All industries

A 64-year-old cellar hand was performing routine duties at a winery. While preparing a batch of ‘brewer water’, a reaction occurred when Ammonium Bisulphite (ABS) and Tartaric Acid combined. This released hazardous sulphur dioxide and ammonia gas into the atmosphere. The fumes affected the cellar hand immediately. It also affected six other workers who experienced respiratory issues.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with the use of hazardous chemicals.

Assess and eliminate or control risks

Ensure:

• you are familiar with the ‘Managing risks of hazardous chemicals in the Workplace - Code of Practice’ which provides guidance on how to manage the risks associated with hazardous chemicals
• the manufacturer/importer’s information provided in the Safety Data Sheet (SDS) is available
• the SDS contains relevant information for guidance on managing risks of the hazardous chemical, such as:
  • hazards of the hazardous chemical
  • control measures for first aid, firefighting, accidental release and safe handling and storage
  • control measures to minimise exposure to workers
  • conditions to avoid in storage handling
  • potential incompatible products
• you maintain and monitor chemical storage containers and systems to ensure they are fit for purpose.

Develop and implement safe systems of work

When the risks of hazardous chemicals cannot be eliminated, you should:

• substitute hazardous chemicals for safer options where possible and consider their physical form, properties and concentration
• design systems to eliminate the risk of inadvertent mixing or interactions of incompatible chemicals
• ensure suitable storage facilities are provided and maintained e.g. isolation/segregates chemicals, extraction/ventilation, temperature management, bunded and protected from impact
• manage exposure standards of each hazardous chemical
• develop and implement documented procedures and make them available to workers (these should be developed with reference to the product’s safety data sheet)
• train workers in the proper handling and storage of chemicals, make them aware of the risks, and explain what to do if a leak, chemical reaction or exposure happens
• supervise workers when they are handling or storing hazardous chemicals
• regularly review and revise (as necessary) control measures to ensure they remain effective.

Ensure information is available for the storage and handling of chemicals by:

• clearly labelling all hazardous chemicals
• keeping a register that lists all the hazardous chemicals used, stored and handled in the workplace. This register must include the current safety data sheet for each chemical listed and must be available to everyone who may be affected by the hazardous chemicals
• displaying placards with information about the hazardous chemical to assist emergency services if stored hazardous chemicals exceed the ‘placard quantity’
• displaying safety signs near chemical handling and storage areas where required
• ensuring chemical storage containers and systems are maintained and monitored so they are fit for purpose
• ensuring fire extinguishers, suitable fire protection and firefighting equipment are available in areas where chemicals are used and stored.

Plan for emergencies

You should:

• have an emergency plan and first aid plan in place
• train staff in the emergency plan and first aid plan
• consult workers about the emergency plan and safety management system
• provide and clearly identity spill kits to manage any spills and leaks
• monitor workers’ health through a registered medical practitioner if they are likely to be exposed to hazardous chemicals
• immediately notify SafeWork NSW if a notifiable incident occurs
• immediately notify emergency services if a spill, leak or exposure occurs.

Related guidance material

• Code of Practice - Managing risks of hazardous chemicals in the workplace (PDF, 1171.43 KB)
• Code of Practice - Labelling of workplace hazardous chemicals (PDF, 1176.83 KB)
• Code of Practice - How to manage work health and safety risks (PDF, 556.72 KB)
• Hazardous chemicals - General requirements
• Placarding for storage of hazardous chemicals

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 24-year-old male worker was undertaking labouring duties for the installation of a new agricultural irrigation system at a farm site when he was tasked with ‘flushing’ the newly installed poly irrigation lines. Whilst undoing the clamps housing the pump filter, a solid plastic cap shot upwards under significant pressure, striking him in the mouth and nose area. He sustained substantial facial injuries.

Image of filter/pump being worked on. Clamps/bolts were being removed from the green sleeve clamp at the top.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with working with pressurised pumps, and with workers from culturally and linguistically diverse backgrounds.

Ensure:

• work should be carried out by a suitably qualified irrigation technician / plumber
• workers are provided documentation on control measures for isolating energy to the plant and equipment when undertaking cleaning, servicing, repairing, or alteration
• workers receive adequate training and instruction in the correct use of plant
• competency systems are in place and validated prior to workers undertake high risk work
• procedures are translated to the appropriate dialects within your workplace
• appropriate supervision is in place for new workers during plant use and maintenance activities
• safe work procedures are implemented and followed by all workers
• the work environment and task are assessed for potential risks prior to work being undertaken
• workers wear adequate personal protective equipment (PPE)
• emergency plans are prepared, maintained and implemented.

Related guidance material

• Plant, Equipment and Machinery Energy Isolation Guidelines (PDF, 10885.87 KB)
• Code of Practice - Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• SafeWork WHS Toolkit
• At Risk Workers
• Diversity in the workplace
• Pressurised pipe incident (29 November 2019)

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 74-year-old retired farmer sustained fatal injuries when he was found under two hay bales weighing approximately 600kg each. The bales fell from a truck whilst being unloaded at a rural property in Rand NSW.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with unloading heavy loads using mobile plant.

Ensure:

• in consultation with workers involved in the loading and unloading process, a detailed traffic management plan including clearly defined exclusion zones and procedures is prepared before the loading and unloading of hay bales
• the traffic management plan is enforced, a clear line of site is maintained between all workers and the activity is stopped if the line of sight is compromised
• the exclusion zones are maintained around mobile plant and if other persons enter the loading and unloading area, work is stopped immediately
• specific control measures are in place to remove the risk associated with falling hay bales while loading and unloading is being undertaken. For example, ensure workers are not on the opposite side of a trailer where the hay bales are being loaded or unloaded.
• workers have the necessary training, experience and supervision to identify hazards and control the risks associated with unloading heavy loads and the general operation of mobile plant
• care is taken not to dislodge other bales – when lifting bales across the surface of the bale below, this can lead to stacks becoming unstable
• stacks are always stable and checked regularly for movement.

Related guidance material

• Code of Practice – Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• Working with hay bales
• Safety around your vehicle glove box guide
• Equipment on farms
• Farm machinery Fact Sheet
• Safety around your tractor (PDF, 1674.31 KB)

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

An 82-year-old worker was undertaking farm work activities on a quad bike at a rural property near Moree in Northern NSW. The worker was found trapped under the quad bike that was rolled on its side. The worker sustained fatal injuries.

Photo shows the rolled quad bike at the location of the incident.

Safety Information

Consider ‘reasonably practicable’ control measures to manage the risks associated with quad bikes.

As a farm owner or farm operator you are responsible for anyone operating a quad bike at your workplace. You must identify the risks associated with quad bike use and do what you are reasonably able to do to eliminate those risks.

Ensure:

• you choose the right vehicle for the job
• an operator protective device (OPD) (also referred to as a crush protection  device or roll bar) is installed when purchasing the vehicle and the device is maintained and never removed from the vehicle
• you protect your head and always wear a helmet
• tell someone where you are going and when you plan to return
• choose the safest route, look out for obstacles and consider the slope of the terrain
• if you cannot see what the ground conditions are like, get off and walk around the area before you drive over it
• regularly check the tyre pressures
• balance your load, keep it low and make sure it is securely strapped down
• follow load limits stated in the owner’s manual
• the rider is trained and capable to safely operate and maintain the quad bike
• no children under 16 rides on adult sized quad bikes – even as a passenger
• the quad bike is serviced and maintained as per the manufacturers owner’s manual.

Statistics

Quad bikes continue to be the biggest killer on Australian farms, with rollover the most common cause of death. Over 80% of quad bike fatalities in NSW are due to quad bike roll over.

Farm owners and operators must be aware that quad bikes are high risk vehicles and are not safe for use on all terrains or for all tasks.

Rollover can occur suddenly, even at low speeds and on flat terrain, putting the operator at risk of injury or death from being thrown from the vehicle, trapped, or crushed beneath it.

Related guidance material

• Code of Practice – Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• Quad Bike safety
• Quad bikes & side-by-side vehicles
• Quad bikes and SSV training
• Farm vehicle pre-purchase checklist (PDF, 56.87 KB)

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 43-year-old worker was seriously injured whilst undertaking maintenance work on an auger. The worker’s hand became entangled and was partially amputated.

Safety information

Auger intakes and harvesting machinery can cause serious and fatal injuries if not used safely. Consider ‘reasonably practicable’ control measures to manage the risks associated with the use and maintenance of augers.

Install machine guarding

Ensure:

• all moving parts including, but not limited to, the auger screw, drive belts, pulleys, chains, sprockets and drive shafts are fully guarded, including back guarding to prevent contact from behind
• there is a correctly fitted intake guard installed
• at the infeed end of the auger, a permanently fixed inner guard is installed over the flight (screw). An outer guard should be installed over the auger’s flight when it is not being used in a silo, grain bin or a guarded hopper
• all machine guarding is compliant with Australian Standard AS 4024
• an emergency stop button is easily accessible near the auger inlet.

Implement and follow safe systems of work

Ensure:

• workers receive adequate training and instruction in the correct use of the machinery and auger
• workers are supervised during machinery use and maintenance activities
• safe work procedures are implemented and followed by all workers
• the auger is only used in line with the original manufacturer’s specifications
• the work environment and task are assessed for potential risks prior to work being undertaken
• when moving grain augers always check for overhead power lines
• an exclusion zone is enforced around the auger during use
• workers wear adequate personal protective equipment (PPE)
• emergency plans are prepared, maintained and implemented.

Perform regular maintenance

Ensure:

• the auger is inspected by a competent person prior to use. Any defects identified must be reported and rectified before use
• the auger is maintained in line with the original manufacturer’s specifications
• isolation and a lock out/tag out system is implemented when performing maintenance and cleaning and guards are replaced before the auger is restarted
• a suitable blockage clearing device that is designed for the purpose is provided. Do not use hands, feet or other objects to clear blockages.

Related guidance material

• Managing the risks of plant in the workplace - Code of Practice
• Plant, machinery and equipment
• Equipment on farms
• How to use machine guarding - SafeWork NSW YouTube
• Australian Standard AS 4024

Further information

• Traumatic event management plan – SafeWork NSW
• Speak Up Save Lives App – SafeWork NSW
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

Side-by-vehicles have been involved in several incidents resulting in serious injuries and fatalities. Using a correctly fitted seatbelt, wearing a helmet and closing the door or cab net could save your life.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with operating Side-by-side vehicles.

Ensure:

• you choose the right vehicle for the task and terrain
• operators have adequate information, training, instruction and supervision to safely operate and maintain the vehicle as well as understand the risks associated with using these vehicles
• seatbelts are worn (including passengers)
• helmets are worn (including passengers)
• doors / cab nets are closed
• only suitable attachments are used (follow manufacturers recommendations)
• safe operating procedures are followed (available from manufacturer)
• the key is removed and stored away from children when not in use
• the vehicle is regularly maintained and used in accordance with manufacturers’ instructions
• you never allow kids under 16 to operate an SSV
• you never exceed load limits
• you never carry passengers in the rear cargo tray.

Statistics

Since July 2023 there have been nine incidents involving side-by-side vehicles resulting in fatal or serious injuries.

Related guidance material

• Side-by-side vehicle fact sheet
• Quad bikes and side-by-side vehicles
• Side-by-side vehicle safety
• SSV Seat Belt Safety - YouTube
• Farm vehicle pre-purchase checklist

Further information

• Traumatic event management plan – SafeWork NSW
• Speak Up Save Lives App – SafeWork NSW
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 41-year-old worker was undertaking flood remediation work on an access road using a 2.5 tonne tandem drum roller to compact road base. As he was operating the roller on the slope parallel to the road the roller slid, partially crushing him as it turned over. The worker suffered severe crush injuries and was ejected approximately 5 metres from the overturned roller.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with using mobile plant.

Ensure:

• safe systems of work are established and maintained in relation to the use of mobile plant
• site conditions are assessed for potential hazards before commencing any work. For example, a competent person should assess ground conditions and put systems in place to eliminate or minimise (if not reasonably practicable to eliminate) the site-specific risks,  so far as is reasonably practicable
• only mobile plant that is specifically designed for the work task is used
• operators are provided with information, training and instruction so they are competent in the correct use of the mobile plant
• mobile plant and machinery are only operated within the design limits as prescribed by the original equipment manufacturer (OEM)
• a safe system of work is developed and followed by all workers. The system of work must detail the:
  • tasks to be performed
  • how the tasks are to be performed
  • the location of the tasks.
• suitable safety devices to protect operators are installed, used, and maintained. For example, seatbelts
• plant and machinery are inspected, tested and maintained in accordance with the manufacturer’s recommendations
• an emergency response plan is in place and has been specifically developed for the task
• mobile plant is securely stored when not in use to prevent unauthorised access or use.

Related guidance material

• Code of Practice: Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• Code of Practice: How to manage work health and safety risks (PDF, 556.72 KB)
• Code of Practice: Managing the work environment and facilities (PDF, 422.29 KB)
• General guide for managing the risks of machinery in rural workplaces - Safe Work Australia

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 20-year-old casual worker who was collecting and analysing grain samples became seriously injured when a newly purchased petrol-powered generator exploded. The explosion happened while the generator was being refuelled with a jerry can. The generator was expected to operate consistently for 14 hours and required refuelling about every 2 hours to constantly power a demountable office building and its equipment. The fire destroyed the generator and the demountable office building, and the young worker sustained severe burns to her face and body.

Photos of the burnt generator and demountable office building.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with generator refuelling.

Ensure:

• a risk assessment is undertaken to ensure control measures are in place to eliminate any heat and possible ignition sources and control the accumulation of flammable and combustible substances when refuelling
• prior to refuelling, the engine and all electrical equipment are turned off and the  engine allowed to cool as per the manufacturer’s instructions
• you follow manufacturer's recommendations, and operating procedures
• you establish designated refuelling areas on firm ground or earth and in a well-ventilated location
• you have suitable firefighting equipment in good working order that is easily accessible
• you use approved fuel containers and funnels to reduce the risk of generating   static electricity while decanting petrol
• you provide instruction, training and supervision to all workers on the safe use, storage and handling of hazardous chemicals
• you wear appropriate personal protective equipment for the task.

Related guidance material

• Flammable substances
• Code of practice: Managing risks of hazardous chemicals in the workplace (PDF, 1171.43 KB)
• Managing risks of hazardous chemicals in the workplace - Safe Work Australia
• Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• Hazardous chemicals

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

Auger intakes and harvesting machinery are a major cause of harm and injury. There have been two recent incidents in the agriculture industry involving young workers who suffered serious injuries after becoming entangled in unguarded augers. Young workers (aged up to 25) are considered a group of workers who are at increased risk in the workplace and require additional consideration when managing health and safety.

Grafton

28 July 2023

A 21-year-old worker was monitoring the flow of grain in an unguarded auger at a cattle farm when her hand became entangled in the auger. The worker suffered severe injuries to her right hand including a severed finger and significant damage to other fingers.

Walgett

6 August 2023

A 17-year-old worker was operating a grain mill at a feedlot when his foot became entangled and pulled into the moving auger. Emergency services attended site and cut the outer casing of the auger to free the worker’s foot. The worker suffered serious injuries to his foot.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with working near augers.

Ensure:

• parts of the auger that can cause injury are adequately guarded
• when access is not required during operation, maintenance or cleaning, the guarding is a permanent fixed barrier
• when access is required during operation, maintenance or cleaning, the guarding is an interlocked physical barrier that prevents access during operation of the plant
• if either of the above are not reasonably practicable, the guarding is a physical barrier that can only be removed using a tool, otherwise a presence-sensing safeguard system is used
• isolation and lock out/tag out systems are implemented when non-permanent guards are removed for maintenance and cleaning purposes and guards are replaced before the auger is restarted
• a suitable blockage clearing device is provided. Do not use hands or feet to clear blockages
• emergency stops are installed, clearly and durably marked, accessible and tested so they remain effective
• emergency plans are prepared, maintained and implemented
• adequate training and instruction is provided to all workers for the safe use of powered plant
• adequate supervision of young and inexperienced workers
• suitable communication systems are in place.

Related guidance material

• Managing the risks of plant in the workplace - Code of Practice (PDF, 1987.96 KB)
• Tools for employers to train and supervise young workers
• Safety first on farm a must to stem injuries
• Grain Safe fact sheet
• Equipment on farms
• How to use machine guarding - SafeWork NSW YouTube
• The A-Z of farm safety guide (PDF, 5673.78 KB)

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 40-year-old worker died when the tractor he was driving rolled shortly after crossing a cattle grid in Western NSW.

Safety information

Farmers and farm workers are at risk of fatal or serious injury operating or working with tractors, implements and attachments.

Ensure:

Consider these ‘reasonably practicable’ control measures to manage the risks associated with tractors:

• before using a tractor with an attachment consider the risks to the operator, machine and environment in which it will operate
• attachments used on the tractor are:
  • designed for the task being carried out
  • installed and secured to the item of plant in accordance with manufacturer’s instructions
  • suitable for the load being moved or lifted
  • regularly inspected and maintained in accordance with the manufacturer’s instructions
• tractors between 560 and 15,000 kgs must be fitted with an approved Roll Over Protective Structure (ROPS)
• seat belts should be worn at all times when operating a tractor
• tractor operators are trained and competent in the correct use of the tractor and any attachments, and have access to all relevant safety information provided by the manufacturer.

Related guidance material

• Managing the risks of plant in the workplace - Code of Practice (PDF, 1987.96 KB)
• Virtual Farm Safety
• The A-Z of farm safety guide – SafeWork NSW (PDF, 5673.78 KB)
• Safety around your tractor (PDF, 1674.31 KB)
• General guide for managing the risks of machinery in rural workplaces - Safe Work Australia
• Farm Safety Advisory Program

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 67-year-old owner of an olive farm in Bumbaldry sustained fatal injuries when he was crushed between the hydraulic clamp of an olive harvester.

The olive harvester at the incident scene

Safety information

Many farm-related fatalities involve harvesting machinery. Consider ‘reasonably practicable’ control measures to manage the risks associated with the use of farm machinery.

Ensure:

• you establish and maintain agreed safe systems of work in relation to the use and operation of the machinery
• plant is properly immobilised, for example parked on a flat, level, hard surface, park brake engaged, ignition turned off and keys removed. Never attempt to access the plant or vehicle if it starts to roll
• bollards, barriers, safety rails and exclusion zones are in place to separate people from moving plant and vehicles
• the surrounding areas are inspected, and any potential risks such as over-head power lines and uneven ground are identified, and control measures are implemented to minimise the risk
• before operating the plant, look in all directions for people and be aware of the exclusion zones
• plant and machinery are inspected, tested and maintained in accordance with the manufacturer’s recommendations
• workers have the necessary training, experience, and supervision to identify hazards and control risks associated with carrying out maintenance on machinery
• adequate lighting is available to enable the task and any machine maintenance to be carried out safely.

Related guidance material

• Managing the risks of plant in the workplace – Safe Work Australia
• Guide for managing the risks of machinery in rural workplaces – Safe Work Australia
• How to manage work health and safety risks – Code of Practice (PDF, 556.72 KB)
• The A-Z of farm safety guide – SafeWork NSW (PDF, 5673.78 KB)
• Farm safety self-assessment (PDF, 478.11 KB)

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 42-year old worker was undertaking embankment remediation work from a boom-type elevating work platform (EWP) when he was hit by a tree, causing him to be catapulted from the platform. The worker fell approximately 11 metres to the ground. The worker was wearing a fall arrest harness but the lanyard was not connected to the anchor point on the work platform.

EWP on embankment and a close-up of damage to the work platform

Safety information

In Australia, you need to be authorised by a high-risk work licence to carry out high-risk work. High-risk work includes operating specified machinery, including boom-type elevating work platforms (WP) where the boom length is 11 metres or more.

Consider ‘reasonably practicable’ control measures to manage the risks associated with working from heights including work from an elevated work platform.

Ensure:

• the right EWP is chosen for the job and only use it for the purpose it was designed
• the rated capacity of the EWP is not exceeded
• information, instruction, and training is provided to workers who use EWPs
• workers are trained in emergency procedures so occupants can be rescued in the event of an emergency
• workers hold a current high-risk work licence for boom type elevating work platforms where the boom length is of 11 metres or more
• a prestart (pre-operational) inspection is carried out and information in the logbook is verified
• operational checks are carried out to ensure the EWP is safe to use
• the ground conditions are suitable for ensuring the stability of the EWP, including operating on inclines
• hazards associated with working from an EWP are identified and risks are eliminated where reasonably practicable. To help you do this, complete a safe work method statement (SWMS) in consultation with others to ensure all hazards and risks are accounted for
• EWPs are not operated if wind speed rating exceeds the maximum limits (as shown on the compliance plate)
• a safety harness is worn at all times and the lanyard is attached to a designated anchor point on the EWP
• safe distances are maintained when working near overhead electric lines
• exclusion zones are set up to keep the EWP separated from pedestrians, other workers, and traffic including other mobile plant
• EWP is regularly inspected and maintained.

Related guidance material

• Managing the risks of falls at workplaces - Code of Practice (PDF, 2326.56 KB)
• Managing the risks of plant in the workplace – Code of Practice (PDF, 1987.96 KB)
• High risk work licenses – SafeWork NSW
• AS2550.10 Cranes, Hoists and Winches - Mobile elevating work platform – Safe use – Australian Standard
• AS1418.10 Crane, Hoists and Winches - Mobile elevating work platforms – Australian Standard

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 28-year-old farm worker suffered fatal injuries when the backhoe he was operating slid approximately 2 metres into a culvert and landed on its side. The worker was ejected from the machine and pinned under the cabin structure.

Safety information

Many farm related fatalities involve tractors, agricultural equipment and earth moving machinery. Consider ‘reasonably practicable’ control measures to manage the risks associated with the use of farm machinery and isolated or remote work.

