A “Toolbox” for Forensic Engineers

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Failure Due to Manufacturing Faults 159 This type of failure could, and should, have been avoided if a solid rivet incorporating a shoulder or an external spacer had been used. 5.9 Scaffolding Guard Rail This case does not strictly belong in this chapter but litigation was already in progress to recover damages from a manufacturer on the grounds of product liability, when a metallurgical investigation revealed that an allegedly faulty casting was not responsible for a serious accident. The circumstances were that an installation engineer fell from a scaffold tower and suffered serious injury while installing an air conditioning unit in the roof space of a shopping mall. He was working from a demountable scaffold. These are structures that can be erected quickly by snapping together lengths of aluminum alloy tubes and frames (Figure 5.21). The tubes have a C-shaped hook at each end and are locked onto the frames by a spring loaded claw, so all that has to be done to erect the scaffold is to press the hook over a crossing tube so that the claw springs shut and holds the tube in position. To dismantle, a trigger is lifted that opens the claw so that the tube may be lifted off. The case pleaded was that the scaffold was defective in its material parts and was inadequate in that it was “of insufficient strength and made of unsound material,” despite the fact that such scaffolds were, and still are, widely used. The specific allegation was that the end of a claw at one end of the guard rail above the platform had broken off as the engineer leaned against it, due to a manufacturing defect. As a consequence of this sudden fracture the guard rail swung outward pulling the claw at the opposite end Figure 5.21 Aluminum scaffolding showing mode of construction.
160 Forensic Materials Engineering: Case Studies Figure 5.22 Broken claw at the end of the scaffold guard rail. off the side-frame. The tube followed him down to the ground, but the end broken off the claw casting was not recovered. Figure 5.22 and Figure 5.23 show two views of the broken claw as received, when a microsection had already been cut from the side of the fracture, and Figure 5.24 shows the unbroken claw at the opposite end. The claws were aluminum alloy casting welded to a length of alloy tube, which would be of different composition as it had been extruded, not cast. The surface of both castings exhibited numerous pin holes, caused by gas porosity. This is a fault that should not occur with good foundry practice but which is nevertheless sometimes found in small castings for general engineering purposes. Unlike shrinkage cavities in a casting, porosity does not have a marked weakening effect unless it is present in excessive quantities
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Library of Congress Cataloging-in-P
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Preface Case studies of product fai
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could not be simpler in shape, they
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Acknowledgments We thank The Open U
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The Authors Peter R. Lewis, Ph.D.,
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Laboratories of Imperial College of
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3 Establishing the Load Transfer Pa
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6.5.2 A Problem in Eire 197 6.5.3 M
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9.4.2 Failure in Femoral Stem of To
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13.3.7 Design Development Sequence
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Materials in Distress 2.1 Introduct
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Materials in Distress 27 It is usef
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Materials in Distress 29 (A) Unload
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Materials in Distress 31 1. Flowing
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Materials in Distress 33 to compens
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Materials in Distress 35 Fracture o
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Materials in Distress 41 somewhat b
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Materials in Distress 43 Figure 2.8
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Materials in Distress 49 Stress Amp
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Accidents in the Workplace 255 8 De
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A “Toolbox” for Forensic Engineers

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