Worker fatally injured when trapped in an elevated scraper

Possible control measures to prevent similar incidents

The Work Health and Safety Regulation 2011 provides specific duties for persons conducting a business or undertaking (PCBU), which involves management or control of plant - including requirements to manage the health and safety risks associated.

The person with management or control of plant at a workplace, must ensure maintenance, inspection, and if necessary, testing of plant be carried out by a competent person.

Before accessing any parts of the plant (including elevated scrapers) for cleaning, maintenance or repairs, all hazards must be identified and adequately controlled. Inspection should be conducted in accordance with a regular maintenance system to identify:

• potential problems not anticipated during plant design or task analysis
• deficiencies in plant or the equipment associated with use of the plant (for example wear and tear, corrosion, cavitation from oil leaks and damaged plant parts)
• adverse effects of changes in processes or materials associated with plant
• uneven ground or unloading / loading aprons
• inadequacies in control measures previously implemented.

Safe systems of work

A safe system of work should be implemented to manage the risks associated with the inspection and maintenance of the plant. The plant must be maintained and repaired according to the manufacturer’s specifications. If you identify deficiencies in the specifications, you should contact the manufacturer.

A safe system of work can include, but is not limited to:

When operating plant or machinery that use hydraulics:

• never place yourself or others in a position where you could be crushed if hydraulics fail, or they are inadvertently used.
  • When working on equipment, assess how it could shift if it were to move unexpectedly, and avoid working with any part of your body in the danger zone.
  • Find alternative ways to access the equipment to maintain it, keeping workers out of the danger zone.
• always read the instructions provided by the manufacturer and follow all safety directions, including:
  • the types of suitable supports needed to be put in place in accordance with manufacturers service procedures to prevent any movement that may cause risk to people preforming the work.
• if a back-up safety system is provided on the plant, ensure it has been correctly installed and is always in use before entering a high-risk zone.
• if a remote control or remote control panel is installed, ensure it is functioning as designed, has an e-stop, and is worn or used in a way that prevents accidental actuation of the remote controls.
• if a safety system is not provided on the machine, make sure you use an alternative system specified by the manufacturer or competent person.
• ensure workers working on, near, or under hydraulics are adequately trained and supervised. A safe work procedure should outline the potential risks of working on or near hydraulic equipment and the likely consequences of hydraulic failure.

Ensuring the plant, or part of the plant that could move, is adequately secured to prevent unexpected movement. This could include:

• installing mechanical locks to support parts suspended by hydraulic systems.
• using props, blocks, or chocks in accordance with the manufacturer’s safety instructions.
• using purpose-designed and engineered support stands, jigs, or cradles.
• Ensuring props, stands or other back-up support devices cannot be ejected if the hydraulics fail or move (e.g. this can occur if side loading is applied).
• warning alarms and hazardous area markings.

Consulting with the manufacturer, workers, and others involved in the work to obtain feedback on the plant’s associated work processes and safe work procedures.

• Ensure there is sufficient space for safe access to the plant for maintenance and repair activities.
• Never operate broken or worn equipment.
• Develop an isolation procedure (known as lock-out/tag-out) which should be followed by workers when they are required to perform maintenance, repair, and cleaning of plant.
  • Isolation procedures involve isolating potentially hazardous energy, so the plant does not move or start up accidentally.
  • Isolating plant may also ensure entry to a restricted area is controlled while the specific task is being carried out.
• Educate and train operators on how to use the plant (i.e., induct operators appropriately, including appropriate supervision for new operators). Additional training and supervision is needed for young or inexperienced workers.
• Consider the operating environment (i.e., wet weather, heat, cold, ground conditions).
• Ensure all energy sources are isolated where required prior to conducting work.

Any remaining risk must be minimised with suitable personal protective equipment (PPE). For example, providing workers with steel cap boots, high visibility vests and protective eyewear.

The control measures you put in place should be reviewed regularly to make sure they work as planned.