Ensure:

• there are systems in place to ensure the health and safety of workers performing remote or isolated work
• site conditions are assessed for potential hazards i.e., ground conditions and systems are in place to eliminate and/or manage the site-specific risks
• appropriate machinery is selected for the job task
• a work plan is developed and is followed by all workers. The work plan must detail the:
  • tasks to be performed
  • how the tasks are to be performed
  • the location of the tasks.
• workers are trained and competent in the use of plant and machinery
• safety devices such as seatbelts are fitted to plant and utilised as part of the safe system of work
• an emergency response plan is in place
• plant and machinery are regularly inspected and maintained by a competent person
• plant is properly immobilised e.g., parked on a flat, level, hard surface, park brake engaged, ignition turned off and keys removed. Never attempt to access the plant or vehicle if it starts to roll
• plant is securely stored when not in use to prevent unauthorised access or use.

Related guidance material

• How to manage work health and safety risks – Code of Practice (PDF, 556.72 KB)
• Managing the work environment and facilities – Code of Practice (PDF, 422.29 KB)
• Managing the risks of plant in the workplace – Model Code of Practice
• Farming safety resources
• Farm safety self-assessment (PDF, 478.11 KB)
• Guide for managing the risks of machinery in rural workplaces
• The A-Z of farm safety guide (PDF, 5673.78 KB)
• Remote or isolated work – safety information
• Incident information release – Bogged farm machinery fatality

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A truck driver has sustained serious injuries when struck by a hay bale weighing approximately 570kg. The bale fell from a truck whilst being unloaded at a rural property in Aberfoyle.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with unloading heavy loads using mobile plant.

Ensure:

• plant and machinery are designed for the task, and regularly inspected, tested and maintained in accordance with the manufacturer’s recommendations
• a detailed traffic management plan including the establishment of a clearly defined exclusion zone and procedures is implemented and enforced
• workers have the necessary training, experience and supervision to identify hazards and control the risks associated with unloading heavy loads and the general operation of mobile plant
• hay bales are never stacked higher than the lifting capabilities of the handling equipment being used
• to never load more bales onto handling equipment, to a height higher than the equipment is designed to handle, nor heavier than the rated capacity of the machine
• care is taken not to dislodge other bales – when lifting bales off a stack and reversing away, ensure that the bales are well clear before moving – do not ‘drag’ the bale across the surface of the bale below, this can lead to stacks becoming unstable
• stacks are always safe and checked regularly for movement
• bales are never removed from the bottom of overlapping layers, leaving overhanging bales unsupported
• a safe means to access the stack is always used.

Always remember – falls from stacks may occur during destacking. This can be caused by trying to free jammed bales, picking up bales with broken strings, and falling from edges. When destacking, plan the work to avoid incidents like these

Related guidance material

• Working with hay bales – WorkSafe QLD
• Safety around your vehicle – Glove Box Guide – SafeWork NSW (PDF, 1466 KB)
• Traumatic event management plan – SafeWork NSW

Further information

• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 33-year-old farmer sustained fatal head injuries during the extraction of a bogged bulldozer at his neighbour’s farm in Regional NSW. He had been assisting his neighbour with the extraction when one of the two D-Shackles connecting the recovery strap failed and was propelled through the glass door of the bulldozer.

An example of bogged farm machinery.

Safety information

There have been multiple fatal incidents involving the extraction of bogged agricultural plant in NSW over the past 12 months. The incidents involved the failure and subsequent propulsion of recovery straps and/or equipment through the windscreen of the plant during the attempted extraction.

Farming accounts for one in every five worker deaths. Reduce the risk to workers and others involved in vehicle and farm equipment recovery by:

• assessing the work environment and conditions prior to commencing work
  • avoid using vehicles and farm equipment if there is a likelihood of becoming bogged
  • postpone the work until conditions improve
• creating an exclusion zone around the vehicle or piece of equipment during the recovery activity
  • only the vehicle operator and those necessary in the recovery should be allowed inside the exclusion zone
  • ensure an effective communication method is established between them (voice, radio, hand signals)
• ensuring anyone within the exclusion zone is standing at 90 degrees to the axis of the tow line
  • do not stand at either end of the tow line as you are at higher risk of injury if the tow line breaks
• only using straps and attachments that are correctly rated for the weight and type of work involved
• using a recovery damper to reduce the force of the recoil and risk of injury if the recovery line does break
• only using anchor points on vehicles and machinery approved by the manufacturer
• aborting the extraction of the bogged vehicle or equipment if things are not going to plan
• choosing plant with laminated glass and external structural protection where available
  • consult the original equipment manufacturers (OEMs) for tougher glass options and operator cabin protection in mobile plant
• only using well maintained and approved equipment in line with the manufacturer’s instructions
• performing a risk assessment before attempting any vehicle or equipment recovery
• ensuring you have an emergency procedure in place.

Related guidance material

• Managing the risks of plant in the workplace – Code of Practice (PDF, 1987.96 KB)
• Safety around your vehicle (SAYV) glove box guide
• WHS duties in the agricultural industry – Safe Work Australia

Further information

• Traumatic event management plan
• Mental health at work
• Speak Up Saves Lives app
• Subscribe to SafeWork NSW newsletters and updates

Download this Incident Information Release (PDF, 271.68 KB)

A 45-year-old worker sustained serious injuries whilst undertaking engine repairs underneath a front-end-loader at a property located in Euabalong. The hydraulic jacks beneath the loader gave way, pinning the worker at the pelvis and hips.

Safety information

Incidents involving farm vehicles are a major cause of injury and death in the agriculture industry. Vehicle related incidents involve rollovers, vehicles running over people and incidents caused by unsafe maintenance activities.

Implement ‘reasonably practicable’ control measures to manage the risks related to working around farm vehicles.

Ensure:

• if plant is not in use, it should be stored so it does not create a risk to workers or other people in the workplace
• plant and machinery are inspected, tested and maintained in accordance with the manufacturer’s recommendations
• any inspection, maintenance or testing is carried out by a competent person
• control measures are implemented to eliminate, or if that is not reasonably practicable, minimise the:
  • risk to health and safety of people during storage. For example, release stored energy, lower moving parts that fall under gravity and provide support to prevent toppling
  • risks of damage to plant during storage. For example, risks may arise from corrosion because of exposure to residues of hazardous substances and deteriorating consumables
• the surrounding areas are inspected, and any potential risks are identified, and control measures are implemented to minimise the risk
• the worker does not place themselves in a position where they are at risk of serious injury
• workers have the necessary training, experience, and supervision to identify hazards and control risks associated with carrying out maintenance on heavy machinery.

Related guidance material

• Managing the risks of plant in the workplace – Safe Work Australia
• Guide for managing the risks of machinery in rural workplaces – Safe Work Australia
• The A-Z of farm safety guide (PDF, 5673.78 KB) – SafeWork NSW
• Refer to the Operators Manual provided by the plant manufacturer.

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

Download this Incident Information Release (PDF, 386.18 KB)

A 22-year-old farmhand was preparing animal feed in the bucket of a front-end loader when the loader moved forward crushing the farmhand between it and the pallets of packaged mineral supplement.

Machinery accounts for a high proportion of farm injuries or fatalities with tractor accidents being highly represented in farm injury and fatality statistics.

Implement ‘reasonably practicable’ control measures to manage the risks related to working with and around farm machinery.

Make sure:

• plant and machinery are inspected, tested, and maintained in accordance with the manufacturer’s recommendations
• any inspection, maintenance or testing is completed by a competent person, and recorded for future reference
• workers have the necessary training, experience and supervision to identify hazards, and control the risks associated with the uncontrolled movement and general operation of mobile plant.

Before operating mobile plant, you:

• must be trained and deemed competent to operate the mobile plant – make sure you understand the operating controls, and the manufacturer’s instructions on safe operation and maintenance
• should always conduct pre-start and operational safety checks to confirm the mobile plant is safe to operate, including testing braking systems.

Related information

• Managing the risks of plant in the workplace – SafeWork NSW Code of Practice
• Managing the risks of machinery in rural workplaces – SafeWork Australia
• The A-Z of farm safety – SafeWork NSW
• Farm machinery fact sheet – SafeWork NSW
• Refer to the Operators Manual – provided by the plant manufacturer

Download this Incident Information Release as a PDF (PDF, 506.06 KB)

A 19-year-old farm worker sustained fatal injuries in a quad bike roll over incident. The incident occurred while maneuvering through a grassed creek. The worker had been tasked with spraying thistles from the quad bike.

Quad bikes continue to be the biggest killer on Australian farms, with roll over the most common cause of death. Over 80% of quad bike fatalities in NSW are due to quad bike roll over.

Farm owners and operators must be aware that quad bikes are high risk vehicles and are not safe for use on all terrains or for all tasks.

Before using a quad bike at your workplace:

• choose the safest vehicle for the job - ensure a quad bike is appropriate for the task, terrain, and the rider
• install an operator protection device (OPD), also known as a roll bar to your quad bike
• tell someone where you are going and when you plan to return – carry a communication device
• check weights and positioning of items being transported
• stabilise loads and consider using internal baffles in tanks to reduce the movement of liquid
• check the tyre pressure before use and at regular intervals
• use and maintain the quad bike in accordance with the manufacturer’s instructions
• assess the environmental conditions and be aware of long grass, rocks, trees, fallen branches, creeks, and gullies, and where the ground is soft or affected by weather or other conditions
• ensure the rider is trained and capable to safely operate and maintain the quad bike
• ensure no children under 16 ride on adult sized quad bikes – even as a passenger.

When using a quad bike at your workplace:

• wear a compliant helmet and other personal protective equipment such as goggles and sturdy footwear
• ride at a speed suitable for the conditions
• avoid traversing on steep, uneven, or slippery terrain.

More information

• Quad Bike Safety - SafeWork NSW
• Quad Bike Side by Side Vehicles – SafeWork NSW
• Quad Bike Safety Rebate Program – SafeWork NSW
• Quad Bike and Side by Side Vehicle Training Program – SafeWork NSW
• Quad Bike Workplace Safety Survey Study - UNSW

Download this Incident Information Release as a PDF

A grain farmer received serious injuries when he fell approximately 10 metres from the top of a silo. New silos had been installed at the property and a witness report indicates that the farmer was releasing the lid on the first silo when he attempted to jump to the second silo and fell.

Top of silo and access lid

Access ladder of top of silo

Safety information

Incidents of falls when moving between two silos can be prevented by providing safe elevated access between the silos, such as a fixed walkway with suitable guardrails or enclosure. Alternately, the silos could be positioned far enough apart that jumping between them is not possible.

This is a timely reminder that work on or around silos is dangerous. For more information on general silo safety please visit the SafeWork NSW Silo Safety webpage.

Statistics

Falls from silos, windmills, buildings and machinery during maintenance and harvest are among the main causes of death and injury on farms. 30 people have died on Australian farms in the last decade falling from heights. Don’t take chances, always be safe working at heights.

More information

• Managing the risks of falls at workplaces – Code of Practice
• Silo safety – Falls from heights video – SafeWork NSW
• Silo safety self-assessment checklist - SafeWork NSW

Download this Information Incident Release as a PDF

A 19-year-old worker was struck by a forklift while assisting to collect chickens within a poultry shed. The forklift was moving forward carrying a module of cages in front of the cabin when it struck the worker. The worker sustained fatal injuries as a result of the incident.

Consider ‘reasonably practicable’ control measures to manage the risks associated with operating forklifts.

Businesses:

• separate people from moving forklifts, using barriers or guardrails
• if you cannot physically separate forklifts from people, designate exclusion zones
• if your forklifts do not have safety features, consider retro-fitting warning devices like forklift-to-worker proximity sensors, reverse lights, reverse sensors, flashing lights, beepers, quackers and focus beams
• ensure all workers operating a forklift have the appropriate high risk work licence and have received training on the type of forklift they are using
• if lighting levels in the work environment are poor, consider fitting additional lighting to the forklift
• talk to all workers - including operators and those who work near forklifts - about how to work safely around forklifts
• ensure workers are wearing high visibility clothing and using other appropriate personal protective equipment.

Forklift operators:

• before moving your forklift, look in all directions for people
• be aware of exclusion zones and pedestrian walkways
• ask about fitting safety or proximity warning devices to your forklift
• always look in the direction of travel and keep your forks lowered
• if the load obscures your view, drive in reverse
• if your vision is restricted, or if travelling in reverse is not practical, use a trained spotter and ensure that you cease operation if the spotter disappears from view
• do not use headphones or operate electronic devices such as mobile phones while operating the forklift.

When working near forklifts:

• always keep a safe distance
• do not work between the path of the forklift and a fixed object even if the park brake is applied
• stay on pedestrian pathways and/or exclusion zones
• be aware that a forklift operators’ field of vision is obscured – don’t assume they have seen you
• wear a forklift-to-worker proximity warning device, if available
• wear high visibility clothing and other appropriate personal protective equipment.

Statistics

Every year forklifts cause workplace deaths and injuries resulting in substantial financial and human costs for workers, industry and the community. The three main reasons workers are killed or seriously injured in forklift incidents are:

1. being hit or crushed by a forklift
2. being hit or crushed by a load that the forklift is moving
3. being crushed in a forklift tip-over.

More information

• Code of practice – Managing the risks of plant in the workplace (PDF 1.5MB)
• Industrial lift trucks guidance material - Safe Work Australia
• Workplace traffic management guidance material - Safe Work Australia
• Forklift safety information – SafeWork NSW

The following incident occurred in October 2020 at a poultry farm:

• Incident Information Release – Fatal telehandler incident

A farm worker died after he was run over by a 3-tonne telehandler as it was reversing. The telehandler operator was transporting straw bales from a stack into a straw chopper located near a poultry shed.  As the operator reversed to pick up another bale from the stack, the worker was run over by the telehandler.

Site specific traffic management control measures must be implemented to manage the risk of mobile plant causing harm to pedestrians.

Keep people and vehicles apart. Have clearly defined pedestrian only spaces and vehicle only spaces, by:

• implementing fixed and secured barriers that prevent people accessing vehicle only areas,
• defining pedestrian areas through permanent or temporary barriers or markings, or
• use high impact traffic control barriers e.g. bollards or temporary structures.

If it is not reasonably practicable to separate people and vehicles, implement additional controls to minimise the risks such as:

• using devices like reversing sensors, reversing cameras, mirrors, rotating lights or audible reversing alarms
• have a spotter direct the reversing vehicle (the spotter must remain in visible contact with the driver at all times)
• provide clearly identified designated reversing areas
• restrict the use of mobile phones by drivers and pedestrians.

Develop a traffic management plan for the site which covers controls and procedures. Further to that, train, instruct and supervise your workers on the traffic management plan.

More information

Code of practice – Managing the risk of plant in the workplace (PDF 2.1MB)

Workplace traffic management guidance material - Safe Work Australia

Plant: Your health and safety guide (PDF 520kb) – WorkSafe Victoria

A 52-year-old worker was killed while conducting minor maintenance works on a home-made front tank attachment on a tractor. Initial inquiries indicate the worker was crushed when the attachment, suspended by the tractor, shifted, resulting in a partial failure of the welded area.

Safety information

You must consider ‘reasonably practicable’ control measures to manage the risks associated with working with tractors and attachments, including:

• assessing the risks associated with each attachment used on the tractor
• planning and selecting the correct equipment or attachment for the task
• ensuring any attachments used on the tractor are:
  • designed for the task being carried out
  • installed in accordance with the supplier or manufacturer’s instructions
  • suitable for the load being moved or lifted
  • regularly inspected and maintained in accordance with the manufacturer’s instructions
• establishing safe systems of work for inspecting or working underneath a tractor including lowering any moveable attachments to the ground or blocking the attachment
• ensuring any work or modification to the tractor is designed and carried out by a competent person
• ensuring tractor operators and those making modifications are trained and competent in the correct use of the tractor and any attachments, and have access to all relevant safety information provided by the manufacturer.

More information

• Safe design and operation of tractors – Code of practice [PDF 512 kb]
• Managing the risks of plant in the workplace - Code of practice [PDF 2.1MB]
• Tractor safety precautions
• Safe use of tractors with attachments [PDF 5.5MB]
• Guide for managing the risks of machinery in rural workplaces
• ISO 6746-2 Earth-moving machinery – Definitions of dimensions and codes – Part 2: Equipment and attachments

A worker sustained serious injuries while operating a roller-compactor at a rural property in the Hunter Valley when the vehicle rolled over. The roller-compactor was fitted with a rollover protection system, however the worker was not wearing a seatbelt and was ejected from the cabin through the front windscreen.

Vehicle rollovers are one of the highest causes of fatalities in the agricultural industry. Businesses must implement ‘reasonably practicable’ control measures to manage the risks associated with the rollover of vehicles such as tractors and earthmoving machinery.

• Fit mobile plant with operator protective devices in accordance with the Work Health and Safety Regulation 2017. Operator protective devices include; a Rollover Protective Structure (ROPS), a Falling Object Protective Structure (FOPS), operator restraining devices and seatbelts
• Ensure mobile plant operators always wear a seatbelt while operating the machinery, to keep the operator within the protected ROPS/FOPS
• Consider the installation of warning devices and ignition interlocks for seatbelts in mobile plant
• Regularly inspect the ROPS/FOPS for rust, cracks, fatigue and deformation and replace any equipment showing any indication of reduced structural integrity
• Never modify the structure of the ROPS/FOPS (e.g. weld or drill) because it could undermine its structural integrity.

More information

• Code of Practice – Safe design and operation of tractors (PDF 511KB)
• Code of Practice – Managing the risks of plant in the workplace (PDF 2.1MB)
• Agriculture work health and safety sector plan
• Small business safety rebate program

A worker suffered fatal injuries and a second worker attempting a rescue was rendered unconscious as a result of lack of oxygen, when conducting cleaning operations inside the confined space of a molasses tank at a rural property.

Site of incident incident molasses tank with (390mm) access hole

Safety information

Farm work may involve accessing confined spaces including various types of tanks, silos, and pits. Common hazards associated with working in tanks are:

• organic materials that ferment and result in oxygen depletion such as molasses
• using petrol or diesel motors inside tanks that generate toxic carbon monoxide

Warning! If someone collapses when working inside a tank, it is important to assess the risks before attempting to rescue them. A high number of people who die in confined spaces are the rescuers. If an incident occurs get help. Do not attempt a rescue without knowing the hazards, understanding the required response and using the proper safety equipment.

When working in or around a confined space such as a molasses tank always:

• consider if the work can be done another way without entering the confined space. For example, use external tank connections for cleaning or emptying the tank
• have a competent person conduct and document a risk assessment that considers the hazards, how the work can be done safely and the emergency response procedure
• test the atmosphere to identify if there is an oxygen deficient atmosphere or atmospheric contaminants and any flammable gas or vapour present in the space
• make sure only workers with a permit enter the space and a stand-by worker is supervising the work from outside the space
• put signs on or near any confined space and at each entry point to warn that only people who have been properly trained and have an entry permit can enter
• make sure there is a safe means of entry and exit
• establish emergency procedures and run regular practice drills with workers
• provide workers and supervisors with suitable and adequate information, training and instruction to do their work safely and without risks to health. This may include training in hazard identification and risk control methods, entry permit procedures, emergency procedures and how to use respiratory protective equipment
• keep records of training, risk assessments and confined space entry permits

More information

• https://www.safework.nsw.gov.au/hazards-a-z/confined-spaces
• SafeWork NSW confined space analysis and emergency plans
• Code of Practice: Confined Spaces August 2019
• https://www.safework.nsw.gov.au/your-industry/agriculture,-forestry-and-fishing/farming/silo-safety
• https://www.safework.nsw.gov.au/your-industry/agriculture,-forestry-and-fishing/farming/virtual-farm-safety-day

View the latest incident information releases at safework.nsw.gov.au

Date of incidents: April 2020

During April there were four separate serious incidents involving quad bikes and a side by side vehicle. Three of the incidents resulted in a fatality, the fourth resulted in spinal injuries to the worker. It is believed that all four incidents involved the vehicle rolling and crushing the rider.

Tamworth

On the morning of the 3 April 2020, a 64-year-old farm worker went to check stock on a sheep stud. When he didn’t return later that afternoon, a search party was organised involving Police and volunteers. The farmer’s body was found that night in a large sloping rocky outcrop, underneath an upright quad bike.

Wauchope

On 8 April, a man was moving his neighbour’s cattle on a side-by-side vehicle. When going up a steep incline the vehicle tipped and rolled, fatally crushing the man underneath. It appears the vehicle's seat belt was fastened so that the vehicle could be started, but not placed around the rider. The man was allegedly not wearing a helmet.

Gloucester

On 13 April, a 69-year-old man sustained a cracked vertebrae and ligament damage when his quad bike rolled over. Westpac Rescue Helicopter transported the man to hospital for treatment.

Grenfell

On 17 April, a 67-year-old woman was found dead in a paddock on her farm. Despite the flat terrain, it appears the quad bike she was riding rolled and crushed her.

Side-by-side vehicle involved in incident (left) and site of incident near Wauchope

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with quad bikes and side-by side-vehicles.

Make sure:

• the vehicle is appropriate for the task, the terrain and the rider
• you do a quad bike or side-by-side vehicle riding course
• you ride at a speed that’s suitable for the conditions
• you wear a seatbelt when operating side by side vehicles
• you wear an approved helmet
• you wear personal protective equipment, such as goggles and sturdy footwear
• you use and maintain the vehicle in accordance with manufacturer’s instructions
• you don’t overload the vehicle or tow anything that exceeds the vehicle's limits
• you assess the environmental conditions, and know where there are rocks, trees, creeks and gullies, and where the ground is soft and rain-affected – a drone might help
• you avoid steep terrain
• an operator protection device (OPD) is fitted to your quad bike
• someone knows where you're going – carry a mobile phone or other communication device
• no child under 16 years ride adult size bikes
• no passengers on quad bikes

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Statistics

• Since 2001, there have been more than 240 quad bike related deaths on Australian farms.
• Over 60 per cent of quad bike fatalities are due to rollover.
• About 30 per cent of quad bike fatalities involve head injuries.
• About 40 per cent of serious injuries from quad bike incidents involve a traumatic head injury.
• Wearing a helmet reduces the risk of fatality in a quad bike incident by 40 per cent.

