazard develops.

At RGM Cranes, we apply the same layered engineering philosophy to every system we design, ensuring that prevention and protection are built in from the start.