Manitowoc Crawler Crane Drops Load During Wind Turbine Hub Installation

Meagan Wood
Sep 20, 2023
3 min read

Updated: Dec 28, 2025

30-Second Takeaway

A large Manitowoc crawler crane dropped a wind turbine hub during installation after an apparent hoist drum brake failure. The incident occurred as the hub was nearly in position. Video footage shows a sudden jolt followed by boom flex and rapid loss of the load. No injuries were reported, though the hub and blades were destroyed. The incident highlights critical risks associated with hoisting systems, brake performance, and dynamic loading during wind turbine installation.

Incident Overview

A large Manitowoc crawler crane was involved in a serious incident during a wind farm construction project, resulting in the loss of a turbine hub and blades.

Information remains limited, which is not uncommon on wind projects. However, based on material provided to Crane Hub Global, the incident occurred as the hub was close to being set in position.

No injuries have been reported.

What Is Known

The crane was a large Manitowoc crawler crane
The operation involved installing a wind turbine hub
The hub was nearly in position when the incident occurred
The load was dropped rapidly
No injuries have been reported
Damage appears limited primarily to the hub and blades, which are a total loss

Observations From Video and Images

Based on video footage and post-incident images shared with Crane Hub Global:

The crane appears to experience a sudden jolt
The boom visibly flexes immediately prior to load loss
The load then falls rapidly
Post-incident images suggest the crane lost several lattice lacings from boom sections

It has been suggested that hoist drum brakes may have failed, though this has not been officially confirmed.

What Is Not Yet Known

At the time of publication, there is no confirmed information regarding:

Exact crane model or configuration
Hoist line reeving and drum setup
Brake condition, testing, or maintenance status
Load weight relative to charted capacity
Wind conditions at the time of the lift
Whether any alarms or warnings were triggered

Until an official investigation is released, the root cause remains unconfirmed.

Why Incidents Like This Can Occur

During wind turbine installation, cranes are often operating near:

High load percentages
Large radii with long boom configurations
Dynamic effects from wind and load movement
High energy stored in hoisting systems

Hoist brake systems are critical safety components. Failure or reduced braking performance can lead to uncontrolled load descent, particularly during final positioning when fine control is required.

Boom flex and structural damage may occur when loads are released suddenly, introducing extreme dynamic forces.

Industry Reminder

Wind turbine lifts place extreme demands on cranes and hoisting systems. Even brief loss of control can result in catastrophic load loss and significant equipment damage.

The absence of injuries in this incident is fortunate, but it serves as a reminder that braking systems and hoist integrity are mission-critical during wind operations.

Editorial Note

Crane Hub Global reports on crane-related incidents using verified information and clearly distinguishes between confirmed facts and unconfirmed observations. This article will be updated if official findings are released.

How Incidents Like This Can Be Prevented

Hoist Brake Inspection and Testing

Hoist drum brakes should undergo regular inspection, adjustment, and functional testing, especially before critical lifts on wind projects.

Redundant Braking and Load Control

Where applicable, redundant braking systems and controlled lowering procedures help reduce risk during high-energy lifts.

Critical Lift Planning

Wind turbine component lifts should be classified as critical lifts, with detailed lift plans covering brake performance, emergency scenarios, and abort criteria.