More information

• Quad bikes and side-by-side vehicle guidance material
• Farm vehicle pre-purchase checklist
• Quad bike safety rebate

A 22-year-old worker had his leg amputated after it became entangled in an unguarded in-ground auger, while he was cleaning grain out of a flat bottom silo.

Auger guard was removed

Safety information

Farmers and workers are killed or seriously injured every year while working on or inside silos.

The three key reasons are:

• falling from a height
• being overcome by fumes in a confined space
• getting dragged into the auger.

Consider ‘reasonably practicable’ control measures to manage the risks associated with working near augers and silos.

Make sure:

• parts of the auger that may cause injury – chutes, channels, belts, pulleys – are guarded
• guards can only be removed using a tool
• you use hydraulic rather than mechanical drive systems
• a competent person regularly inspects, maintains and services the auger
• you shut-off machinery before servicing
• you use a lock-out/tag-out procedure when working with augers – don’t use hands or feet to clear blockages
• guards are replaced after maintenance
• workers are trained to use augers
• inexperienced workers are supervised.

More information

• Code of practice for managing the risks of plant in the workplace
• Farm machinery fact sheet
• The A-Z of farm safety
• Tiffany's film - in it for the long haul

Date of incident: 20 March 2020

A 20-year-old stablehand suffered a brain injury after she was kicked in the head and face by a horse, while leading it from its stable to a yard in windy conditions. Displaying flighty, anxious behaviour, it broke free of the lead rope and kicked out with both hind legs.

Safety information

Many workers have been killed or injured falling from a horse, or being bitten, struck or kicked.

When working with or around horses:

• match the person and the horse – knowledge of the horse’s background and the person’s skill level is vital – this involves a separate assessment of the person and the horse
• make sure all workers are inducted, trained and supervised
• make sure workers wear personal protective equipment, such as a helmet (compliant with AS/NZ 3836:2006 Helmets for horse riding and horse related activities or equivalent), safety vest, enclosed boots and gloves
• create a safe environment, with enough space for horses and workers, and suitable exit points
• develop safe work procedures for moving and handling horses
• move quietly and confidently around horses
• be alert to sudden changes in a horse’s behaviour
• consider the age and behaviour of a horse
• consider things that might ‘spook’ a horse, such as weather, traffic or other horses
• always be in a position where you can quickly move away from a horse
• never approach a horse in its kicking zone.

When leading a horse, you should:

• approach it with safety zones in mind, and make a noise so it’s aware you’re approaching
• do so from the left shoulder of the horse, with both hands on the lead rope
• do one horse a time.

Statistics

• More than 10 people are hospitalised every day due to a horse-related injury.
• More than 130 horse-related fatalities occurred in NSW between 2000 and 2014
• Young females are most prone to horse-related injuries, while males are most likely to suffer fatal injuries.
• 40 per cent of all injuries involve being hit by a horse.

More information

• Video: Working safely with horses
• Code of practice for managing risks when new or inexperienced riders or handlers interact with horses
• Horse stables and track riding safety

Date of incident: 19 December 2019

A farmer died after being crushed by a tractor when trying to jump-start it at a property in Coolabah

Incident scene

The investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Consider ‘reasonably practicable’ control measures to manage the risks associated with working on tractors. Make sure:

• the tractor is routinely inspected and maintained according to the manufacturer’s recommendations or, if none, the recommendations of a competent person
• all work on the tractor is done by trained and suitably experienced workers, according to the manufacturer’s recommendations
• interlocking devices that prohibit jump-starting are in proper working condition, and not bypassed or removed
• you don’t jump-start the tractor unless the manufacturer has given you specific procedures.

Further information

• Code of practice for safe design and operation of tractors
• Code of practice for managing the risks of plant in the workplace
• Tractor safety precautions
• Small business rebate
• Managing the risks of machinery in rural workplaces

Download a PDF of this release

Date of incident: 5 November 2019

A 36-year-old man died when the tractor he was steering – which was being towed by another tractor – rolled over and crushed him. The incident occurred at Clybucca.

Safety information

A vehicle rollover is one of the most common causes of fatalities in the agricultural industry.

Consider ‘reasonably practicable’ control measures to manage the risks associated with the rollover of vehicles such as tractors. Make sure:

• you don’t hitch above the centre line of the axle when pulling heavy loads
• you hitch to the front drawbar and use reverse gear when towing a vehicle, to eliminate the potential for the tractor to backflip
• you use the clutch gently when starting up a slope, or towing
• you use an approved fold-down ROPS, with a locking device, when working inside or close to buildings or trees – and install other rollover-protection measures when the ROPS is folded down
• you don’t steer sideways when going up or down a slope
• the tractor is fitted with a rollover protection structure (ROPS), in accordance with section 26 of the regulation – more information is in AS1636:1996
• the ROPS is regularly checked for rust, cracks, fatigue and deformation – if it is present, repair or replace the ROPS
• you don’t change the ROPS – weld it or drill it - without first getting advice from the manufacturer or a suitably competent person
• a seatbelt, when fitted, is always worn.

Further information

• Code of practice: Safe design and operation of tractors
• Tractor rollover protection structures (ROPS) – Requirements – WorkSafe Victoria
• Tractor safety precautions – WorkCover Queensland
• Safe use of tractors with attachments – WorkSafe WA
• Code of practice: Managing the risks of plant in the workplace
• Small business safety rebate program (includes purchase of a ROPS).

Download a PDF of this release

Date of incident: 20 October 2019

Incident overview

A male farmer sustained fatal crush injuries when the side-by-side vehicle (SSV) he was operating rolled on a farm in Kybeyan.

The investigation

Caption: Side-by-side vehicle involved in the incident.

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Businesses must implement ‘reasonably practicable’ control measures to manage the risks associated with operating a side-by-side vehicle, including

• doing a side-by-side vehicle driving course
• driving at a speed that’s suitable for the conditions
• wearing a seatbelt and helmet
• maintaining the vehicle in accordance with manufacturer’s instructions.

Further information

You can also refer to the following guidance materials:

• Side-by-side vehicle fact sheet
• SafeWork NSW Quad bike reference material
• Farm vehicle pre-purchase checklist

Date of incident: 5 October 2019

A 38-year-old man sustained fatal injuries after losing control and rolling a 4WD farm vehicle as he descended a steep hill at Yaven Creek, near Adelong, in the Riverina region of NSW.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks of using plant, such as farm vehicles, on steep terrain. Make sure:

• the vehicle is appropriate for the task and the terrain
• the vehicle is maintained according to the manufacturer’s recommendations
• you reduce the tyre pressure, to increase the traction
• you use seat belts and drive in low gear
• the load is secure and doesn’t affect the vehicle’s stability
• you assess the environmental conditions, knowing where there are rocks, trees, creeks and gullies, and where the ground is soft and rain-affected – consider walking the route before driving
• you have plan B if the terrain is too steep or the vehicle too unstable
• the driver is well-trained in using the vehicle for the task being undertaken.

Further information

• SafeWork’s Managing the risk of plant in the workplace code of practice
• SafeWork’s Farm vehicle pre-purchase checklist
• WorkSafe Victoria’s Belt and survive fact sheet
• WorkSafe Queensland’s Serious about farm safety

Download a PDF of this release

Date of incident: 6 August 2019

Incident overview

A 69 year old, male, contract transport driver sustained fatal crush injuries after being struck by a bull in north western NSW. The worker was loading cattle onto a single deck trailer cattle transporter when a bull turned to exit the truck and pinned him against the race wall.

The investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risk of being crushed, kicked, trampled or gored. If you work with cattle during loading or unloading you are at greater risk of being injured when:

• you are inside the confines of the loading ramp (either behind or in between the cattle)
• you put your limbs through the bars of the ramp to move the cattle up or down the ramp.

Handlers must anticipate unpredictable animal behaviour when animals are in confined situations during loading, particularly when loading cattle by ramp. To stay safe:

• Train workers to perform the task safely.
• Design the loading ramp to accommodate the size and flow of the cattle.
• Ensure the width of the loading ramp is appropriate to the breed or class of cattle that will be negotiating the ramp.
• Ensure the slope of the loading ramp is not too steep.
• Put sheeting or panels along the walls of the loading ramp (sheeted panels make the cattle focus on the ramp exit and eliminate other distractions, sheeting also prevents your legs getting caught).
• Use a non-slip material on the floors of the ramp that does not vibrate or create noises likely to startle the animals.
• Use a catwalk and handrail alongside the ramp to help handlers move cattle at a safe distance.
• Fix a sliding gate at the top of the ramp that can be safely used to secure animals on the truck once it is loaded.
• Employ ‘low stress’ livestock handling techniques during loading or unloading.

Further information

You can also refer to the following guidance materials:

• Guide to managing risks in cattle handling
• Working with livestock: factsheet
• Cattle handling safety – a practical guide
• Guide for safe design of livestock loading ramps and forcing yards
• Safe loading and unloading of cattle – WorkSafe QLD
• Small business safety rebate program (use towards purchase of a cattle crush)

Download a pdf of this release.

Two separate incidents occurred at residential construction sites during bath installations. In both incidents, plumbing workers were applying expanding foam under the baths when an ignition source ignited the foam or its fumes, leading to explosions and fires. The workers were seriously injured with burns of varying severity, requiring medical treatment and hospitalisations.

Preserved bathroom sites with visible fire damage.

Safety information

Expanding foam is classified as ‘hazardous’ and is extremely flammable. Even very small quantities of flammable vapours may ignite and cause serious injuries and damage.

If using expanding foam products, identify hazards, assess risks and apply ‘reasonably practicable’ control measures in accordance with the hierarchy of controls to manage the risks associated with using expanding foam products.

You should eliminate the use of expanding foam by:

• ensuring design quality, for example, use freestanding baths with adjustable feet and a pre-fabricated base
• ensuring quality of workmanship
• using quality building products
• using compatible building products
• substituting expanding foam for less hazardous materials such as:
  • sand and cement
  • timber or plastic shims
  • multifoil insulation
  • mineral wool insulation
  • Room Temperature Vulcanising (RTV) materials like silicone
  • plaster based fillers.

You should implement controls if using expanding foams.

Isolation controls

• ensure exclusion zones using temporary barriers for access by trained workers only.

Engineering controls

• use a combination of natural and mechanical ventilation including forced air fans and/or extraction fans
• use ‘intrinsically safe’ equipment (equipment that does not introduce an ignition source).

Administrative controls

You should ensure:

• a current Safety Data Sheet (SDS) is obtained, provided to workers and the measures within the SDS are understood and implemented at the workplace
• an emergency plan is implemented at the workplace, workers have been trained in the plan and the plan has been tested
• suitable firefighting equipment is readily available at the workplace and workers have been trained in its use, noting direct water jets are not recommended for expanding foam fires
• suitable and adequate supervision is provided when workers are using hazardous chemicals
• a site-specific safe work method statement (SWMS) is prepared in consultation with workers, made readily available and understood by workers and supervisors at the workplace
• air monitoring is conducted to ensure Workplace Exposure Limits (WEL) are not exceeded for hazardous chemicals contained in the SDS for the expanding foam in use. Common hazardous chemicals with a WEL contained in expanding foam include:isocyanates, isobutane and dimethyl ether
• ignition sources such as flames, sparks and heat are identified and do not enter the workplace by training workers, providing documented procedures and signage
• health monitoring is provided to workers exposed to expanding foams that contain isocyanates
• ensure ventilation is adequate to avoid the creation of a hazardous atmosphere.

Personal Protective Equipment (PPE)

• provide suitable PPE to workers recommended by the SDS, taking into consideration the level of exposure. For example, gloves, organic vapour respirator, flame resistant overalls and eye protection.

Related guidance material

• Work Health and Safety Regulation 2017
• Code of Practice - Construction work (PDF, 1014.41 KB)
• Code of Practice - Managing risks of hazardous chemicals in the workplace (PDF, 1171.43 KB)
• Building and construction safety information
• Pocket guide to construction safety (PDF, 1352.71 KB)
• Hazardous chemical - general requirements
• Workplace exposure limits for airborne contaminants
• Guide to handling isocyanates
• Isocyanates technical fact sheet

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 21-year-old dogman was assisting a mobile crane operator in lifting portable buildings from a truck flatbed. The mobile crane overturned and the boom of the crane struck the dogman, causing traumatic injuries to his foot.

Photos of the Franna Crane involved at the incident site.

Safety information

Common risks associated with mobile cranes include:

• crane tip/roll over
• the load or falling objects from the load striking someone
• the crane striking or crushing someone
• the crane coming into contact with objects such as buildings, scaffolds, other plant and overhead powerlines.

Consider ‘reasonably practicable’ control measures to manage the risks associated when working around mobile plant.

Ensure:

• the crane has been maintained according to the manufacturer's guidelines and all inspection logs and maintenance records are up to date and available for review
• you conduct a thorough pre-start inspection of the mobile crane as per the manufacturer’s guidelines including operating and emergency controls, crane structure, tyres, wire ropes and safety features
• the crane is only operated in accordance with the manufacturer's guidelines
• the operator can interpret and apply the crane’s load charts in consideration of the crane configuration, lift task and site constraints
• prior to pick and carry operations, an appropriate assessment of the travel path is undertaken to identify influences on lifting capacity. This includes fore/aft/side slope of the surface, ground condition, rough terrain and required crane articulation angle (where applicable)
• the crane operator holds the appropriate High Risk Work Licence and has received specific training for the mobile crane they are operating
• the crane operator is competent and/or has relevant experience specific to the lift task being performed
• a Safe Work Method Statement is completed before commencing work to identify potential hazards and implement the appropriate control measures, particularly when crane operations are conducted near other workers, with clearly defined exclusion zones and designated spotters as required
• appropriate communication systems are established between the crane operator, dogman and any other workers directly involved in the lift
• if tag lines are being used to guide and control loads, they must be of sufficient length to permit a safe distance from the load and the path of the crane. Caution must apply when using tag lines to control loads consisting of a large mass or large surface area or in windy conditions
• the ground is stable and level, if working on soft or uneven ground additional measures such as mats or plates are used to stabilize the crane
• the position of the crane is in a safe area, avoid positioning the crane near hazards such as overhead powerlines or over underground services
• you check weather forecasts for high winds, poor visibility, lightning and thunderstorms.

Related guidance material

• Code of Practice – Managing the risk of plant in the workplace (PDF, 1987.96 KB)
• Australian Standards AS 2550.5-2002 – Safe use Part 5: Mobile cranes
• Roles & Responsibilities when hiring or using a mobile crane
• Safety Alert – Using mobile cranes in ‘pick and carry’ operations safety alert
• Safety Checklist – Mobile Crane Safety for PCBU’s (PDF, 166.04 KB)
• Guide for Crane Operators (PDF, 1225.66 KB)

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 29-year-old labourer was undertaking cleaning and general labouring work at a construction site. He fell over 7 metres through a skylight to the ground below, sustaining serious injuries.

Two photos taken from above and below the skylight involved in the incident.

Safety information

Falls from heights remain the leading cause of traumatic fatalities in the NSW building and construction industry. Many of these incidents occur from stepping on an unstable or non-trafficable surface. Consider ‘reasonably practicable’ control measures to manage the risks associated with working at heights.

Ensure:

• work is undertaken on the ground or on a solid construction where possible
• an inspection is carried out to identify the presence and condition of skylights and other fragile roof materials prior to commencing work
• skylights, fragile roof materials, penetrations and voids are clearly identified, and physical barriers are installed including guard rails and covers around non-trafficable areas
• a site-specific Safe Work Method Statement (SWMS) is developed and implemented for work where a person could fall more than 2 metres
• falls are prevented by
  • using a fall-prevention device, such as:
    • temporary work platforms
    • guardrails
    • scaffolding.
• the use of a work-positioning system, such as:
  • a restraint system
  • industrial rope access.
• if it is not possible to use a fall prevention device or a work positioning system, use a fall arrest system, such as:
  • industrial safety nets
  • catch platforms
  • harness-based fall-arrest used with lifelines or individual anchors.
• warning signs are installed around non-trafficable areas and are communicated to all workers
• all workers complete a site induction and have received adequate information, training and instruction
• an emergency plan is developed in consultation with workers and is always followed.

Related guidance material

• Code of practice – Managing the risk of falls at workplaces (PDF, 2326.56 KB)
• Code of practice – Construction work (PDF, 1014.41 KB)
• The pocket guide to construction safety (PDF, 1352.71 KB)
• Safety Alert - Falls through skylights and plastic roof sheeting
• High risk work licences
• Safety Checklist – Working at Heights in Construction (PDF, 208.69 KB)

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

During licensed demolition activities, an uncontrolled partial collapse of multiple levels of concrete slabs occurred. This led to the instability of connected scaffold. This posed a significant risk of falling objects within the worksite as well as onto public footpaths, adjacent streets and nearby premises. No injuries were sustained in the incident.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with an uncontrolled structural collapse and falling objects during demolition works.

You should ensure that:

• demolition works are completed by trained and licensed PCBUs in accordance with WHS legislation
• the licence holder notifies SafeWork NSW at least five calendar days before starting any demolition work
• the licence holder, in consultation with a competent person and all relevant stakeholders, prepares a site-specific demolition control plan before work begins
• the demolition plan includes the sequence of demolition activities and identifies structural components
• workers and plant operators engaged in demolition follow the demolition sequence as detailed in the demolition plan
• fit for purpose plant and structures are selected when planning the demolition work
• the demolition licence holder prepares a site-specific Safe Work Method Statement (SWMS) before starting demolition work
• scaffold is purpose-designed by a suitably competent person (such as a structural engineer) and scaffold is erected, altered and dismantled by workers with the appropriate scaffolding high risk work (HRW) licence
• demolition workers complete their mandatory training by 1 March 2025.

Related guidance material

• Code of Practice - Demolition Work (PDF, 668.8 KB)
• Code of Practice - Construction Work (PDF, 1014.41 KB)
• Code of Practice - Managing the risk of falls at workplaces (PDF, 2326.56 KB)
• AS/NZS 2601: The demolition of structures
• AS/NZS 1576 Part 1: Scaffolding – general requirements
• AS/NZS 4576: Guidelines for scaffolding
• Scaffolding Industry Safety Standard (PDF, 11195.23 KB)
• Falling Objects in Construction Fact Sheet (PDF, 122.91 KB)
• Demolition - SafeWork NSW

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 54-year-old mechanic was in the process of lifting weighing scales to a skip bin loading truck.  He was working on the chassis underneath the bin hook attachment which was extended above him by two hydraulic rams. The bin hook attachment weighing approximately 2950kg suddenly collapsed on him causing serious crush injuries.

Photo of truck and bin hook attachment at incident scene.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with working on mobile plant and moving parts.

Ensure:

• manufacturers recommendations are available, understood and followed prior to any installation or maintenance work commencing
• appropriate controls are applied to support the load (e.g. props are placed in the correct location) prior to the works commencing, as per manufacturer’s recommendation
• you have been provided with information, training and instruction so the work can be carried out safely
• you’re familiar with the components and limitations of the plant being worked on
• where possible, eliminate or minimise the risk by not working directly under hazard areas
• you develop specific safe systems of work for different types of plant
• workers are competent in the task and supervision is available to identify hazards and control the risks associated with uncontrolled movement of plant
• an emergency plan is in place and workers are trained in relation to the emergency procedures.

Related guidance material

• Code of practice – Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• Self-Assessment Checklist – Safety around Moving Plant (PDF, 171.08 KB)
• Safety Alert – Uncontrolled movement of vehicles
• Guide – Inspecting and maintaining plant (PDF, 1309.63 KB)
• Guide – Safety around your vehicle glove box guide

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 34-year-old 4^th year apprentice plumber was undertaking plumbing drainage work at a construction site when he was struck by an excavator bucket sustaining multiple fractures and serious injuries.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with working around moving plant.

Ensure:

• traffic hazards are identified:
  • consult with workers and mobile plant operators
  • determine where mobile plant is in use
  • determine potential locations and circumstances where people and plant could collide
• a Safe Work Method Statement (SWMS) is developed and documented in consultation with workers. Make sure all relevant workers understand and implement the SWMS
• an exclusion zone is set up around the plant to keep people safe around moving plant and machinery
• the risk is eliminated, if possible
• the risk is minimised, if elimination isn’t possible:
  • use bollards, barriers, safety rails or exclusion zones to separate people from moving plant and vehicles
  • effective system of communication between ground workers and operators
  • use alarms to warn people of moving plant – eg. reversing alarm, flashing lights
  • operator/s of the plant to hold the correct licence or qualification for the specific item of plant being used.
  • plan the site’s layout to minimise plant and vehicle hazards
  • establish traffic flow patterns, develop right of way procedures, use signs and speed limits
  • restrict access
  • have mobile phone procedures
  • wear high-visibility garments
• workers involved in a task are consulted, properly instructed, and trained on how to carry out the task safely. They must know all relevant health and safety information about the task, including the risks and how to manage them.

Statistics

Safety around moving plant is a SafeWork NSW regulatory priority with a focus on reducing workplace safety incidents related to moving plant, and forms part of the Work Health and Safety Blueprint to 2026.

Moving plant and vehicles such as excavators, forklifts, utes, and trucks create a risk to workers when reversing, loading, and unloading. Incidents such as workers or others being hit by moving plant or vehicles can cause injury and death.

