Mobile Elevating Work Platforms (MEWPs)—including scissor lifts, boom lifts, and cherry pickers—are vital tools for safe access to work at height. However, when MEWPs fail, the consequences can be severe. Falls, entrapment, tip-overs, and equipment damage are just some of the risks that can arise.
In this post, we’ll explore the most common causes of MEWP failures, what they mean for site safety, and what you can do to prevent them through proper maintenance, inspection, and operator training.
What is a MEWP?
MEWPs are machines designed to lift personnel, tools, and materials to elevated work areas. They are governed under:
- PUWER (Provision and Use of Work Equipment Regulations 1998)
- LOLER (Lifting Operations and Lifting Equipment Regulations 1998) if used for lifting people
Routine inspections, planned maintenance, and safe operation are essential to ensure they function safely and reliably.
Common Causes of MEWP Failures
1. Hydraulic System Leaks or Failures
Hydraulic failure is one of the top mechanical issues affecting MEWPs. Causes include:
- Worn hoses and seals
- Contaminated hydraulic fluid
- Burst pipes due to pressure spikes
Risk: Sudden drop of the platform, uncontrolled movement, or complete loss of function.
2. Electrical or Control System Faults
Modern MEWPs rely heavily on electrical and sensor systems for:
- Emergency stops
- Limit switches
- Load sensors and tilt alarms
Common failures include water ingress, corroded connectors, or faulty switches.
Risk: The platform may become unresponsive, fail to stop at height limits, or give incorrect safety readings.
3. Structural Damage or Wear
This includes:
- Bent guardrails
- Cracked welds on booms or platforms
- Damaged outriggers or stabilisers
These often result from collisions, overloading, or improper use.
Risk: Structural instability can cause platform collapse, tipping, or operator injury.
4. Out-of-Date or Missed Inspections
MEWPs must be inspected regularly—typically every 6 months under LOLER if used to lift people.
Failure to do so can lead to:
- Undetected wear or damage
- Lapsed compliance
- Insurance invalidation
Risk: A mechanical failure that was preventable, and serious legal implications in the event of an accident.
5. Overloading or Misuse
Operators may exceed the Safe Working Load (SWL) or use the MEWP in conditions it was not designed for, such as:
- Rough terrain (when not rated for it)
- High winds
- Carrying tools or materials that exceed platform limits
Risk: Tip-overs, platform instability, or mechanical stress leading to failure.
6. Operator Error or Lack of Training
Even a perfectly maintained MEWP can become dangerous in the wrong hands.
Common mistakes include:
- Driving the MEWP elevated
- Ignoring alarms or bypassing safety systems
- Incorrect setup on slopes or unstable ground
Risk: Unsafe operation is one of the leading causes of MEWP-related incidents.
Prevention: How to Avoid MEWP Failures
- Stick to a Strict Inspection Regime
Schedule LOLER and PUWER inspections on time. Keep full maintenance records and act quickly on any defects reported. - Conduct Daily Pre-Use Checks
Operators should inspect MEWPs before every shift. Look for leaks, tyre condition, guardrail damage, and ensure controls function properly. - Only Use Trained Operators
Make sure operators are IPAF-certified (or equivalent) and competent for the specific type of MEWP they’re using. - Respect Load and Terrain Limits
Never exceed the SWL or use a MEWP in unsuitable environmental conditions. Always use the right machine for the job. - Service Equipment Regularly
Don’t wait for something to go wrong—planned preventative maintenance can catch small issues before they lead to big problems.
Final Thoughts
MEWPs are fantastic tools for safe work at height, but only when treated with the care and respect they require. Most MEWP failures are avoidable—caused by neglect, misuse, or lack of proper inspection.
Whether you operate a single lift or manage an entire fleet, staying proactive with maintenance and compliance is key to keeping your people safe and your operation running smoothly.
Need help with your MEWP inspections?
We provide thorough LOLER and PUWER inspections across all types of access equipment. Clear reports, fast service, and practical advice you can trust.
Contact us today to book your inspection or safety review.
