1. Fatal Risks: Structural Damage and Mechanical Failure

Overloading a crane can directly cause irreversible plastic deformation or even fracture of metal structures, such as bending of the main girder, crushing of the outriggers, or snapping of the wire rope (with fracture surfaces typically showing a 45° shear pattern). When the load exceeds 85% of the rated capacity, the risk of wire rope breakage increases sharply. If dynamic impact loads reach 1.5-2 times the static load (as specified in GB/T 3811-2008), the entire machine may overturn instantly, leading to casualties and equipment destruction.

2. Chain Disasters: From Localized Damage to Complete Collapse

Overloading not only endangers the crane itself but can also trigger a series of secondary disasters. For example, excessive loads may pull out embedded structural components or even cause floor slabs to crack. If the foundation's bearing capacity is insufficient, it may lead to ground collapse. Even more dangerously, the impact force of falling objects from height is catastrophic—a 10-ton load dropped from 20 meters releases energy equivalent to 3 kg of TNT. Additionally, the lateral impact force from swinging loads can reach up to 40% of the vertical load, further expanding the scope of the accident and causing even greater devastation.