Data from the SafeWork NSW Safety Around Moving Plant Priority Plan shows from 2017-2021, 65% of all injuries which involved machinery and fixed plant resulted in a major workers compensation claim.

In 2022, SafeWork NSW delivered compliance projects including Earthmoving Plant in Construction, Concrete Placing Equipment, and Cranes (mobile and tower) with a specific focus on types of plant. Inspectors continued to see low safety compliance levels with some key areas including plant collisions, workers being hit, and inadequate traffic/vehicle management systems in place, particularly involving excavators, concrete pumps, cranes, and skidsteers.

Ref: Findings Report: Safety around moving plant and vehicles 2023

Related guidance material

• Code of Practice - How to manage work health and safety risks (PDF, 556.72 KB)
• Code of Practice - Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• Code of Practice - Excavation work (PDF, 4128.95 KB)
• Code of Practice - Moving plant on construction sites (PDF, 594.88 KB)
• Working with or around mobile plant safety alert – SafeWork NSW
• Workplace traffic management guidance material
• Findings report: Earthmoving Plant in Construction 2022-2023
• Earthmoving plant in construction safety checklist (PDF, 669.46 KB)

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 16-year-old worker was undertaking labouring work on the first floor of a construction site when he fell approximately 3.3 metres through a penetration sustaining serious injuries.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated when working with young workers, working near open penetrations, and working at heights.

Ensure:

• adequate supervision of young and inexperienced workers is provided having regard of their age, experience, and competence
• penetrations and voids are covered with fit-for-purpose covers that are:
  • designed to withstand the load of workers and materials
  • securely fixed in position, and
  • clearly identified so they are not mistaken for construction material
• all workers receive adequate information, training, and instruction
• all workers complete a site induction
• emergency plans are prepared, maintained and implemented
• suitable communication systems are in place
• guard rails are installed if penetrations or voids are large or are needed for temporary access
• a site-specific SafeWork Method Statement (SWMS) is developed and implemented where the risk of falls is two metres or more.

Statistics

In NSW, there are more than half a million young people (aged 25 and under) in the workforce. More than 15,000 young people in NSW are injured at work each year, making up 14% of all workplace injuries in NSW.

By investing time and resources in young workers from their first day on the job, they are more likely to remain healthy and safe throughout their working life. This contributes to a happier and more efficient work environment.

The Young Workers e-Toolkit provides a range of resources developed to support young worker’s safety. This includes information tailored for young workers, employers, parents, and guardians as well as educators.

Related guidance material

• Code of Practice - Managing the risk of falls at workplaces (PDF, 2326.56 KB)
• Code of Practice - Construction work (PDF, 1014.41 KB)
• Young workers Toolkit
• Guide for labour hire workers, apprentices and trainees (PDF, 2988 KB)
• Checklist for training young workers (PDF, 1191.25 KB)
• Falls through voids - safety information
• Pocket guide to construction safety (PDF, 1352.71 KB)
• Working at heights information

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 31-year-old formwork worker was seriously injured on a construction site when he fell approximately 3 metres whilst descending a ladder into a jumpform cell.

Safety information

Falls from heights are the leading cause of traumatic fatalities in the NSW building and construction industry. There has been a recent trend in falls from heights involving formwork activities on construction sites. The risks are foreseeable, and these incidents are entirely preventable.

Assess and eliminate or minimise risks

Ensure:

• the formwork plan is readily available on site before commencing work and is approved by a competent person such as a structural engineer
• formwork is only installed, altered and dismantled by a qualified and competent person
• exclusion zones are implemented when formwork is being installed, altered or dismantled
• a ‘formwork only’ exclusion zone is maintained behind the leading edge to separate formworkers and other workers, clearly marked by signs and a barrier
• formwork components are only used in accordance with the original manufacturer’s specifications
• formwork is installed on a solid and stable foundation
• safeguards such as hand rails, edge protection and perimeter safety screens are installed
• the formwork is regularly inspected by a competent person and any defects identified are immediately reported  and rectified

Provide safe access and egress

Ensure:

• adequate access and egress between formwork levels is provided
• ladders should only be used as a means of access and egress after safer means (such as scaffolding stair towers) have been considered and found to be not reasonably practicable in the circumstances
• where ladders are used for access and egress, you should ensure so far as reasonably practicable t hat:
  • there is a firm, stable work platform, free from obstructions, to step onto from the ladder
  • the ladder is securely fixed in place at both the top and bottom, at a ratio of 4:1
  • the ladder extends at least 1 metre above the stepping-off point on the working platform
  • fall protection is provided at the stepping-off point.
  • no materials should be carried by hand when using a ladder for access and egress.
• ladders should be regularly inspected by a competent person and removed from service if any defects or faults are identified

Implement and follow safe systems of working

Ensure:

• voids and penetrations in the formwork are adequately identified and protected
• adequate sole boards and base plates are installed beneath props and frames, where appropriate
• adequate catch decks, false decks and temporary working platforms are installed between formwork levels
• where required, fall prevention devices and work positioning systems such as harnesses are provided and used by all workers
• the work zone for ‘other workers’ is only used once the working deck has been deemed as complete by a competent person
• there is adequate lighting for safe access and work activities
• a site-specific Safe Work Method Statement (SWMS) is developed and implemented
• all workers receive adequate information, training and instruction
• all workers complete a site induction
• all workers wear adequate personal protection equipment (PPE)
• an emergency plan is developed in consultation with workers and followed.

Related guidance material

• Managing risks of falls at workplaces – Code of Practice (PDF, 2326.56 KB)
• Formwork - Code of Practice (PDF, 1390.17 KB)
• Formwork safety in construction - checklist (PDF, 171 KB)
• Pocket guide to construction safety (PDF, 1352.71 KB)
• Working safely at heights in construction
• Falls though voids - safety information
• Working at heights in construction safety checklist (PDF, 208.69 KB)
• High risk work licences ()

Further information

• Traumatic event management plan
• Speak Up Save Lives App
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 17-year-old formwork worker was seriously injured when he fell backwards approximately 9.5 metres through a void between scaffolding and a building under construction.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with falls from heights and young workers.

Young workers may be at higher risk of injury or illness at work and need additional support to stay healthy and safe.

Ensure:

• scaffolding is only erected, altered and dismantled by a qualified and licenced person, with an appropriate scaffolding high risk work (HRW) licence. They must provide a scaffold handover certificate
• scaffolding is designed, installed and maintained in line  with Australian Standards
• the gap between the scaffolding and the working  face is not greater than 225mm
• scaffolding is constructed on solid foundations  or foundations certified by a competent person such as structural engineer and the bearing capacity of the foundation is provided by geotechnical engineer
• all scaffolding edges are protected by guard rails , midrails, toeboards, infill or other physical means to prevent workers falling
• scaffolding is adequately tied to the supporting structure
• all scaffolding planks are securely installed
• a qualified person inspects the scaffolding at least every 30 days and tagged with the inspection date
• workers visually inspect the scaffolding daily before use and any defects or issues are immediately reported  for rectification before using the scaffolding
• workers do not climb on top of rails or outside of the scaffolding structure
• penetrations and voids are considered during planning  and design stages and suitable controls are installed before the penetration or v oid is formed
• penetrations and voids are securely covered with fit-for-purpose covers that are designed to withstand the load of workers and materials, are fixed in position, and clearly identified so they are not mistaken for construction material
• guard rails are installed if penetrations or voids are large or are needed for temporary access
• there is safe access and egress from all work areas and the work site, including in between levels of the scaffolding deck levels
• high risk workers hold a valid licence for the type of work to be undertaken. For example, a basic, intermediate or advanced level of scaffolding licence
• a site-specific Safe Work Method Statement (SWMS) is developed and implemented where the risk of falls is two metres or more
• young or inexperienced workers are adequately supervised
• all workers receive adequate information, training and instruction
• all workers complete a site induction.

Related guidance material

• Managing risks of falls at workplaces – Code of Practice (PDF, 2326.56 KB)
• Managing the risks of falls in housing construction - Code of Practice  PDF, 2296.79 KB
• Construction Work – Code of Practice (PDF, 1014.41 KB)
• AS 4576:2020 Guidelines for scaffolding
• AS 1576 series, Scaffolding
• Scaffolding Industry Safety Standard (PDF, 11195.23 KB)
• Young workers eToolkit
• Checklist for training young workers (PDF, 1191.25 KB)
• Guide for labour hire workers, apprentices and trainees (PDF, 2988 KB)
• Pocket guide to construction safety (PDF, 1352.71 KB)
• Working safely at heights in construction
• Falls though voids - safety information
• Working at heights in construction safety checklist (PDF, 208.69 KB)
• Erecting, altering and dismantling scaffolding - Part 1: Prefabricated steel modular scaffolding
• Dogging, rigging and scaffolding licences
• Scaffold Inspection Checklist (PDF, 392.98 KB)
• Scaffold and Scaffolding work general guide
• Guide for scaffold inspection and maintenance
• Using Scaffolds Toolbox Talk
• SafeWork SafetyCast

Further information

• Traumatic event management plan
• Speak Up Save Lives App
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 68-year-old worker was painting the façade of four adjoining buildings when they fell approximately 6-8 metres to the ground below sustaining fatal injuries. A ladder was used to reach the awning from the ground and a second ladder was used on top of the awning.​ The worker was standing on the ladder on top of the awning on the 1^st floor when it appears they have made contact with an overhead electrical service line directly above the ladder.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with working near overhead powerlines.

Ensure you:

• you eliminate the risk by arranging for the electricity supply authority to isolate the electricity supply for the duration of the work
• you clearly identify the height and voltage of high and low voltage power lines, including overhead service lines to buildings
• you relocate work away from overhead service lines wherever possible
• you only perform work near low voltage overhead services lines in accordance with approach distances as listed within the “Code of Practice: Work near overhead power lines” (for example, 0.5m when using handheld tools)
• you minimise the risk by substituting and/or using engineering controls (such as using an insulated fibreglass extension handle on a paint roller)

Related guidance material

• Code of Practice – Work near overhead power lines (PDF, 3569.89 KB)
• Handling conductive material near overhead powerlines
• Work near overhead power lines: the basics
• Incident information release – Overhead powerline contact fatality
• Incident information release – Contact with overhead powerlines
• Safety alert – Mobile plant operating near overhead power lines
• Hazards A-Z – Power lines

Further information

• Traumatic event management plan
• Speak Up Save Lives App
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 34-year-old worker was seriously injured when he slipped and fell approximately 3.4 metres from the roof of a shed he was engaged to construct. A second worker sustained minor injuries when he attempted to grab onto the worker as he slid down the roof. The two injured workers and a third worker had been engaged to complete the construction works by an owner-builder.

Safety information

People who believe they have the skill or capacity to build their own house or supervise the construction work may do so under an owner-builder permit. Owner-builders must apply for a permit and complete a training course. This allows them to supervise or do building work worth more than $10,000 on a single dwelling-house, dual occupancy, or secondary dwelling.

Ensure you:

• you complete a recognised owner-builder training course
• you and any workers engaged on your site hold a general construction induction (white card) qualification
• you hold a valid owner-builder permit before undertaking or supervising any owner-builder work
• you comply with all requirements of the permit
• you only undertake or supervise work that is covered by the permit
• any workers and subcontractors who attend your site complete a site induction
• you develop a safe system of work for all work tasks and workers are trained in them
• pre-start safety briefing meetings are held with workers prior to the commencement of work
• Safe Work Method Statements (SWMS) are developed and followed for high-risk construction work
• the risk of falls is eliminated. If it is not reasonably practicable to do so, then you must implement controls such as scaffold or temporary roof guard rails to manage the risk
• workers engaged for any works hold the relevant licence or qualification required prior to commencing work
• where necessary hold the relevant high risk work licence for structural steel erection, which includes dogging and basic rigging.

Related guidance material

• Work Health and Safety Act 2011 (NSW)
• Code of Practice: Construction Work (PDF, 1014.41 KB)
• Code of Practice: Managing the risks of falls at workplaces (PDF, 2326.56 KB)
• Code of Practice: How to manage work health and safety risks (PDF, 556.72 KB)
• Working as an owner-builder – Fair Trading NSW
• Owner-builder permits – Fair Trading NSW
• Building and construction
• Incident animation – Owner builder – fall through void
• High risk work licences
• Roof Edge Protection Factsheet

Further information

• Traumatic event management plan
• Speak Up Save Lives App
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 26-year-old worker was constructing a shed on a rural property when they fell approximately 4.1 metres through the roof purlins, landing on the ground below. The worker sustained serious injuries from the fall.

Ensure you:

• follow structural engineering, manufacturer and supplier information when constructing a shed
• plan the work – consider the risks and suitable controls
• develop a Safe Work Method Statement (SWMS) and implement the documented the controls to be used
• install roof safety mesh to the entire roof and in accordance with AS/NZS 4389 utilising suitable access methods, for example an elevated work platform (EWP) or scaffold
• install roof edge protection
• install safe access/egress to the roof area
• hold a valid General Construction Induction Card (White Card)
• hold valid licences for the type of work to be undertaken, for example a dogging and basic rigging licence.

Related guidance material

• Safe Work on Roofs - Commercial and Industrial Buildings (PDF, 493.51 KB)
• Prepare a safe work method statement
• Temporary edge protection (roof rails) factsheet (PDF, 2885.66 KB)
• Working at heights
• Work safely at heights in construction
• Working at heights – Safety Checklist (PDF, 208.69 KB)
• Code of Practice: Managing the risk of falls at workplaces (PDF, 2326.56 KB)
• Pocket guide to construction safety (PDF, 1352.71 KB)
• High risk work licences

Further information

• Traumatic event management plan
• Speak Up Save Lives App
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 38-year-old male was straddling an A-frame ladder at the height of approximately 3.5 metres to install a roller door on a shed. Whilst loosening the tension a wrench spun out of control and struck him on the left cheek. The man, who was working alone, fell from the ladder and landed on concrete below, sustaining serious injuries.

Photographs of the shed and roller door at the incident site, taken when the work was complete.

Safety information

Ensure:

• ladders are used for simple access jobs, or for a short duration
• you choose the right tool for the job. Your decision to use a specific ladder should not be based solely on the availability of a particular ladder at a workplace. You may be able to buy or hire purpose built equipment that would provide a safer means of access (such as mobile scaffold, elevated work platform or platform ladder)
• you only use A-Frame ladders locked in the fully open position
• the ladder is in good condition and industrial rated (120kg)
• the ladder is set up on a flat, stable surface
• the ladder is high enough, to prevent overreaching
• you maintain three points of contact when climbing or descending the ladder. This means two hands and one foot, or two feet and one hand. Also use your waist to balance against the ladder
• other trained workers are utilised with the task, if available.

Statistics

Each year there are dozens of serious incidents where workers have fallen from ladders. Most of these incidents involve a ladder being used incorrectly or inappropriately.

Related guidance material

• Hazards A-Z Ladders
• Pocket guide to ladder safety (PDF, 1104.94 KB)
• Poster: Work safely at any height (PDF, 2419.61 KB)
• Toolbox talk: Using ladders in construction
• Code of Practice: Managing the risk of falls at workplaces (PDF, 2326.56 KB)

Further information

• Traumatic event management plan
• Speak Up Save Lives App
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 49-year-old man was seriously injured while moving a loaded pallet down a concrete ramp with another worker. The man was using a manual pallet jack to move a pallet of 48 bags of rapid screed grout, each weighing 20kg and with a total weight of approximately 960kg. The pallet jack and load rolled away from the workers, causing one of the men to be crushed between the uncontrolled loaded pallet and another pallet of goods.

Safety information

Each year people suffer serious and fatal injuries in NSW due to incidents involving the uncontrolled movement (roll away) of mobile plant.

While the use of a pallet jack may be simple, the operation of a manual pallet jack is a hazardous manual task as high forces are often required to move or stop the load. If operating on inclined floors the forces required to maintain control of the load and to ensure it can be safely brought to a stop are greater.

Consider ‘reasonably practicable’ control measures to manage the risks associated with moving loads on slopes using manually operated mobile plant including pallet jacks, to reduce the risk of workers and others being struck or crushed by loads.

Ensure:

• you refer to the manufacturer’s information to ensure the pallet jack is safely operated and to assist in implementing suitable controls when used on unlevel floors such as:
  • the maximum allowable slope
  • the correct direction of travel
  • safe operator position/location (including other workers that may be assisting)
  • how to stop the pallet jack in an emergency (for example lowering the forks so that the pallet contacts the ground).
• workers are provided with information, training and supervision for the tasks they undertake
• the correct plant is available for use, taking the task, risk assessments and site conditions into consideration
• the use of electric powered pallet jacks, or manual powered pallet jacks fitted with brakes, if operating on uneven surfaces is a regular practice
• all plant used is fit for purpose and serviced as per the manufacturer's specifications.

Related guidance material

• Choosing and using trolleys – WorkSafe Vic
• Working with or around mobile plant
• Code of Practice: Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• Hazardous manual tasks (PDF, 1499.23 KB)
• Workplace traffic management – Safe Work Australia
• AFITA-011 – Using hand pallet trucks on an incline – Australian Forklift & Industrial Truck Association

Further information

• Traumatic event management plan
• Speak Up Save Lives App
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 25 tonne articulated crane was in the process of moving a metal casing for a pier. The operator has traversed across a slight slope when the load shifted. The crane rolled on to its side and the hook block struck a 49-year-old worker resulting in serious injuries.

Overturned articulated crane on NSW worksite.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with operating articulated cranes.

Ensure:

• crane operators hold an applicable HRWL and be experienced in the operation of the crane being used
• the correct crane is being used for the job
• the crane being operated is in good working order, regularly maintained with current registration
• there are safe systems of work in place for set-up, placement and crane operations
• adequate exclusion zones are in place
• the route of travel has been reviewed for the ability to operate the crane safely including enough clearance, appropriate ground conditions, right load and clear lifting path
• you configure crane to mobile load, stowing outriggers and positioning boom to manufacturers recommendations
• you maintain minimum speed ensuring load is up hill when ascending or descending.

Statistics

Since June 2023, there have been four articulated crane rollovers on worksites within New South Wales. On each occasion the loads were being walked across sloping ground surfaces and the crane has travelled out of radius.

Related guidance material

• Guide for crane operators
• Plant, machinery and equipment
• Roles and responsibilities when hiring or using a mobile crane
• Safety Checklist - Mobile crane safety for PCBUs (PDF, 166.04 KB)
• High risk work crane classes licence requirements
• Using mobile cranes in ‘pick and carry’ operations – safety alert
• Guide to mobile cranes– Safe Work Australia

Further information

• Traumatic event management plan
• Speak Up Save Lives App
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A worker fell approximately 5.1 metres to the ground through fibreglass roofing at a manufacturing warehouse, sustaining fatal head injuries.  The Person Conducting a Business or Undertaking (PCBU) was conducting maintenance work at the premises.

Views from outside and inside the warehouse

Safety information

Falls from heights may occur in any workplace and they continue to be a major cause of fatalities and serious injuries at workplaces across NSW.

Consider ‘reasonably practicable’ control measures to manage the risks associated with working at heights, ensuring adequate fall protection.

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Ensure:

When considering ‘reasonably practicable’ control measures to manage the risk of falls, before starting work on an existing roof, carry out an inspection (from below) to determine:

• the presence and condition of non-trafficable sheeting and other brittle roof sheeting such as sky lights, plastic roof sheeting or asbestos cement sheeting
• the presence and condition of safety mesh.

When determining whether roof surfaces are safe to walk on, consider the product materials and method of fixing, including any possible deterioration in strength. Note: products may become brittle, and fixings may become less rigid over time.

Implement these control measures to prevent workers from falling through non-trafficable roofs and apply these measures consistently, reviewing as work progresses:

• Plan the work to avoid accessing unsafe or non-trafficable areas.
• Work from an elevated work platform or boom lift to avoid standing on the roof itself.
• Install temporary work platforms (e.g. crawling boards) and roof ladders as appropriate.
• Install barriers (e.g. guard rails or covers) that are secured and labelled with warning signs.
• Install safety mesh when installing the roof sheeting.
• Install and ensure the use of a fall restraint / arrest system (harness system) which has adequately installed anchorage points, adjusting the length to limit slack as the worker moves, along with training and instruction in the use.

Statistics

Falls from heights are the number one cause of traumatic fatalities in the NSW building and construction industry. The biggest risks for roof work are falling off the edge or through fragile roof materials.

Related guidance material

• Managing the risk of falls at workplaces – Code of Practice
• Pocket guide to construction safety
• Temporary Edge Protection (roof rails) factsheet
• Working at heights
• Work safely at heights in construction
• Working at heights – Safety Checklist

Further information

• Traumatic event management plan – SafeWork NSW
• Speak Up Save Lives App – SafeWork NSW
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates
• See SafeWork NSW latest incident information releases
• Webinar: Working safely at heights in Construction

Two workers were working from a false car platform to install lift rails in a lift well. While descending the false car fell approximately 15-20m into the crash protection deck below. One worker sustained serious spinal injuries and the other worker suffered head lacerations and bruising.

Safety information

A false car is a temporary work platform used during the installation of a lift to provide a working area designed to prevent workers from falling. Consider ‘reasonably practicable’ control measures to manage the risks associated with the operation of false car platforms in lift shafts.

