How Heavy Equipment Malfunctions Can Lead to Lawsuits Against Manufacturers

Construction sites are inherently dangerous, but some of the most devastating accidents are not caused by worker error or unsafe job-site practices. Instead, they occur when tools or heavy machinery fail, not because they were misused, but because they were defective from the start.

In these cases, families often assume that workplace injuries are only handled through workers’ compensation. However, when a defective crane, lift, saw, or other piece of equipment causes a catastrophic injury or wrongful death, the most responsible party is often not the employer; it’s the machine's manufacturer.

How Do Tools And Heavy Machinery Fail, Causing Catastrophic Injuries?

Construction tools and equipment are designed to lift, push, cut, transport, and move massive loads. When any part of this equipment is defective, the resulting injuries are rarely minor. They are usually catastrophic and often fatal.

Some of the types of defects that regularly lead to life-altering injuries include:

• Design flaws that make the machine inherently unstable or dangerous.
• Manufacturing defects such as faulty welds, poor-quality materials, or improperly assembled components.
• Failing or missing safety features, such as guards, latches, stabilizers, limit switches, or warnings.
• Improperly repaired or modified equipment, often involving defective replacement parts.

These failures can cause crushing injuries, amputations, falls from height, electrocutions, traumatic brain injuries, and spinal-cord damage. When a worker is killed or permanently disabled, families deserve answers and accountability.

What Is An Example Of A Preventable Heavy Equipment Malfunction?

A powerful example of how devastating equipment failures can be is a case handled by Ross Feller Casey founding partner Matt Casey, which resulted in a $19.5 million settlement for a severely injured worker.

Brian Smith, a 42-year-old truck driver for a masonry company, was delivering 3,500 pounds of concrete blocks to a residential construction site. Attached to his truck was a trolley boom lift, a crane system used to offload heavy materials. As Brian worked, he heard a strange creaking sound coming from the crane. Before he could react, the lift snapped in two, and a section of the crane came crashing down, striking him directly on the top of his head. The injuries were catastrophic, leaving him permanently paralyzed.

The most important fact in his case is that Brian’s employer did nothing wrong. The crane didn’t fail because of operator error, improper use, or unsafe site conditions. The crane failed due to a defect. Matt Casey filed a product liability lawsuit in the Philadelphia Court of Common Pleas against the crane’s manufacturer, the dealer who sold it, and the equipment’s owner. The lawsuit alleged that the crane had dangerous structural defects, lacked adequate safety features, and failed during normal operation, rendering it unreasonably unsafe.

Why These Cases Are Not Just Workers’ Compensation Claims

Families often believe that workplace injuries must be handled through workers’ compensation. But when the injury is caused by a defective tool or piece of machinery, the law works differently.

Workers’ compensation:

• Covers medical bills and a portion of wage loss
• Prevents workers from suing their employers
• Does not allow for pain and suffering damages

Product liability cases hold manufacturers, sellers, or distributors fully accountable and allow for significant compensation, including:

• Pain and suffering
• Lifetime medical care
• Home modifications
• Loss of earning capacity
• Loss of companionship
• Wrongful death damages

When a tool or machine is defective, the responsible party is often not the employer; it is the company that designed, built, sold, or distributed the dangerous equipment. That distinction can make the difference between limited compensation and true justice.

What Are The Common Types of Defective Equipment in Construction-Related Claims?

Some of the common types of defective equipment include:

• Cranes, boom lifts, and hoists
• Forklifts and telehandlers
• Scaffolding systems
• Power saws, nail guns, and drills
• Hydraulic lifts and jacks
• Heavy vehicles or attachments
• Temporary structures and lifting devices

Failures in these machines often occur without warning because the defect is hidden inside the equipment, out of workers' sight.

How Ross Feller Casey Helps Families Seek Justice

Ross Feller Casey is nationally recognized for handling catastrophic injury and wrongful death cases involving defective machinery. When we take on these cases, we:

• Work with engineering and safety experts
• Conduct detailed breakdowns of the equipment
• Investigate the design, materials, assembly, and maintenance history
• Identify defects that caused the failure
• Build a compelling case against manufacturers and distributors
• Fight for full, life-changing compensation for victims and families

Our results, including the $19.5 million crane-failure settlement mentioned, reflect our commitment to uncovering the truth and holding wrongdoers accountable.

A catastrophic equipment failure isn’t just a tragic event. It’s often a sign that something was fundamentally wrong with the machine. Families deserve answers, accountability, and the resources needed to rebuild their lives.

If you or someone you love was severely injured or killed by a tool or machinery malfunction, contact Ross Feller Casey today for a free, confidential consultation with a product liability attorney. We handle all our cases, including heavy equipment malfunctions, on a contingency basis. That means you will not pay anything until a financial recovery is made in your case.