IPAF Safety Alert | Learn from the Incident: Post-Maintenance Verification Is Critical
2026-07-22
The International Powered Access Federation (IPAF) has recently issued a safety alert to its members following an incident involving a Mobile Elevating Work Platform (MEWP). The case highlights a crucial lesson for the powered access industry: every maintenance task must be followed by thorough verification before the machine is returned to service.
Fortunately, no serious injuries were reported. The company involved responded promptly by conducting a comprehensive investigation and voluntarily sharing its findings with IPAF, enabling the entire industry to learn from the incident and strengthen safety practices.
RQ Parts
Incident Overview
A boom-type MEWP experienced an uncontrolled descent while in operation.
The investigation confirmed that the incident occurred shortly after the main boom lift cylinder had been replaced during maintenance.
Investigators discovered that a transport sealing plug had not been removed after installation (see Figure 1). The remaining transport seal may have compromised the integrity and sealing performance of the hydraulic connection.
Although the machine underwent routine inspections before being returned to service, the maintenance-related issue was not identified.
Figure 1 – Transport sealing plug left in place after installation
Key Lessons Learned
This incident reinforces several important safety principles:
- Replacement parts must be installed correctly and verified before equipment is returned to operation.
- Failure to complete or verify maintenance properly can introduce significant safety risks.
- Components supplied with transport sealing plugs should feature clear, permanent warning labels reminding technicians to remove them before installation.
- All maintenance procedures must strictly follow the manufacturer’s service instructions.
- Non-routine maintenance should only be carried out by qualified personnel with the necessary technical competence.
- Completed maintenance work should be independently verified whenever possible.
- Final inspections must confirm that all components are correctly installed, configured, and functioning as intended.
- Routine pre-operation inspections alone may not be sufficient to detect hidden defects introduced during maintenance.
Safety Recommendations for the Industry
Maintenance and repair activities should be treated as safety-critical operations, not simply routine service work.
To reduce the risk of maintenance-related incidents, organizations are encouraged to:
- Establish a structured post-maintenance verification process.
- Maintain complete maintenance and inspection records for traceability.
- Follow manufacturer instructions without deviation or shortcuts.
- Promote the sharing of incident investigations and lessons learned to improve safety across the powered access industry.
Final Thought
Every maintenance task has the potential to affect machine safety. A properly executed repair is only complete after it has been thoroughly inspected and verified. Robust post-maintenance verification not only protects operators but also helps prevent avoidable incidents and improves the overall safety standards of the powered access industry.
At RQ Parts, we believe that reliable replacement parts and proper maintenance procedures go hand in hand. We are committed to supplying high-quality aftermarket parts for Genie, JLG, Haulotte, Skyjack, Dingli and other MEWP brands, helping our customers maintain safe, reliable and efficient equipment throughout its service life.