Ensure:

• a SafeWork Method Statement (SWMS) specific to the high-risk construction works is completed prior to any works commencing and revised prior to any changes to the false car assembly
• an emergency response plan (ERP) applicable to the work is developed and implemented
• installations are completed by competent persons holding the relevant high risk work licences (HRWL) if the activity involves high risk work
• protective decking is provided above each working area
• robust lift well enclosures are securely fixed to control the risk of falls into the lift well, prevent materials falling into the lift well and to prevent unauthorised access at all access locations
• lighting for the lift installation and provision of power is provided for safe access, safe working condition and safe egress
• all persons working on a lift or related equipment within a well or carrying out risk assessments, should possess demonstratable competence in basic lift safety and procedures.
• all false car components are fitted in accordance with the manufacturer’s recommendations or the recommendations of a competent person including the wire ropes are the correct length fitted with end loop and clamps, guardrails in place, and emergency stop buttons are in proper working condition
• daily pre-operational checks and maintenance procedures are established, implemented and monitored. Checks include but are not limited to:
  • visual inspection of lift well ensuring path is clear of obstructions
  • visual inspection of the suspension system for wear, broken strands, corrosion, wire distortion, reduction in diameter and lengthening of the lay
  • visual check of the wire rope of the device which operated independent of the hoisting winch and false car safety gear from broken wires, surface wear, corrosion, wire or strand distortion, reduction in diameter and lengthening of lay.
• periodic tests are completed by a competent person as per the manufacturer's instructions or at a maximum of 3 monthly intervals
• written records of all maintenance, inspection and repairs shall be signed by those completing the works and kept on site
• clear communication protocols have been established and tested daily between the operators, personnel involved in the operation and other workers on the site
• ensure the false car has the maximum safe working load limit prominently displayed in kilograms and this will not be exceeded.

Related guidance material

• Managing the risk of falls at workplaces – Code of Practice (PDF, 2326.56 KB)
• Managing the risk of plant in the workplace – Code of Practice (PDF, 1987.96 KB)
• SafeWork NSW’s Code of practice – Construction work (PDF, 1014.41 KB)
• Falling objects
• Falling Objects Factsheet – Safe Work Australia
• Safety Alert: Lift installation – false cars maintenance and inspection - Electrical Tradies Union
• Working at heights
• Plant Design Registration ()
• Managing Electrical Risks in the Workplace – Code of Practice (PDF, 1337.36 KB)
• Electrical work
• AS 4431: 2019 Safe working on new lift installation in new constructions

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A section of scaffold for a multi-unit residential project has separated from the building face and come to rest against low voltage distribution powerlines. It appears scaffold ties were removed resulting in serious immediate risk of collapse.

Images of scaffolding on power lines.

Safety information

PCBUs are reminded to consider reasonable and practicable control measures to identify hazards and manage the risk of scaffold collapse:

Ensure:

• the scaffold is adequately tied to its supporting structure, in accordance with instructions from a competent person. Consult with the scaffold designer, manufacturer, supplier, or an engineer, and prevent unauthorised removal or changes by workers on site
• to develop systems of work that allow construction activities such as bricklaying, painting, rendering, glazing, and cladding installation to be completed without unplanned changes to or removal of scaffold ties, e.g., relocate ties so they do not interfere with the work. Examples of systems of work, include and are not limited to:
  • providing all workers adequate information, instruction, training and supervision regarding the control measures required to prevent the removal of ties and any other unauthorised alterations that could lead to the collapse of the scaffold
  • workers completing a visual check of the scaffold daily before use and reporting any defects or issues for rectification
  • regular inspection of scaffold ties to check they are not modified or altered by unauthorised people (e.g., finishing trades who may loosen, relocate or remove ties to gain access to walls and openings)
  • all workers completing a site-specific induction and are trained in the appropriate safe work method statement (SWMS)
• to engage a competent person who holds the same or higher class of high-risk work licence appropriate to the class of scaffolding to regularly inspect the scaffold, at least every 30 days, to ensure it has not been modified or altered by unauthorised persons.
• a handover certificate must be provided before first use of the scaffold after scaffolders have completed their scaffolding work i.e. after a new scaffold has been erected, or an existing scaffold has been repaired or altered. Examples of alterations requiring an inspection and new handover certificate include:
  • adding/removing additional bays or lifts
  • changing ties or tie locations
  • changing platforms, hop-ups and decking component locations
  • changing edge protection or containment
  • partial disassembly or removing components (e.g., create an access opening)
• the competent person when erecting and handing over a scaffold for use on site must consider the following:
  • provision and maintenance of sufficient ties of adequate strength for the loads, including wind load
  • ensure the scaffold is stable at all times, including during erection, in situ, during and after any alterations, and when dismantling
  • ensure altering or partially dismantling the scaffold does not weaken it, e.g., removing returns or adjacent bays may require additional ties or bracing on the remaining scaffold
  • scaffolds are not left in a state of weakness when installing or dismantling the scaffolds (e.g., removing returns as they act like ties, or removing ties in preparation for dismantling)
  • ensure the scaffold can withstand all anticipated loads, including the weight of workers, all stored material and any loads due to weather such as wind and rain

On-the-spot fines of up to $3,600 apply for altering a scaffold without a licence or failing to protect workers from the risk of falls from heights.

Statistics

After conducting 428 Scaff Safe 2021 project site visits, SafeWork NSW compiled a report highlighting many unsafe practices in scaffolding. Some key findings include:

• Principal Contractors had allowed workers to access incomplete scaffolds at 49% of sites
• 43% of sites had working decks with missing planks, ledgers or hop-ups
• 43% of sites had missing mid rails
• 32% of sites did not have a handover certificate (or written confirmation) by a competent person
• 30% of sites had scaffolds that appeared to have been altered by unlicenced tradies – mostly bricklayers.

Related guidance material

• Construction Site Supervisor Workshop - Young and at risk workers
• Young workers eToolkit
• Checklist for training young workers (PDF, 1191.25 KB)
• Guide for labour hire workers, apprentices and trainees (PDF, 2988 KB)
• Managing the risks of plant in the workplace – Code of Practice (PDF, 1987.96 KB)
• Managing the risk of falls in housing construction – Code of Practice (PDF, 2296.79 KB)
• Working at heights in construction
• Roof edge protection fact sheet (PDF, 2885.66 KB)
• Incident Information – How to prevent falls on a construction site using void covers

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 20-year-old worker was undertaking roof works at a residential construction site when he fell through a skylight opening on the roof of a pergola. The worker was seriously injured from the fall and later died from his injuries in hospital.

Images of the pergola worksite and skylight opening.

Safety information

In NSW, there are more than half a million young people (aged 25 and under) in the workforce. More than 15,000 young people in NSW are injured at work each year, making up 14% of all workplace injuries in NSW.

By investing time and resources in young workers from their first day in the job, they are more likely to remain healthy and safe throughout their working life. This contributes to a happier and more efficient work environment.

The Young Workers e-Toolkit provides a range of resources developed to support young worker’s safety. This includes information tailored for young workers, employers, parents, and guardians as well as educators.

Ensure:

• adequate supervision of young or inexperienced workers. Provide them with suitable information, training and instruction to be able to complete their tasks safely
• work is undertaken on the ground or on a solid construction where possible
• falls are prevented by using a fall-prevention device, such as:
  • temporary work platforms
  • guardrails
  • scaffolding.
• the use of a work-positioning system, such as:
  • a restraint system
  • industrial rope access.
• if it is not possible to use a fall prevention device or a work positioning system, use a fall arrest system, such as:
  • industrial safety nets
  • catch platforms
  • harness-based fall-arrest used with lifelines or individual anchors.
• you complete safe work method statement (SWMS) for work where a person could fall more than 2 metres.

The biggest risks for roof work is falling off the edge or through fragile roof materials. Safety measures include using:

• a physical barrier, such as temporary edge protection or guardrails on roof edges
• skylight covers, crawl boards, or physically marked exclusion zones for fragile surfaces.

On-the-spot fines of up to $3,600 apply to businesses who put workers lives at risk from a fall.

Related guidance material

• Construction Site Supervisor Workshop - Young and at risk workers
• Young workers eToolkit
• Checklist for training young workers (PDF, 1191.25 KB)
• Guide for labour hire workers, apprentices and trainees (PDF, 2988 KB)
• Managing the risks of plant in the workplace – Code of Practice (PDF, 1987.96 KB)
• Managing the risk of falls in housing construction – Code of Practice (PDF, 2296.79 KB)
• Working at heights in construction
• Roof edge protection fact sheet (PDF, 2885.66 KB)
• Incident Information – How to prevent falls on a construction site using void covers

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 39-year-old worker sustained serious burns when a concrete vibrator and jerry can ignited following refuelling on a construction site in Sydney.

Images of the construction site where the incident occurred.

Safety information

Consider reasonably practicable control measures to manage the risks associated with refuelling plant.to

Ensure:

• obtain a current safety data sheet and ensure it is readily accessible to the workers involved before they use any hazardous chemical
• identify any ignition source in your workplace that has the potential to ignite flammable or combustible material
• follow operating procedures for setting-up, operating, cleaning and maintaining plant items
• establish designated refuelling areas
• have suitable materials handy to enable spills and leaks to be contained wherever chemicals are used, handled or stored
• properly seal containers storing hazardous chemicals when they are not in use
• provide instruction, training and supervision to all workers on the safe use, storage and handling of hazardous chemicals
• wear appropriate personal protective equipment for the task.

Related guidance material

• Managing risks of hazardous chemicals in the workplace - Code of practice (PDF, 1171.43 KB)
• Managing the risks of plant in the workplace - Code of practice (PDF, 1987.96 KB)
• Hazardous chemicals
• Flammable substances
• Concrete placing equipment operations fact sheet

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 40-year-old non-English speaking worker sustained serious injuries when he was struck by building materials. At the time of the incident, the building materials were being loaded onto a cantilevered crane-loading platform by a tower crane. The worker fell approximately 8 metres, striking temporary chain mesh fencing before landing on the ground below. The injured worker later died in hospital.

Images of the crane load and the location where the incident occurred.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with plant in the workplace.

Ensure:

• the path of travel is clear from obstructions when a load is hoisted by a crane, and the load remains under control
• an exclusion zone is set up around the plant, and any suspended loads during loading/unloading processes, to keep people safe around plant and machinery
• you understand the requirements to be authorised by a high-risk work licence, and in the correct class, when undertaking work with cranes. For example:
  • to sling the load
  • directing a crane operator in the movement of load when it is out of the operator's view
  • perform dogging or rigging work
• authorised persons do not place themselves at risk of being crushed between the load and any other surface
• Workers involved in a task are consulted, properly instructed, and trained on how to carry out the task safely. They must know all relevant health and safety information about the task, including the risks and how to manage them
• Training and instruction provided is easy to understand, even for those whose first language is not English and have additional needs.

Related guidance material

• How to manage work health and safety risks – Code of Practice (PDF, 556.72 KB)
• Managing the risks of plant in the workplace – Code of Practice (PDF, 1987.96 KB)
• Construction Work – Code of Practice (PDF, 1014.41 KB)
• Guide for crane operators (PDF, 1225.66 KB)
• Tower crane safety for PCBUs (PDF, 166.44 KB)
• Tower Cranes - safety information
• Loading, Unloading Exclusion Zones
• Safety around your vehicle (SAYV) glove box guide
• Working with or around mobile plant safety alert – SafeWork NSW
• Falling objects fact sheet (PDF, 122.91 KB)
• Translated safety resources

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates
• The pocket guide to construction safety – SafeWork NSW

In May 2023, SafeWork NSW responded to an incident where a young worker was fatally injured after falling through a penetration that was not adequately covered on a construction site.

Construction workers risk serious injury or even death when working at heights, and these risks are greatest when there are open penetrations and voids workers can fall through.

Businesses are reminded to consider reasonably practicable control measures to manage the risk of working near penetrations and voids.

Ensure:

• penetrations and voids are considered during planning and design stages and suitable controls are installed before the penetration or void is formed
• penetration / void covers are used that withstand the load of workers and materials
• covers are secured in position and are clearly identified so they are not mistaken for construction material
• guard rails are installed if the penetration / void is large or needed for temporary access
• if using the penetration / void to access another level, consider using temporary stairs, or make sure your ladder extends one metre past the landing point
• adequate training, instruction and supervision are provided to all workers
• a site-specific safe work method statement (SWMS) is prepared before work commences, where the risk of falls is two metres or more.

Related guidance material

• Managing risks of falls at workplaces – Code of Practice (PDF, 2326.56 KB)
• Managing the risk of falls in housing construction – Code of Practice (PDF, 2296.79 KB)
• Working safely at heights in construction
• Working at heights in construction safety checklist (PDF, 208.69 KB)
• The pocket guide to construction safety (PDF, 1352.71 KB)
• Prepare a safe work method statements
• Incident animation - Fall through void
• Incident animation - Owner builder fall through void
• Incident animation - How to prevent falls on construction site using temporary stairs
• Incident information - How to prevent falls on a construction site using void covers

Further information

• SafeWork launches campaign targeting unsafe work at heights
• Join one of our upcoming work safely at heights in construction webinars
• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW

A 62-year-old worker was fatally injured after being crushed by windows while unloading them from a shipping container at Glenwood.

Safety information

Unpacking shipping containers can be hazardous, particularly when unpacking heavy, awkward and unsecured items or handling sheet materials such as glass, stone, panels, or timber. Workers are at risk of being crushed by materials and falling objects as well as being hit by the plant and machinery used in unpacking.

Consider reasonably practicable control measures to manage the risks associated with unpacking shipping containers.

Ensure:

• items are packed into the container in order of removal to eliminate sorting the items inside the container
• extra care is taken when unpacking items such as windows, glass sheets, panels, stone sheets, and composite slabs. You can do this by:
  • strapping items to an ‘A’ frame or to the side of the container.  Securing each sheet using a separate strap means workers can only release the item that is being removed – one at a time
  • using mechanical aids to eliminate the need to manually handle goods
  • ensuring individual items are secured as you unpack
  • unpacking only in a designated area
  • ensuring the load is secured in its final destination
• the area around the container is clear of obstructions
• there is an appropriate traffic management plan in place
• if manual unpacking is necessary workers are trained in the safest system of work to unload the container
• personal protective equipment is used such as gloves, hard hats, safety glasses, and hi-visibility clothing.

Related guidance material

• Guide for unpacking shipping containers – SafeWork NSW
• Unpacking shipping containers checklist – SafeWork NSW (PDF, 560.38 KB)
• Unpacking shipping containers – Video Safety Alert

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 28-year-old worker was installing insulation batts on the third level of a residential construction site when he fell approximately three metres through a stair void to the concrete floor below. The worker sustained serious injuries.

Incident location - stair void

Safety information

Each year SafeWork NSW responds to incidents where workers have been killed or seriously injured from falls from heights. Many of these incidents involve falling from unprotected edges or through penetrations.

Workers in the construction industry are the most at risk of injuries from falling. However, working at height is a risk for any worker.

Businesses are reminded to consider reasonably practicable control measures to manage the risk of falls.

Ensure:

• a site-specific safe work method statement (SWMS) is prepared before work commences where the risk of falls is two metres or more
• all workers understand and follow the SWMS
• workers are provided with safe means to access and exit the work site, and work areas
• work is carried out on the ground where possible. If work cannot be conducted on the ground, minimise the risks of working from heights by:
  • using scaffolding
  • ensuring all edges are protected by handrail, guard rail, or other physical means that prevents a person from falling
  • using an elevated work platform
• any scaffolding used at the site:
  • is constructed on solid foundations
  • is adequately tied to the supporting structure as well as all handrails, midrails and
  • has securely installed planks
• all voids and penetrations have a clearly marked cover that is secured and can’t be dislodged (plywood that is marked and screwed into the ground is a cost-effective solution)
• large voids are protected by suitable fit-for-purpose void covers that accommodate safe access of handrails and scaffolds, or consider using temporary stairs
• adequate training and instruction are provided to all workers
• adequate supervision and assistance are provided to less experienced workers.

SafeWork NSW inspectors regularly blitz construction sites to check compliance and talk with businesses and workers about how to work safely at heights. Use this checklist (PDF, 208.69 KB) to find out if your construction site is working at heights safely.

‘Do work safety right, at any height’ campaign

One wrong step could be your last.

Visit the working safely at heights in construction web page to access a range of resources about how to work safely on roofs and around voids.

Related guidance material

• Managing the risks of falls in housing construction - Code of Practice (PDF, 2296.79 KB)
• Pocket guide to construction safety (PDF, 1352.71 KB)
• Working safely at heights in construction
• Falls though voids - safety information
• Fall through stair void animation

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 64-year-old worker was undertaking traffic control on a public road near Newcastle when he was struck by a moving vehicle sustaining serious injuries.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with traffic in the workplace.

Control measures

• To eliminate traffic risks consider closing the road and not allowing traffic through the worksite.
• To direct traffic in and around the workplace, you may be able to use electronic traffic control devices or traffic lights instead of traffic controllers.
• Install delineation devices such as traffic cones, temporary bollards and barrier boards to define the traffic path through, past or around the workplace.
• Use directional signage such as workers ahead and speed reduction signs.
• Implement a traffic management plan that should include:
  • the duties and responsibilities of the people involved
  • risks and relevant controls to be implemented
  • the desired flow of pedestrian and vehicle movements, including the space needed for plant operators to safely get in and out of their machines
  • the expected frequency of interaction of vehicles and pedestrians
  • illustrations of the layout of barriers, walkways, signs and general arrangements to warn and guide traffic around, past, or through a work site or temporary hazard
  • how short-term, mobile work and complex traffic situations will be managed
  • instructions or procedures for controlling traffic including in an emergency.

• Prepare a safe work method statement (SWMS) in consultation with workers and put in place arrangements to ensure the work is carried out in accordance with the SWMS.
• Provide any information, training, instruction, and supervision that is necessary to protect workers from risks to their health and safety.
• High visibility vests should be worn when working in the vicinity of moving traffic or plant.

Related guidance material

• Workplace traffic management guidance material – Safe Work Australia
• Construction work – Code of Practice (PDF, 1014.41 KB)
• Pocket guide to construction safety (PDF, 1352.71 KB)
• Safe Work Method Statement – SafeWork NSW

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 32-year-old worker sustained a serious leg injury after being struck by a projectile in a rail corridor in Sydney. At the time of the incident the worker was in the vicinity of an excavator that was using a mulching attachment to carry out de-vegetation work.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with mobile plant.

Ensure:

• exclusions zones are established in line with manufacturer’s recommendations
• the parameter for exclusions zones recommended by the manufacturer is incorporated into safe work method statements
• pre-starts include thorough checks of plant including attachments by a competent person
• plant and attachments are maintained in a safe condition and operated in accordance with manufacturer’s recommendations
• workers are provided with adequate information, training, instruction, and supervision to protect them from plant related risks
• all duty holders are consulted on the risks associated with the tasks.

Related guidance material

• Managing the risks of plant in the workplace – Code of Practice (PDF, 1987.96 KB)
• Working with or around mobile plant safety – Safety Alert
• Work health and safety consultation, cooperation and coordination – Code of Practice (PDF, 635.62 KB)
• Prepare safe work method statement

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

Seven workers were injured after falling approximately 3.6 metres (m) while trying to move a compressor across unsupported ceiling panels. Five of the workers were trapped beneath the compressor after the fall.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with falls while accessing and egressing ceilings.

Ensure:

• any work involving a risk of a fall is carried out on the ground or on a solid construction with a surface structurally capable of supporting workers, materials and any other loads applied to it
• manufacturer’s specifications for ceiling panels are available and safe working loads are known prior to using ceiling to store materials or for egressing
• the surface and its supports must be able to safely carry the expected loads, including workers, materials, tools and equipment. When in doubt, have a structural engineer determine the safe load capacity before use
• when work cannot be performed on the ground or from a solid construction, the risk of a fall must be minimised by providing adequate protection against the risk, for example, by providing a fall prevention device, if it is reasonably practicable to do so
• administrative controls may be used to support other controls. Administrative controls must not be used exclusively to minimise the risk of falls unless it is not reasonably practicable to use a higher order control. If relying on administrative controls, it may be necessary to provide a high level of supervision to ensure compliance
• a Safe Work Method Statement (SWMS) for working at heights is prepared for any height with a risk of a fall of over 2 m.

Statistics

Falls from heights are the major cause of fatalities in the construction industry. Most serious and fatal falls are from roofs, ladders or scaffolds – and from a height of less than 4 m.

On-the-spot fines of up to $3,600 apply for failing to protect workers from the risk of falls from heights.

Related guidance material

• Managing the risks of falls at workplaces – Code of Practice (PDF, 2326.56 KB)
• Working at heights – Hazards A-Z
• Prevent falls from heights – poster
  (PDF, 2419.61 KB)
• Work safely at heights in construction – safety campaign

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 64-year-old male was fatally injured while operating a nine inch angle grinder at a residential construction site in Ermington. The angle grinder was being used to cut a brick pier.

The angle grinder involved in the incident.

Safety information

The increased power and size of nine inch (230 mm) angle grinders makes the grinder more difficult to manoeuvre and can cause severe kickback.

Consider ‘reasonably practicable’ control measures to manage the risks associated with operating angle grinders.

Always:

• plan the work to eliminate or minimise risk to health and safety
• ensure a SafeWork Method Statement is developed, and followed for high risk construction work
• conduct a risk assessment to identify alternative methods and tools prior to selecting a nine inch (230 mm) angle grinder
• carry out a visual inspection of the angle grinder before use, ensure damaged discs are thrown out and not re-used
• use the angle grinder with the correct guard supplied by the manufacturer
• ensure the handle is inserted on the side of the unit that gives the best grip for the work activity
• only use an angle grinder if you have been trained, your employer authorises you to operate it and you follow your employer’s Safe Operating Procedures
• only use approved and appropriate safety controls in accordance with manufacturer’s recommendations if operating an angle grinder on materials likely to generate hazardous dust
• ensure the angle grinder is maintained and repaired according to the manufacturer’s specifications
• ensure the angle grinder has been inspected and tested for electrical faults by a competent person
• wear appropriate personal protective equipment, such as safety glasses and earmuffs.

Related guidance material

• Managing the risks of plant in the workplace – Code of Practice (PDF, 1987.96 KB)
• Construction work – Code of Practice (PDF, 1014.41 KB)
• Guards and disks on angle grinders safety alert
• Pocket guide to construction safety (PDF, 1352.71 KB)

Further information

• Traumatic event management plan
• Mental health at work
• Speak Up Save Lives App
• Subscribe to SafeWork NSW newsletters and updates

Download this Incident Information Release (PDF, 646.91 KB)

A 26-year-old apprentice sustained serious injuries when he fell from incomplete scaffolding used to access the roof of a two-storey house under construction in Avalon Beach.

Safety information

Falls from heights are the major cause of death on NSW construction sites. Most serious and fatal fall incidents occur at a height of less than 4 metres.

Employers and PCBUs must ensure the safety of workers moving from one level to another, no matter the height. Workers are most at risk of falls from scaffolding when it is missing components, is misused, or has not been erected or altered by a competent person.

When working with scaffolding, businesses must ensure:

• any erection, alteration or dismantling work on scaffolding with a risk of fall of greater than 4 metres is performed by a person with the relevant High Risk Work Licence (HRWL)
• scaffolding is only constructed on solid foundations and is adequately tied to the supporting structure
• handrails, mid-rails, and planks are securely installed
• workers are provided with a safe way to access and exit the work area
• safe access and egress onto stairs and between deck levels
• workers do not climb on top of rails or on the outside of the structure
• workers, supplies and equipment to be used on the scaffolding are under the duty rating (weight limit)
• voids and penetrations are covered and appropriately marked
• mesh and kickboards are installed to scaffolding to prevent debris falling onto neighbouring properties or workers below the work area
• scaffolding is inspected by a qualified person at least every 30 days and tagged with the inspection date
• workers complete a visual check of the scaffold daily before use and report any defects or issues for rectification
• a Safe Work Method Statement (SWMS) for working at heights is prepared for any height with a risk of a fall of over 2 metres
• all workers complete a site-specific induction and are trained in the appropriate SWMS for working at heights including working on scaffold.

On-the-spot fines of up to $3,600 apply for altering a scaffold without a licence or failing to protect workers from the risk of falls from heights.

Incident related guidance material

• Managing the risk of falls at workplaces – Code of Practice (PDF, 2326.56 KB)
• Managing the risk of falls in housing construction – Code of Practice (PDF, 2296.79 KB)
• Scaffolding Industry Safety Standard ( PDF, 11195.23 KB)
• AS 4576:2020 Guidelines for scaffolding
• Work safely at heights in construction
• Construction falls from heights blitz checklist (PDF, 208.69 KB)
• The pocket guide to construction safety (PDF, 1352.71 KB)
• Dogging, rigging and scaffolding licences
• Erecting, altering and dismantling scaffolding - Part 1: Prefabricated steel modular scaffolding

Further information

• Traumatic event management plan
• Mental health at work – NSW Government
• Speak Up Save Lives App
• Subscribe to SafeWork NSW newsletters

Download this Incident Information Release (PDF, 440.04 KB)

A 19-year-old apprentice was seriously injured while clearing a trench on a residential building site. The worker was positioned within a two-metre-high unsupported trench when a section collapsed and engulfed him with soil. The worker sustained multiple fractures and needed to be dug out by other workers on site.

Safety information

Excavation works and working in or near a trench present a serious risk of injury or death. Hazards can include ground collapse, instability of adjoining structures and underground essential services.

You must implement ‘reasonably practicable’ control measures to manage the risks associated with excavation works and working in or near a trench, including to:

• obtain the current underground essential services information (location and depth) relating to the workplace and adjacent areas
• ensure a Safe Work Method Statement (SWMS) is developed and followed for high-risk construction work, such as when the trench depth is more than 1.5 metres, or work is near certain underground essential services
• ensure a competent person, experienced in trenching works, supervises and monitors the work
• ensure the plant is only used for the purpose for which it is designed, is appropriate for the work, maintained in a safe condition and operated by a competent person
• ensure workers not involved with the work and the public cannot access the trench and work areas
• minimise the risk to any person arising from ground collapse on trenches deeper than 1.5 metres by implementing one or more of the following:
  • benching – creating a series of steps in the vertical wall of an excavation to reduce the wall height and ensure stability
  • battering – sloping the wall of an excavation to a predetermined angle to ensure stability
  • shoring – using support systems for an excavated face or faces to prevent the movement of soil and therefore, ground collapse
  • obtaining written advice from a geotechnical engineer that all sides of a trench are safe from collapse
• obtain advice from competent persons regarding the soil and groundwater conditions of the site – especially after any event that could affect the safety of the trench (e.g. a weather event or ground slip)
• obtain advice from competent persons regarding any temporary or permanent control measures required to adequately support potentially affected structures, their foundations, and excavated faces
• ensure young workers and apprentices are suitably supervised by a competent and qualified person
• ensure an emergency plan is prepared for the site.

Related information

• Excavation Work – Code of Practice (PDF, 4128.95 KB)
• Construction Work – Code of Practice (PDF, 1014.41 KB)
• How to Manage Work Health and Safety Risks – Code of Practice (PDF, 556.72 KB)
• Construction Safety Information – SafeWork NSW
• The Pocket Guide to Construction Safety – SafeWork NSW (PDF, 1352.71 KB)
• Young workers e-toolkit – SafeWork NSW
• Checklist for training young workers – SafeWork NSW (PDF, 1191.25 KB)
• Traumatic event management plan - SafeWork NSW
• Speak Up Save Lives App – SafeWork NSW
• Mental health at work – NSW Government

Download this Incident Information Release (PDF, 292.04 KB)

A 22-year-old 4^th year electrical apprentice sustained serious injuries when he fell approximately four metres from a rooftop. The apprentice was installing solar roof panels on a house under construction.

Front and side view of incident site.

Safety information

In NSW, there are more than half a million young workers (aged up to 25) and more than 15,000 of them are injured at work each year. Regardless of how they are employed, or in which industry, young workers need extra support to ensure they are carrying out their tasks correctly and safely.

Solar panels are becoming increasingly popular in NSW, however, there are significant falls from heights risks to workers when installing these systems including:

• falls over unprotected roof edges
• falls through uncovered penetrations and voids
• falls though skylights, alsynite, fibre cement and other weak materials
• falls though damaged, brittle, weakened or otherwise non-supporting roof surfaces
• slips and trips on pitched/sloping roof surfaces
• slippery surfaces due to algae, moss, moisture, dirt etc.
• falls during access (both people and equipment) e.g. ladders.

Consider ‘reasonably practicable’ control measures to manage the risks associated with solar panel installations.

You must ensure:

• a site-specific safe work method statement (SWMS) is prepared where the risk of falls is two metres or more
• the SWMS is prepared in consultation with workers – make sure they follow it
• the correct safety equipment is in place before work commences
• the hazards, risks and suitable controls are identified before accessing the roof
• workers have a safe means of access and egress to work areas
• falls are controlled using a fall prevention device, such as covers, temporary edge protection (guardrails) and scaffolding
• a harness-based system is only to be used when higher order controls are not reasonably practicable
• ladders are placed at a ratio of 1:4 to the wall, secured at the top and bottom, and extended at least one metre above the roof edge – consider using an elevating work platform or scaffolding instead of a ladder
• adequate training and instruction in the correct use of the equipment is provided to all workers.
• adequate supervision and assistance is provided to less experienced workers.

Related information

• Solar panel photovoltaic (PV) installations – SafeWork NSW
• Solar safety video safety alert – SafeWork NSW
• Guide to safe solar panel installation – Safe Work NSW
• Managing the risk of falls in housing construction (PDF, 2296.79 KB) – SafeWork NSW
• Young workers eToolkit – SafeWork NSW
• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government

Download this Incident Information Release (PDF, 193.97 KB)

A 30-year-old worker sustained injuries when the temporary support post for the roof he was tiling failed, causing the roof to collapse. At the time, tiles had been stacked on the unsupported eaves in preparation to be installed.

The collapsed roof and temporary support that gave way.

Safety information

Structural collapses pose risks to workers on top of the structure as well as those working underneath and around the structure. These risks include falls from heights, being hit by falling objects and being crushed under the collapsed building material.

You must implement ‘reasonably practicable’ control measures to manage the risks associated with structural collapses, including:

• consult with suitably qualified and competent persons regarding engineering and structural requirements during construction
• follow all engineering and construction requirements as per the approved construction plans, including meeting hold points and inspection requirements
• ensure structural supports are correctly sized and have the load bearing capacity required
• ensure temporary structural supports are correctly located and fixed in position
• ensure heavy materials are not placed on unsupported roof areas
• implement safe work areas to reduce the risk to workers working beneath structures from being injured from falling objects or crush injuries in the event of a structural collapse
• communicate any safety concerns with the designer or engineer and do not continue work until the issue is resolved
• ensure a SafeWork Method Statement (SWMS) is developed, and followed, for high-risk work
• ensure all workers have the required licences and qualifications
• ensure all workers complete a site induction and are provided with all relevant safety information
• ensure all workers are wearing the correct PPE
• prepare an emergency plan for the site.

Related guidance material

• Managing the Risk of Falls at Workplaces – Code of Practice (PDF, 2326.56 KB)
• Managing the Risk of Falls in Housing Construction – Code of Practice (PDF, 2296.79 KB)
• Construction Work – Code of Practice PDF, 1014.41 KB
• How to Manage Work Health and Safety Risks – Code of Practice (PDF, 556.72 KB)
• Safe Design of Structures – Code of Practice (PDF, 1039.8 KB)
• The Pocket Guide to Construction Safety – SafeWork NSW (PDF, 1352.71 KB)
• Work Safely at Heights in Construction – SafeWork NSW

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters

Download this Incident Information Release (PDF, 353.51 KB)

A 39-year-old plasterer was seriously injured while carrying out renovation work in a school library at Wahroonga. The worker was removing clips from the inside of an unprotected window when he fell approximately five metres through the window to the ground below sustaining serious head and spinal injuries.

The worker fell through the first story window.

Safety information

Employers must protect workers from the risk of falling from one level to another – no matter the height. Workers from culturally and linguistically diverse backgrounds can be more at risk in  workplaces and may require additional supervision or information to work safely.

Consider ‘reasonably practicable’ control measures to manage the risks associated with working at heights.

Businesses should:

• inspect the site prior to commencing any work at heights in order to assess and plan for suitable safety controls to prevent risk of falls
• develop a site specific Safe Work Method Statement (SWMS) for any high risk construction work with risk of falls over two metres. Ensure the SWMS is understood by all persons using the document
• conduct work on the ground or on a solid construction. If you don’t have to work at heights, don't. Working from the ground is always the safest option
• use a fall-prevention device. If you have to work from a height, you need to manage the risk of a fall. A fall-prevention device is best because it will prevent your workers from falling. Examples include temporary work platforms, guardrails and scaffolding
• use a work-positioning system. When it is not possible to use a fall-prevention device, a work-positioning system is your next best option. This system either prevents a fall hazard being reached or enables a person to work supported in tension in a way that prevents the person from falling. Examples of this include elevating work platforms such as scissor lifts
• use physical barriers such as temporary edge protection or covers in unprotected areas where there is a risk to workers
• provide information, training and instruction to workers. This should be provided in a way that is readily understandable to all workers
• provide adequate supervision by a competent person, especially if they are undergoing training or are unfamiliar with the working environment.

The Working safely at heights in construction campaign (launched by SafeWork NSW in June 2021) aims to provide resources especially aimed at young workers and workers from culturally and linguistically diverse backgrounds in particular.

Related information

• Managing the Risk of Falls at Workplaces – Code of Practice (PDF, 2326.56 KB) – SafeWork NSW
• Construction Work – Code of Practice (PDF, 1014.41 KB) – SafeWork NSW
• The pocket guide to construction safety (PDF, 1352.71 KB) – SafeWork NSW
• Prepare a safe work method statement – SafeWork NSW

Download this Incident Information Release (PDF, 489.77 KB)

A 67-year-old worker performing repairs and maintenance to a vessel has fallen from bracket scaffolding on a slipway in Ulladulla. The worker removed a timber scaffolding plank before falling approximately three to four metres to the concrete ground below. As a result of the incident the worker sustained foot, leg, hip and spinal fractures.

Tasks undertaken by marine businesses can involve working at heights to access the hull and topsides of vessels. Much of this work is done on temporary work platforms when the vessels are on slipways or on exposed or covered hardstand areas. Consider ‘reasonably practicable’ control measures to manage the risks associated with working at heights and temporary work platforms.

Fall prevention

Employers must consult with other duty holders and manage the risk of falls at the workplace by working from the ground or solid construction. If this is not possible, consider using fall prevention devices, a work positioning system or fall arrest system.

Fall protection devices

Fall prevention devices include fencing, edge protection, covers, scaffolds, elevating work platforms, work boxes and other temporary work platforms. Such devices should always be installed and used in accordance with the manufacturer's instructions.

Employers must ensure:

• scaffolding includes edge protection if:
  • a person could fall more than two metres, or
  • if a fall of less than two metres is reasonably likely to cause injury

• scaffolding where a person could fall more than four metres must be erected by a licensed scaffolder and have a valid handover certificate
• work positioning systems include industrial rope access or a restraint system that stops a worker from reaching a position where they could fall
• falls arrest systems include catch nets and harness-based fall arrest systems - such systems should only be used by workers with suitable training and a rescue plan to retrieve a fallen worker is required
• other measures to control the risk of falls are in place, including having safe systems of work (Safe Work Method Statements) and adequate training/supervision of workers.

Related information

• Managing the Risk of Falls at the Workplaces - Code of Practice SafeWork NSW
• Managing risks in stevedoring - Code of Practice SafeWork NSW
• Tower and mobile scaffolding information sheet - SafeWork Australia
• Working at heights - SafeWork NSW
• Scaffolding - SafeWork NSW
• Develop Workplace Health & Safety Guidance for Recreational & Light Commercial Boating Industries - Boating Industry Association NSW

Download this Incident Information Release as a PDF

A 34 year-old worker was injured while working on the balcony of a townhouse in Botany.

A temporary plastic canopy was installed over the balcony to act as a rain barrier. The worker was undertaking waterproofing at the time using a highly flammable solvent-based contact adhesive, membrane sheets and a hot air tool. An open plastic bucket containing the decanted adhesive ignited, and remained on fire, resulting in second to third degree burns to both legs of the worker. Parts of the balcony, including the plastic canopy, caught on fire.

Location of the incident

Balcony where the fire took place

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with working with hazardous chemicals and when conducting hot work activities.

When conducting hot work activities:

• implement a hot work permit which includes a detailed review to identify all potential hazards associated with the proposed hot work activity and to eliminate the hazards,or where this is not reasonably practicable control the resulting risks
• identify and remove any possible flammable or combustible materials in the area,including rubbish, paper or dust that could be potential fuel sources or produce dust explosions
• ensure the area is not a confined space
• ensure the area is adequately ventilated
• ensure adequate firefighting equipment is available and ready for use
• utilise a fire watch person to monitor the hot work environment
• provide training to workers about the hazards associated with hot works, the use of the hot work permit system and emergency planning
• ensure workers are wearing appropriate non-flammable personal protective equipment.

When working with hazardous chemicals:

• identify the physical and health hazards of chemicals at work before first use. Inform and train workers in safe use, following manufacturer’s instructions or instructions on the Safety Data Sheet
• remove ignition sources from hazardous areas
• substitute a highly flammable liquid with one that is less flammable or combustible
• ensure ventilation is adequate to avoid the creation of a hazardous atmosphere
• physically separate hazardous chemicals from any chemicals or other things that may be incompatible
• distance workers from hazardous chemicals and any potential hazards generated by their use
• use intrinsically safe electrical equipment - consider whether the hazardous chemicals can generate flammable or explosive atmospheres, and ensure that any equipment being used, like stirrers, is safe.

More information

• Managing Risks of Hazardous Chemicals in the Workplace - Code of Practice
• Hot Work Safety Alert – SafeWork NSW
• Flammable substances – SafeWork NSW

Download this Incident Information Release as a PDF

A 43-year-old male was operating a tracked dumper. While he was tracking down a set of ramps the tracked dumper tipped forward throwing him from the operator’s platform. He suffered a neck fracture and serious head laceration.

Implement ‘reasonably practicable’ control measures to manage the risks associated with working with plant in the workplace.

Tracked dumpers are generally used to transport materials such as soil or rubble to and from locations within a site where access is tight.

Even though these plant items are small, overturning of the dumper or the operator being thrown from the plant can result in serious injury or death. Unlike large plant items where the operator’s cabin offers some form of protection, the operator is not secured with a seatbelt or protected by a roll over protection system. The safe use and operation of tracked dumpers plays an important part in keeping the operator safe.

When considering whether a tracked dumper is suitable to use on a site you must ensure:

• the manufacturer’s instructions clearly set out the safe operating conditions and limitations for the plant; and the site conditions allow for the plant to be used in accordance with those instructions e.g. ground stability, maximum slope (transverse and longitudinal)
• all necessary training, information and instruction is provided to and understood by operators prior to use, e.g. direction of travel, maximum capacity (load)
• operators are provided all necessary supervision to confirm the manufacturer’s instructions are followed
• if you are unsure how to safely use the plant, do not use it until you have consulted with the supplier (e.g. hire shop) or manufacturer and have all the necessary information.

More information

• Managing the risks of plant in the workplace [PDF] – Code of practice
• Working with or around mobile plant safety alert – SafeWork NSW

SafeWork NSW Inspectors have responded to a number of incidents that have resulted in the suspension or cancellation of high-risk work licences.

These incidents involved the operation of tower cranes, slewing mobile cranes, vehicle loading cranes, forklift trucks and the undertaking of scaffolding work.

Persons must be authorised to undertake high-risk work. High-risk work licence holders must ensure they take reasonable care for their own health and safety and must ensure that their acts or omissions do not adversely affect the health and safety of others.

Inspectors have the power to immediately suspend a high-risk work licence where there is an imminent serious risk to the health and safety of any person.

Several licence holders have recently had their licence suspended or cancelled resulting in them not being authorised to undertake high-risk work. Persons who have had their licence cancelled will need to be retrained and reassessed as competent. They may also incur a disqualification period where they are unable to apply for another high-risk work licence. Penalties apply for persons undertaking high-risk work while their licence is suspended or cancelled.

High-risk work licence holders must:

Only do work you are licenced to carry out

• always have your licence available for inspection when undertaking high-risk work
• only carry out high-risk work for the class of licence you hold

Be familiar with the plant before you start

• ensure that the plant is in a safe condition prior to operating
• know all the operating controls and the limitations of the plant

Operate the plant safely

• operate the plant in a safe manner and within its rated capacity and capability
• ensure you take reasonable care to carry out the high-risk work safely and competently

Control access to / separation from the plant

• prevent unauthorised or unintentional use of the plant
• have adequate pedestrian separation and traffic control measures in place

If an incident occurs

• ensure that the plant is inspected by a suitably competent person before it is put back into service.

More information

• High risk work licences – SafeWork NSW
• Forklifts – SafeWork NSW
• Tower Cranes – SafeWork NSW
• Tower Crane Safety – SafeWork NSW
• Scaffold – SafeWork NSW
• Mobile Cranes – SafeWork NSW
• Code of Practice: Managing the risks of plant in the workplace – SafeWork NSW

Download this Incident Information Release as a PDF

A 32-year-old worker was injured when he fell approximately 5 metres through a void on a bridge under construction near Gilgandra. The worker was walking along reinforcement bars and across the concrete bridge beams when he stepped on to a steel void panel which dislodged.

Safety information

Falls from heights is the number one killer on construction sites in NSW and every year there are dozens of serious incidents. Many of these incidents are from stepping on an unstable surface.

Consider ‘reasonably practicable’ control measures to manage the risks associated with working at heights.

You must ensure:

• a safe method of construction is incorporated into the design of formwork/ falsework e.g. minimising work at height, incorporating edge protection, using catch decks etc
• formwork/falsework is erected according to the design, and within any tolerances required by the designer
• formwork/falsework is secured from movement due to construction loads, wind loads, concrete pour loads etc
• suppliers/manufacturers limits are not exceeded (e.g. maximum span between supports, minimum bearing area, maximum applied load, number of fixings etc)
• voids, penetrations, and non-trafficable areas are covered, or access is prevented by physical barriers or edge protection
• covers are strong enough to support the load from people, are securely attached to prevent dislodgement and marked (e.g. “Danger - void”)
• lower order control measures such as harness-based restraint or fall arrest systems are used in situations where covers or physical edge protection can’t be used.

More information

• Managing the risk of falls at workplaces code of practice
• Formwork code of practice
• Working safely at heights

A 45-year-old worker was struck by a reversing track skid steer while surveying levels as part of a road construction in the Southern Highlands. The worker sustained significant crush injuries.

• Workplace specific induction for all workers before work starts
• Mobile plant operation area exclusion zones (eg: the use of fences, bollards, barriers, safety rails, etc to separate pedestrians from moving plant and vehicles)
• Sequencing work to minimise the number of trades and labourers on foot when heavy vehicles are operational
• Dedicated turning bays, to allow heavy mobile plant to maintain operator visibility by moving forward
• Dedicated footpaths (plant exclusion) for workers on foot
• The use of spotters where heavy mobile plant is required to reverse (or operate in the direction of less visibility)
• The use of formal and trained traffic controllers where required
• Establishing and maintaining communication systems e.g. radios to notify plant operators of persons approaching work area
• Using audible and visible alarms to identify moving plant (e.g. reversing alarm, flashing lights)
• The use of proximity sensing devices
• Using high visibility garments to increase a person’s visibility
• Training workers in relation to blind spots for certain vehicles, such as the blind spot created by the arm of an excavator

More information

• Working with or around mobile plant safety – SafeWork NSW
• Workplace traffic management guidance material - SafeWork Australia
• Mobile plant - SafeWork SA
• Code of Practice: Managing the risks of plant in the workplace (PDF 1.5MB) – SafeWork NSW

Download this Incident Information Release as a PDF

A 49-year-old tiler has fallen approximately three metres from the internal first floor hallway through an unprotected void at a residential construction site in Carlton. The worker sustained a fractured eye socket and serious head injuries.

Most falls through voids or penetrations occur because they:

• are uncovered
• have unsuitable covers in place, or
• have no guardrail.

You must implement ‘reasonably practicable’ control measures to manage the risks associated with falls through voids or penetrations.

Make sure:

• areas that have a void / penetration are clearly highlighted and communicated to all workers
• guardrails are installed where the void/penetration is large or needed for temporary access
• if using the void/penetration to access another level, you consider using temporary stairs or make sure your ladder is secure and extends one metre past the landing point
• all voids and penetrations that will not be used for access, have a clearly marked and secured cover so it can’t be dislodged and is structurally suitable for purpose. Plywood that is marked as covering a penetration and properly secured into place, is a cost-effective solution.

SafeWork NSW campaign

SafeWork NSW launched the ‘Working safely at heights in construction – when you fall – they fall’ campaign in June 2021. Several relevant resources are available from the campaign page.

More information

• Code of practice managing the risk of falls at workplaces (PDF 1.5MB)
• Code of practice construction work (PDF 1MB)
• Working at heights guidance material
• Falls through voids guidance material

A 23-year-old scaffolding labourer has fallen from a scaffold during dismantling at a Hurstville residential unit complex. The worker climbed the exterior of the scaffold to remove loose scaffold components on the upper decks. While climbing he has fallen from the scaffold onto the awning below that covered the entrance to the unit complex. The awning collapsed landing on two elderly members of the public and another worker who were entering the building. All three sustained injuries after being hit by the awning and falling worker.

Consider ‘reasonably practicable’ control measures to manage the risks associated with falls while working with scaffolding.

You must:

• ensure no one climbs the exterior of the scaffold
• provide safe access to platforms on the scaffold, either internal access such as scaffold stairs (preferred) or fixed ladders, or direct access from an adjacent structure
• erect and dismantle scaffolds using a safe system of work that ensures scaffolders are behind edge protection at all times
• ensure no one climbs standards, ledgers, or transoms to gain extra height
• prepare a safe work method statement when working two metres or more from the ground and ensure it is understood and followed by all workers
• prevent all unauthorised access to scaffold
• ensure scaffolds are only erected, altered and dismantled by a worker with the appropriate scaffolding high risk work (HRW) licence. You can check if a HRW licence is valid by visiting verify.licence
• ensure workers hold a valid construction induction card (white card) prior to directing or allowing them to work on a NSW constructions site

Scaff Safe 2021

SafeWork NSW will continue to target scaffold safety on construction sites throughout 2021. Inspectors will be attending worksites and talking with employers and workers to ensure compliance. On the spot fines of between $432 and $3,600 apply for those not managing scaffold safety, falls from heights risks, and unlicenced workers.

More information

• SafeWork NSW Industry Safety Standard – Erect, alter and dismantle scaffold
• Safe Work Australia: Scaffolds and scaffolding work general guide
• Safe Work Australia: Guide for scaffold inspection and maintenance
• SafeWork NSW scaffolding page
• SafeWork NSW scaffold inspection checklist

An unsupported formwork platform has collapsed on a multistorey construction site at Westmead. Two workers were accessing the temporary platform and fell approximately 3.5 metres, suffering fractured ribs and serious lacerations to the head and legs. This is the second incident in less than a month where workers have fallen due to a structural collapse on a construction site.

Implement ‘reasonably practicable’ control measures to manage the risks associated with the collapse of incomplete formwork, including:

• Restrict unauthorised access to incomplete formwork. Access should be restricted via fixed barriers where reasonably practicable, which are clearly marked
• Make sure all workers are aware of the documented system of work for gaining authorisation to access incomplete formwork. Provide workers with the necessary instruction and training
• Monitor the controls, including inspecting the fixed barriers and supervising workers to ensure the documented system of work is being followed

Formwork inspections should be undertaken:

• Routinely as the formwork is being constructed and while workers can access the area
• Prior to loading
• Periodically following loading
• Following unplanned events e.g. adverse weather

Inspections should be recorded and include evidence of the condition of the formwork at the time of the inspection e.g. photographs.

Certification that the formwork complies with AS3610 and the design should only be provided upon completion of the formwork, including the completion of rectification works and re-inspection of any identified issues.

More information

• Construction work – Code of practice
• Formwork – Code of practice
• Managing the risk of falls at workplaces – Code of practice
• Pocket guide to construction safety
• Construction falls from heights blitz checklist
• Poster -  Prevent falls from heights (PDF, 2419.61 KB)
  
  • Arabic (PDF, 2526.83 KB
  • Chinese simplified (PDF, 2537.56 KB)
  • Chinese traditional  (PDF, 2532.26 KB)
  • Vietnamese (PDF, 2545.19 KB)
• SafeWork NSW formwork podcast

Two bricklayers sustained injuries after the first floor they were working on collapsed at a Marsden Park residential construction site. Approximately four pallets of bricks had been stored on the timber first floor of the house construction when the floor gave way. The floor was supported by timber joists, supported by a timber beam at one end and a steel beam at the other end. The steel beam was supported by the wall frame at one end and a temporary supporting member at the other.

You must implement ‘reasonably practicable’ control measures to manage the risks associated with the collapse of a structure loaded with heavy materials during construction, including:

• only store materials on constructed surfaces with a known safe working load capacity. If the safe working load capacity is unknown, store materials on the ground until the capacity can be determined by a competent person e.g. structural engineer
• where temporary structures are used to support a working surface, make sure the temporary structures are designed to support the expected loads and/or the safe working load capacity is adjusted accordingly, and the temporary supports are secured and protected to prevent unauthorised alterations and accidental dislodgement
• workers are informed and trained on the safe load capacity of constructed surfaces, including point and distributed loads
• work practices involving the storage of materials on constructed surfaces are monitored by competent persons
• the work surface has a safe means for people to enter and exit and move around the work area.

More information

• Managing the risk of falls in housing construction – Code of practice (PDF 2.2MB)
• Construction work – Code of practice (PDF 1MB)
• Formwork – Code of practice

A 46-year-old skid-steer loader operator / construction labourer suffered serious back injuries after falling feet first approximately six metres into an unprotected pier hole on a residential construction site. The worker was walking around the front of the truck when he fell into the pier hole. The hole was not visible due to shadowing from the cab of the truck. A pier hole covering was not in place when the incident occurred.

The risk of falls into pier holes on construction sites is a known risk and continues to present a significant risk of fatality or serious injury.

You must implement ‘reasonably practicable’ control measures to manage the risks associated with falls in and around pier holes. Make sure:

• pedestrian and/or vehicle access to the area is prevented, or where this is not reasonably practicable, pier hole covers are installed to minimise the risks associated with falls
• pier hole covers are designed by competent person(s) to withstand all potential pedestrian traffic and impact forces, and vehicular traffic where it is deemed permissible. Fence panels are not rated as penetration covers and should not be used as a control measure
• pier hole covers are installed in accordance with their design, including fixing the covers securely in place and being clearly labelled to prevent unauthorised removal or movement
• pier hole covers are designed to minimise ingress of materials and debris
• pier hole covers are only removed by authorised persons and when it is safe to do so
• inspections of pier hole covers occur routinely and following unplanned events e.g. adverse weather

Excavating pier holes more than 1.5 metres deep is considered ‘high risk construction work’. You must have a Safe Work Method Statement for the work being conducted.

On-the-spot fines of up to $3,600 may be issued for placing workers lives at risk by not protecting them from falls from heights.

More information

• Excavation work – Code of practice
• Managing the risk of falls in housing construction – Code of practice

A 52-year-old worker has suffered fatal injuries after falling eight storeys at a Liverpool construction site. The worker was repairing flashing on the side of a building using an industrial rope access system at the time of the incident.

Work involving industrial rope access should only be undertaken when other means of accessing the work area are not reasonably practicable, such as scaffolding or an Elevated Work Platform.

When it is necessary to use an industrial rope access system you must implement ‘reasonably practicable’ control measures to manage the risks associated with working at heights.

Prior to connecting to an industrial rope access system ensure:

• work has been planned, including hazard identification and risk assessment of rope access related tasks, and a suitable rope access system is designed
• anchor points have been inspected by a competent person and certified as safe to use, and information is available regarding their safe use, for example, load ratings
• the anchor points are marked with their load rating and the load correlates with the certification
• a visual inspection is conducted of the anchor points and site to ensure a safe access system can be implemented, and to determine what equipment will be needed to provide safe access to, and descent from, the work area
• consideration is given to how post-installation/certification modifications to the site may affect the useability of anchor points, for example, changes to the surface, or additional surfaces around anchor points
• the building façade is inspected for areas that may compromise the rope access equipment, and for materials that could be loosened and fall during the work
• all equipment to be used is inspected by a competent person and is safe to use
• a spotter is on site, has clear sight of the workers, communication means, and clear procedures are established
• emergency rescue procedures are established and clearly communicated to all workers
• all workers are competent in the technique, including emergency procedures, and have been trained in the correct operation of the particular equipment they are using
• exclusion zones are established and enforced that exclude and alert the public that industrial rope access systems are in use below the work area and near any anchorage locations
• the work is planned to account for the expected weather conditions

Industrial rope access systems should include:

• a main working rope and a back-up safety rope, each anchored independently to the other
• safe access to anchor points to set up the rope access system
• a full body or work positioning sit harness with shoulder straps
• descending/ascending devices and back up devices that are suitable for the type of work being undertaken, and appropriate for the size/type of rope and combined weight of the rope access technician and any equipment worn
• descenders that automatically stop the descent if the rope access technician loses control, i.e. lock automatically in the hands-free mode, and preferably should also fail to safe in all modes of operation, for example, stop the descent automatically when gripped too tightly in panic (panic locking)
• preferably, back up devices that require minimal manipulation by the rope access technician, and fail to safe in all modes of operation, for example, prevent or arrest a fall even when gripped in panic
• the correct personal protective equipment (PPE) for the tasks being undertaken, for example, helmets, gloves, hearing protection, goggles or masks

The use of industrial rope access systems is considered high risk construction work if it involves construction work where there is a risk of a person falling more than 2 metres. The Work Health & Safety Regulation 2017 requires that high risk construction work must not be carried out unless a safe work method statement (SWMS) is prepared for the work.

More information

• Managing the risk of falls at the workplace code of practice
• AS/NZS 4488.2 – Industrial rope access systems – Selection, use and maintenance
• IRATA International code of practice for industrial rope access
• AS/NZS 22846.1 Rope access systems Part 1: Fundamental principles for a system of work
• AS/NZS 22846.2 Rope access systems Part 2: Code of practice

A 26-year-old casual worker employed by a labour hire company sustained neck injuries when he was pinned underneath a construction garbage chute as it collapsed. The chute, designed for free-flowing material, was filled vertically with soil when it collapsed. The worker had only been on site for a week and a half.

Implement ‘reasonably practicable’ control measures to manage the risks associated with using construction garbage chutes.

When planning to install a chute at a workplace, make sure it can be installed, used and dismantled in accordance with the designer’s requirements. Consider:

• the type and weight of materials expected to be moved
• the planned location of the chute, including local weather conditions e.g. exposure to wind
• the means of support required to support the chute and the intended materials and
• any risks that may be introduced by its installation.

Where the designer or manufacturer’s information is not sufficient to manage all associated risks, consult with the designer or manufacturer. Where this is not practical, consult with a competent person.

Installing a chute

When installing a chute on site make sure:

• the chute is installed in accordance with the designer or manufacturer’s instructions, or those of a competent person
• the chute is secured to the scaffold or other supporting structures ensuring any weight placed on the fixtures does not impact overall integrity
• no alterations or changes to design of the chute or its method of support / fastening are made without prior approval from the designer, manufacturer, or competent person
• any joins in the chute are tightly secured to help support the chute against high wind gusts and prevent breakages as large garbage passes through
• a visual inspection of the chute and its fastenings is completed before any work begins
• the chute system is isolated and not used if there is any damage or unusual performance identified, until advice has been received from a competent person on how to manage the risks.

Using the chute

When using the chute on site make sure:

• you provide clear instructions for what can, and what cannot, be placed in the chute and ensure this is communicated and understood by all workers onsite
• additional measures are put in place when using wet materials or large articles that can cause blockages and/or overloading (e.g. spotters that confirm the movement of the material/articles)
• you immediately stop using the chute system if it becomes blocked or overloaded
• any material put into the chute is not heavier than the weight rating of the chute
• guardrails are in place to protect any opening in the chute to prevent workers falling into the chute
• a perimeter is enforced around the landing spot at the bottom of the chute to prevent injuries from falling garbage or debris – consider barricades, guardrails and warning signs
• the top of the chute is covered to prevent falls when not in use.

At risk workers

If you have at risk workers, such as labour hire, CALD, migrant or young workers on your site, make sure:

• they have met the supervisor
• someone suitably skilled inducts them onto the site
• they are told about any places they should not go, and why
• someone suitably skilled shows them how to do the job and use any equipment or machinery required
• they understand any instructions provided – language and literacy barriers need to be considered
• they are supplied with any required safety equipment and know how to use it correctly
• they understand what to do in an emergency, including where any evacuation points are located and who to contact if required
• they are encouraged to raise safety concerns and understand who they should speak to about their concerns.

Download a PDF of this Incident Information Release - Construction garbage chute collapse (PDF 244kb)

More information

• Code of Practice – Construction work (PDF 1MB)
• Code of Practice - Managing the risk of falls in housing construction (PDF  2.2MB)
• Code of Practice – How to manage work health and safety risks (PDF 555kb)
• At risk workers information page
• Induction of labour hire workers for host employers guide
• SafeWork NSW translated resources hub

A 19-year-old labour hire worker suffered serious injuries after falling more than 12 metres through an open penetration at a Shellharbour construction site. The worker was drilling holes into Dincell wall panels in the lift shaft on Level 2 when he fell through the open penetration to the concrete lower ground floor.

Implement ‘reasonably practicable’ control measures to manage the risks associated with falls through penetrations while completing formwork and other construction. Make sure you:

• install edge protection or cover any penetrations that will be exposed during the stripping/dismantling process, such as:
  • leading or perimeter edge protection – handrails should comply with AS 1657, or
  • fit-for-purpose penetration covers that withstand the load of workers and materials. Ensure they are secured in position and are clearly identified so they are not mistaken for construction material
• include cast-in-mesh as a back-up system to protect penetrations in concrete slabs. They should be 50mm x 50mm or smaller mesh size and made of material capable of withstanding potential loads
• ensure workers always use a suitable work platform for the task, such as scaffolds, elevated work platform, boom or scissor lift where possible. Workers must be trained to use the work platform or scaffold
• provide a safe way to access and exit the work area
• prepare a safe work method statement for all high-risk construction work
• have an emergency plan in place and ensure it has been adequately explained to all workers.

SafeWork NSW inspectors regularly blitz construction sites to check compliance and talk with businesses and workers about how to work safely at heights. Use this Construction Falls from Heights Blitz checklist (PDF 504kb) to find out if your construction site is working at heights safely.

More information

• Formwork - Code of Practice
• Managing the risk of falls at workplaces - Code of Practice (PDF 4.1MB)
• SafeWork NSW formwork information page
• Falls through voids – safety video

A building in Crows Nest partially collapsed after excavation work had been undertaken at an adjacent construction site. Workers were completing steel fixing and formwork for a capping beam when they observed cracking and evacuated the site before the collapse. Fortunately, no workers or members of the public were injured.

Implement ‘reasonably practicable’ control measures to manage the risks associated with unplanned structural collapse before, during and after excavation work.

Before excavation work

Seek engineering advice

• consult with experienced and qualified competent persons such as engineers and specialist excavation contractors regarding all potentially affected structures and the proposed excavation methods, depths, and sequence
• carry out the necessary testing and analysis to determine the soil and groundwater conditions of the site in consultation with a geotechnical engineer
• determine the size, type, and extent of a potentially affected structure’s foundations by obtaining all relevant information and carrying out the necessary inspections and testing in consultation with a structural engineer
• obtain written advice from competent persons regarding any temporary or permanent control measures required to adequately support all potentially affected structures, their foundations, and excavated faces. For example, structural supports to adjacent foundations or structures; designs for benching, battering, shoring, piling and/or earth anchors, limitations to excavation depths or distances from structures, limitations to de-watering, limitations to excavation methods or sequencing
• carry out detailed inspections of any potentially affected structure and record the results in a dilapidation report to be shared with all relevant parties
• develop a monitoring plan for all potentially affected structures which may include implementing survey markers and/or vibration monitoring devices.

Plan your work

• incorporate all ‘hold-points’ into your construction program as required by competent persons
• consider the type of plant being used, including the size, type position and reach to minimise the risk of plant colliding with existing structures and overhead powerlines
• establish exclusion zones to protect workers from unplanned structural collapses
• ensure safe access and working areas
• have designated areas for the storage of excavated, demolition or construction materials.

During excavation work

• ensure the adjacent building’s foundations are not undermined
• ensure any requirements identified by the structural or geotechnical engineers are in place
• continue to consult with experienced and qualified professionals at critical stages of the excavation work and following unplanned events, e.g. heavy rainfall. Do not proceed beyond pre-determined ‘hold-points’ without written confirmation from the relevant party.
• ensure all workers carrying out the excavation are competent (e.g. check qualifications, experience, and any required licences)
• provide clear instructions to site workers and visitors including any updates as required
• ensure the work is supervised by a competent person and in accordance with the planned methods and sequencing
• if issues arise, stop, take action to ensure everyone is safe, and consult with all parties about how to rectify the issues.

More information

• Excavation work code of practice (PDF 4MB)
• Demolition work code of practice - Safe Work Australia (PDF 1.3MB)

Incident animation - building collapse

A worker and an apprentice were waterproofing a laundry in Seaforth when it appears vapours from an adhesive and solvent ignited. The small room they were working in was engulfed in a fire ball, resulting in burns to 55% of one worker’s body, and 45% of the other’s body. Both workers were transported to Royal North Shore Hospital.

Consider ‘reasonably practicable’ control measures to manage the risks associated when working with chemicals.

You must:

• Remove all ignition sources such as heat welders and heat guns. Assess the distance of possible ignition sources from the hazardous area, considering ventilation and minimum 3 metre distances. Make sure flammable chemicals are stored in a cool, well ventilated area, away from heat and keep containers closed when not in use
• Make sure workers have access to safety data sheets and adhere to instructions on labels
• Make sure emergency preparedness on site such as suitable extinguishers and access to running water
• Make sure personal protective equipment is worn as per the safety data sheet for the product
• Make sure flammable chemicals are used in a well ventilated area to minimise the risk of a hazardous atmosphere developing
• Consider the use of mechanical ventilation that is specifically rated for hazardous areas

More information

• SafeWork NSW: Hazardous Chemicals

View the latest incident information releases at safework.nsw.gov.au

A worker has fallen approximately 8m into a lift shaft while working on the refurbishment of a building in Sydney. The worker was removing timber rafters from a roof frame when he fell and sustained serious injuries.

This is the twelfth incident information release SafeWork NSW has published this year relating to falls from heights in the construction industry. Falls from heights are the biggest killer on NSW construction sites.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with working at heights.

Consultation and coordination between a principal contractor and sub contractors on site is essential to ensure any task being undertaken is done so in a safe manner and does not impact others around you. Businesses cannot delegate their work health and safety duties to someone else.

Make sure:

• workers always use a suitable work platform for the task, such as scaffolds, elevated work platform, boom or scissor lift
• workers are trained how to use the suitable work platform or scaffold
• workers are provided with a safe way to access and exit the work area
• you prepare a safe work method statement for all high-risk construction work
• you have a plan in place in case of an emergency.

SafeWork NSW inspectors regularly blitz construction sites to check compliance and talk with businesses and workers about how to work safely at heights. Use this checklist (PDF 504kb) to find out if your construction site is working at heights safely.

More information

• Working at heights guidance material
• Managing the risk of falls at workplaces – Code of practice (PDF 4.1MB)
• Falls from heights poster (PDF 1.8MB)
• Pocket guide to construction safety (PDF 1MB)
• Construction Site Supervisors: Take 5 podcast (Audio podcast)

A 32 year old worker fell approximately 4m after the glass atrium roof he was standing on smashed. Scaffolding immediately above the glass atrium roof was being dismantled and a scaffold standard fell onto and smashed the glass panel the worker was standing on. The worker suffered pelvic and limb injuries, concussion, severe cuts and bruising in the fall. A courier walking through the foyer of the building at the time also suffered minor injuries as a result of the incident.

Reasonably practicable control measures must be implemented to manage the risks associated with dismantling scaffold and working at heights. You must make sure:

• workers must hold the correct High Risk Work Licence when dismantling scaffolding
• workers are provided with an adequate Safe Work Method Statement (SWMS) before starting any high-risk construction work, which should be kept on-site until the scaffold is dismantled
• any work undertaken at the workplace is done in accordance with the SWMS provided
• principal contractors have systems in place to ensure proper planning and sequencing of trades so that the scaffold remains structurally safe and compliant throughout the build, including ensuring components are stacked appropriately through the dismantling process
• exclusion zones are established so that only workers involved in dismantling process can access the area
• consideration is given to damage that may occur from falling objects and controls are implemented to minimise this risk, including those that may impact areas outside of the workplace and other persons
• new workers to the workplace are provided with adequate information and supervision to manage health and safety, such as inductions
• work is undertaken from secure surfaces/platforms that are specifically designed to support the weight of persons and/or construction materials.

Scaff Safe 2020

SafeWork NSW continues to target scaffold safety on construction sites. Inspectors are attending worksites and talking with employers and workers to ensure compliance. Inspectors are also working with scaffold suppliers and installers to ensure scaffolds are built to standard and are safe.

On-the-spot fines of $720 for individuals and $3,600 for employers can be issued to those who place workers lives at risk from falls from heights, or for undertaking scaffolding work without a high risk work licence.

More information

• Safe Work Australia: Scaffolds and scaffolding work general guide
• Construction falls from heights safety checklist (PDF 503kb)
• Guidance material on falling objects
• AS\NZS 4576-1995 Guidelines for scaffolding

A 40-year-old steel worker suffered a fractured leg and ankle injury after falling approximately 2.4 metres through a formwork deck infill panel that gave way on a construction site in Newcastle.

The location where the incident occurred.

Safety information

Implement ‘reasonably practicable’ control measures to manage the risks associated with infill panel in formwork.

You must ensure:

• access to the area is prevented, or where an infill panel is used, the panel and supporting components such as props, frames, bearers and joists are designed and installed to withstand pedestrian traffic
• the design of formwork and infill panels is developed by a competent person
• supporting falsework, props or components are protected and secured to prevent unauthorised alterations and accidental dislodgement
• components used to support infill panels are incorporated into the design and installed in accordance with the manufacturer’s instructions or the instructions of a competent person
• visual inspections of the infill panel and supporting components are included in all formwork inspections to ensure they remain structurally sound and installed in accordance with their design

Formwork inspections should be undertaken:

• routinely as the formwork is being constructed and while workers can access the area
• prior to loading
• periodically following loading

Inspections should also occur following unplanned events (e.g. adverse weather). Inspections should be recorded and include evidence of the condition of the formwork at the time of the inspection (e.g. photographs).

Certification that the formwork complies with AS3610 and the design should only be provided upon completion of the formwork, including the completion of rectification works and re-inspection of any identified issues.

On-the-spot fines of up to $3,600 may be issued for placing workers lives at risk by not protecting them when working at heights.

More information

• Formwork – Code of practice
• Managing the risk of falls in housing construction – Code of practice
• Managing the risk of falls at workplaces – Code of practice
• Pocket guide to construction safety
• Construction falls from heights blitz checklist
• Poster -  Prevent falls from heights (PDF, 2419.61 KB)
  • Arabic (PDF, 2526.83 KB
  • Chinese simplified (PDF, 2537.56 KB)
  • Chinese traditional  (PDF, 2532.26 KB)
  • Vietnamese (PDF, 2545.19 KB)

Safety information

If working at height, planning should be undertaken to ensure the safest method and correct equipment is used for the job. The decision to use a specific MEWP should not be based solely on the availability of a MEWP at a workplace.

When selecting the type of MEWP to be used be aware of the limitations regarding terrain, slope, wind loading and manual side force. Some MEWPs are not designed for outdoor use or have different operation limitations for outdoor use. Note a maximum side manual force of 200 N is equivalent to a 20kg force at waist height.

If you have determined that a MEWP is the most suitable method to perform the work at height, you must implement ‘reasonably practicable’ control measures to manage the risks associated with using the MEWP throughout the job. These include:

• choose the right MEWP for the job and only use it for the purpose it was designed
• ensure that information, instruction and training is provided to workers who use MEWPs
• train workers in emergency procedures so occupants can be rescued in the event of an emergency
• hold a high-risk work licence for boom type MEWPs with a boom length over 11 metres
• carry out a prestart (pre-operational) inspection and record the information in the logbook
• ensure the MEWP is suitable for the ground conditions, including gradeability
• do not exceed the safe working load of the platform (some MEWPs have dual ratings to limit the number of people in the platform if used outdoors)
• do not exceed the manual side force (as shown on the compliance plate) when carrying out activities such as drilling, pushing
• do not work in locations where the loss of control of external objects could impact the platform of the MEWP, e.g. tree branches, steelwork
• do not use indoor rated MEWPs outdoors
• make sure outdoor rated MEWPs are not operated outside if wind speed rating exceeds the maximum limits (as shown on the compliance plate)
• wear a safety harness if there is a risk of falling from a height and ensure it is attached to a designated anchor point on the MEWP

Further information

You can also refer to the following guidance materials:

• Work Health and Safety Regulation 2017:
  • Clause 214 – Powered mobile plant – General control of risk
• SafeWork NSW – Code of practice – Managing the risk of plant in the workplace (PDF 2.1MB)
• SafeWork NSW – Code of practice – Managing the risk of falls at workplaces (PDF 4.1MB)
• AS 2550.10-2006 Cranes hoists and winches – Safe use – Mobile elevating work platforms (PDF 597kb)

A 29-year-old concrete cutter fell approximately 7 metres after temporary edge protection gave way on a construction site at Caringbah. He was taken to hospital with back and pelvic injuries.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with falls on construction sites.

You must:

• develop a plan – in consultation with workers and before work begins – for managing the risk of falls on site, including in and around excavations
• make sure excavations, trenches and openings are securely fenced to prevent falls and unauthorised access
• ensure that temporary edge protection has sufficient height and strength
• provide safe access for workers that is clearly defined and free of debris or stored materials
• limit access to excavations and trenches to only those required to work in or near the area
• have adequate site fencing to prevent unauthorised access to the site.

Statistics

Falls from heights are the biggest killer on NSW construction sites. This is the ninth incident information release published by SafeWork NSW this year relating to a serious fall incident.

On-the-spot fines of up to $3,600 may be issued for placing workers lives at risk by not protecting them when working at heights.

More information

• Managing the risk of falls in housing construction – Code of practice
• Managing the risk of falls at workplaces – Code of practice
• Pocket guide to construction safety
• Construction falls from heights blitz checklist
• Falls from heights poster – Arabic
• Falls from heights construction poster - Chinese

A 43-year-old worker suffered serious head injuries after falling from a work platform while installing ceiling joists at a residential construction site in Bellevue Hill. He was standing on a plank, that at one end was resting on the top of an A frame ladder and the other end resting on scaffolding. The plank was set up to raise the worker high enough to install the roof section.

Consider ‘reasonably practicable’ control measures to manage the risks while working at heights on work platforms or scaffolds.

Make sure:

• you always use a suitable work platform for the task, such as scaffolds, elevated work platform, boom or scissor lift
• workers are trained how to use the suitable work platform or scaffold
• workers are provided with a safe way to access and exit the work area
• you prepare a safe work method statement for all high-risk construction work
• you have a plan in place in case of an emergency

When using scaffold, make sure:

• you use a system suitable for the task and compliant to AS/NZS 1576.1:
  • Working platforms at least 450mm wide
  • Edge protection installed on platforms that are 2m or higher
  • Edge protection installed on other platforms where the nature of work prevents worker being fully aware of proximity to platform edge
• scaffolds are erected and dismantled by competent persons in accordance with manufacturer’s instructions, and by persons who hold the appropriate class of high-risk work licence where required
• the scaffold is stable at all times, including during erection, in situ, during and after any alterations, and when dismantling
• people can’t access incomplete scaffolds

Statistics

Falls from heights are the biggest killer on NSW construction sites and this is the eighth incident information release this year published by SafeWork NSW due to a serious fall from height incident. Most serious falls incidents occur from a height of four metres or less.

On-the-spot fines of up to $3,600 may be issued to those placing workers lives at risk by not adequately protecting them when working at heights.

More information

• Scaffold safety checklist
• Working at heights guidance material
• Managing the risks of falls in housing construction – Code of practice
• Managing the risk of falls at workplaces – Code of practice
• Falls from heights poster
• Pocket guide to construction safety

View the latest incident information releases at safework.nsw.gov.au

Since the start of this year, we've been notified of 10 incidents where a worker has fallen through a roof, resulting in either a serious injury or fatality.

Falls from heights continues to be a major cause of fatalities and serious injuries at workplaces across NSW.

Sydney

A 52-year-old subcontractor fell more than three metres onto a concrete pavement at a school in Wahroonga. He was cleaning the roof gutters when he stepped onto polycarbonate roof sheeting and it gave way. He suffered severe head injuries and passed away in hospital.

Wahroonga school

Molong

A  21-year-old apprentice carpenter fell through perspex roof sheeting at a manufacturing plant in Molong, in western NSW. He fell seven metres onto a concrete floor, fracturing his wrist, ribs and pelvis.

Molong manufacturing plant

Alectown

A 27-year-old roofing contractor fell more than three metres through the roof of a sheering shed at a rural property near Parkes. He was installing solar panels when the alsynite roof sheeting gave way. He fractured his back.

Roof of shearing shed

Safety information

Not all areas on a roof are safe to walk on. Even roof sheeting that claims to be okay to walk on is reliant on correct installation and can become brittle over time. Don’t walk on skylights, or plastic and asbestos roof sheeting, unless assessed as structurally sound by a competent person.

Consider what tasks can be done without accessing the roof. For example, work from underneath using a scaffold or elevated work platform.

If you must access the roof, check its condition, the roofing materials, fixings and safety mesh to determine the safest path.

If sheeting appears brittle, you must manage the risks of falling through the roof.

You must:

• install guardrails around non-trafficable areas, or use a work positioning system
• cover non-trafficable sheeting securely and place warning signs nearby
• work from temporary work platforms (crawling boards) or roof ladders, where appropriate
• install safety mesh
• use an adjustable fall-arrest system, such as a harness, with proper anchor points, and train workers in how to use them
• prepare a site-specific safe work method statement (SWMS) for all high risk construction work
• have plans in place in case of emergency, particularly with respect to the use of fall arrest systems.

More information

• Code of practice for managing the risk of falls at workplaces
• Falls through skylights and plastic roof sheeting
• Working safely at heights

A worker was crushed between a punt and piles at a marine construction site at King Street Wharf, Sydney.

While measuring the piles, the worker accidentally knocked the punt controls, propelling it forward, crushing him between the piles and the punt, before he fell into the water. He suffered broken ribs, a broken collar bone and a punctured lung.

NSW Water Police and Australian Maritime Safety Authority also responded to the incident.

Site of incident

Safety information

Implement ‘reasonably practicable’ control measures to manage the risks associated with working on water.

You must:

• perform the task from land, where practical
• make sure operator controls are properly located or guarded to prevent accidental activation
• consider the conditions, such as weather and swell, and choose a safer location if necessary
• make sure there is a safe system of work for doing the task on water, and prepare a safe work method statement (SWMS) if the task is considered high risk construction work
• make sure workers are trained in the correct procedures/SWMS
• make sure there are enough workers to do the task safely, such as operating the vessel, acting as spotter when visibility is poor, and helping with emergency rescues
• make sure all plant, equipment, e-stops and lanyards are used and are functioning as per manufacturer’s specifications
• manage the risk of falling overboard - use guardrails, harnesses, safety lines and life-jackets.

More information

• Code of practice for managing the risk of plant in the workplace
• National Standard for Commercial Vessels – Part C – Section 1 Arrangement, accommodation and personal safety
• AMSA Guidance Notice – Unpowered Barges
• AMSA National Law – Exemption 41 (unpowered barges)
• Construction safe work method statement

Date of incident: 15 May 2020

A 51-year-old labourer suffered serious head injuries after falling nearly three metres onto a tiled surface at a house in Eastwood. He stepped off the roof onto plastic covering a pergola and it gave way. He later died in hospital.

Safety information

Falls from heights is the number one killer on construction sites in NSW and every year there are dozens of serious incidents. Many of these incidents involve a ladder being used incorrectly or stepping on an unstable surface.

Consider ‘reasonably practicable’ control measures to manage the risks associated with working on ladders and roofs.

Before starting work on a roof, inspect the condition of skylights, plastic sheeting and asbestos cement sheeting, wire mesh and anchor points. To determine if surfaces are safe to walk on, check the material, how it’s fixed and whether it’s brittle.

Make sure you:

• plan the work to avoid walking on brittle material
• work from a solid construction to avoid standing on the roof - use temporary work platforms, such as crawling boards and ladders
• install barriers, such as guardrails, covers and warning signs
• install safety mesh
• use a scaffold or scissor/boom lift
• use an adjustable fall-arrest system, such as a harness, with proper anchor points – train workers how to use them

When working in situations where a ladder may be required, you must:

• consider using an elevated work platform or scaffold, rather than a ladder
• choose the right ladder for the job. It should meet Australian standards and the load requirements of the job. An A-frame or extension ladder may be appropriate for some tasks, but a platform ladder is safer
• inspect the ladder for damage before using
• only use a ladder if you’re physically capable of doing so safely
• set-up a ladder on a flat, stable surface, or use leg levellers, anti-slip gutter guards and stabilisers
• maintain three points of contact when climbing or descending the ladder - two hands and one foot, or two feet and one hand
• only take small items up or down a ladder – never large or heavy items such as building materials. Wear a toolbelt to enable you to maintain three points of contact
• never lean or reach away from the ladder
• not exceed the working load limit on the ladder
• only use A-frame ladders locked in fully open position
• secure your extension ladder at the top, bottom or both - or have someone hold it
• make sure the ladder is one metre past the stepping point
• extension ladders are angled at a ratio of 1:4 - position the base of the ladder one metre away from the structure for every four metres of height
• not climb or work past the second-last rung of a ladder, and never straddle the top of an A-frame ladder
• make sure fall prevention is used at the stepping off point of the work area
• remain facing the ladder and climb to the bottom rung before stepping off.

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

More information

• Code of practice for preventing falls in housing construction
• Code of practice for managing risks of falls at workplaces
• Safe use of ladders video
• Ladder safety page – Safe Work Australia
• Australian standards related to ladders

A worker suffered cuts and bruises when his telehandler overturned as it was lifting a 650kg piling cage, while located across a sloping driveway.

Resting place of telehandler

Safety information

Telehandlers are generally used with fork tynes. If allowed by the manufacturer, other attachments, such as bale grabs, buckets, work platforms, lifting hooks and crane jibs can be used.

The correct attachment must be used for the task. For example, tynes must not be used to freely suspend a load.

When travelling with a load, the load should be as close to the ground as possible, and the boom retracted.

A freely suspended load affects the stability of a telehandler, due to the raised boom and swinging load. Instability is even greater when working on a slope as the load swings further from the point it is connected to the telehandler.

When lifting a load with a telehandler, make sure:

• you follow the telehandler operating instructions
• the telehandler has the appropriate attachments for the task
• you know the maximum slope for operating the telehandler, and its limitations
• you assess the slope of the ground
• you don’t travel across the slope, unless within the limits of the telehandler
• you use ground support, if required, to maintain stability
• you use percentage deration charts when working on a slope
• you use exclusion zones.

Operator licences

If the telehandler has a capacity greater than three tonne and is configured as a crane, you must have a high-risk work licence – non slewing crane (CN class) or a slewing mobile crane licence.

If the telehandler has a capacity less than three tonne, you must be trained and competent in operating the telehandler and attachments.

To use a slewing telehandler, with a slewing limit greater than five degrees, you must have a high-risk crane licence – C0, C1, C2 or C6.

If the telehandler is used as a work platform, with a boom length of 11 metres or more, you must have a high-risk work licence – elevated work platform (WP class). If the boom is less than 11 metres, you must be trained and competent in operating the telehandler and attachments.

More information

• Guidance note: Telehandlers – Design and licensing
• Code of practice for managing the risk of plant in the workplace
• Working with or around plant safety alert
• Code of practice for moving plant on construction sites
• AS 2550.19 Cranes, hoists and winches - Safe use Part 19 Telescopic handlers

Date of incident: 29 April 2020

At a construction site in Belrose, a 36-year old dogman fell through an open void in a deck as he was instructing a crane operator to lower materials. He fell three metres, impaling his left shoulder on a steel bar.

The void the worker fell through

Safety information

Falling from a height is the number one cause of death and permanent disability in the formwork industry. Most incidents involve open voids on formwork decks and unprotected edges.

Consider ‘reasonably practicable’ control measures to manage the risks associated with falls from formwork decks and through open voids.

Make sure:

• all voids have edge protection or are covered, and that covers are securely fixed in place and marked ‘Danger: penetration below’
• you install guardrails and other edge protection, such as perimeter scaffolds and formwork screens, into pre-assembled systems before they’re lifted into position
• leading edges are minimal
• you work below the formwork deck, using temporary work platforms, and limit the distance between joists to 450 mm
• catch platforms are used when other edge protection is not reasonably practicable
• guardrails comply with Australian standards
• access to incomplete decks is prevented.

More information

• Formwork 
• Working at heights 
• Code of practice for managing the risk of falls at workplaces
• Code of practice for construction
• AS 1657: Fixed platforms, stairways and ladders

Date of incident: 23 March 2020

A 24 year old worker suffered broken hips, a dislocated shoulder and a broken jaw when he fell more than 20 metres down a ventilation duct. Falls from heights is the number one killer on NSW construction sites.

The duct opening (left) and the exit point (right)

The investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to work health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

You must consider ‘reasonably practicable’ control measures to manage the risk of falls from heights.

Make sure you:

• establish and highlight ‘no go’ zones around openings and penetrations during construction work
• immediately make safe any opening or penetration after it is formed using edge protection and or covers that are strong enough to withstand the load of a worker and materials, fix them in place, and mark them so they’re not mistaken for construction material.

Further information

• Code of practice for managing the risk of falls at workplaces
• Code of practice for managing the risk of falls in housing construction
• Code of practice for construction work
• Falls through voids - safety video
• SafeWork pocket guide to construction safety

Date of incident: 19 February 2020

An 80-year-old man fell in the carpark of a supermarket in western NSW after appearing to trip on a piece of plywood, lying at the rear of a ute. The man suffered an injury to the left side of his head and died in hospital a week after the fall.

The site just before incident happened. Note plywood at rear of ute.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with working in public areas.

Make sure you:

• prepare a safe work zone in consultation with the client, principal contractor and subcontractor
• work zones don’t obstruct safe access to public areas
• fence and identify your work area from general public areas
• use appropriate signage
• use alternate pedestrian access, if required, with signs
• materials are contained within your isolated work zone
• good housekeeping practices are maintained in and around the work zone
• serious incidents and near misses are immediately reported to the site controller
• serious incidents are reported to us
• contact ambulance and police, if required.

More information

• Code of practice for managing the risk of falls at workplaces
• Fact sheet: Slips and trips at the workplace.
• Code of practice for construction work
• Code of practice for work environment and facilities

Date of incident: 9 January 2020

A worker died after falling more than two metres through a fibro roof at Wollongong, while attempting to get onto a ladder to get off the roof.

The investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.The investigation

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Consider ‘reasonably practicable’ control measures to manage the risks associated with falls.

Before starting work on a roof, you should inspect the condition of sheeting to determine if it can be walked on, such as a skylight, plastic or asbestos cement. Also, inspect the supporting roofing materials and fixings.

Make sure:

• you plan the work to avoid walking on brittle material
• you use an elevated work platform or boom lift, if possible
• you use temporary work platforms, such as crawling boards,
• you use a fall arrest system, such as a harness, with anchor points – train workers how to use it
• you install safety mesh.

When you use a ladder, make sure:

• it’s at a 1:4 ratio
• it’s tied off at the top (and/or footed) and extends at least 900mm past the landing
• you don’t unclip the lanyard until standing on the ladder
• you review your control measures.

Further information

• Code of practice for managing the risk of falls at workplaces
• Falls through skylights and plastic roof sheeting
• Working safely at heights

Download a PDF of this release

Date of incident: 7 January 2020

An apprentice electrician fractured his pelvis and vertebrae after falling more than three metres from a roof while installing solar panels at a construction site in Parklea.

Worker fell from roof off this building.

The investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.The investigation

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Consider ‘reasonably practicable’ control measures to manage the risks associated with falls from roofs. Make sure:

• you work from the ground or on a solid construction, wherever possible
• before accessing the roof, you:
  • plan the work and use the right equipment to access the roof
  • discuss the work with all workers
  • check the condition of the roof and type of roofing material
• the roof is dry and clean
• workers have a safe means of access and egress to work areas
• a fall prevention device – temporary work platform, edge protection, guardrails or scaffolding – is used and workers know how to use them
• a fall-restraint or fall-arrest system – harness, lifeline or industrial safety net – is only used when edge protection or work platforms are not reasonably practicable
• you securely cover and mark, or edge protect, all open penetrations in the roof
• ladders are placed at a ratio of 1:4 to the wall, secured at the top and bottom, and extended at least one metre above the roof edge – and you always maintain three points of contact
• you consider using an elevating work platform or scaffolding instead of a ladder
• your workers always use equipment properly.

More information

• Video safety alert – Solar Installation – risks of falls
• Video safety alert – Solar Installation – electrical risks
• Code of practice for managing the risk of falls at workplaces
• Code of practice for managing the risk of falls in housing construction
• Construction falls from heights safety checklist (for principle contractors and site supervisors)

Date of incident: 6 December 2019

A 31-year-old man suffered critical injuries when he fell more than 10 meters through a plastic roof-panel at a school in Croydon.

Worker fell from this roof

The investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.The investigation.

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Consider ‘reasonably practicable’ control measures to manage the risk of falls.

Before starting work on a roof, carry out an inspection to determine:

• the condition of sheeting that shouldn’t be walked on, such as a skylight, plastic or asbestos cement sheeting
• the presence and integrity of safety wire mesh
• the suitability of anchor points.

To determine if surfaces are safe to walk on, check the surrounding material, how it’s fixed and whether it’s brittle.

Make sure you:

• plan the work to avoid walking on brittle material
• work from a solid construction to avoid standing on the roof
• use temporary work platforms, such as crawling boards and ladders
• install barriers, such as guardrails, covers, and warning signs
• install safety mesh
• use a scaffold or scissor/boom lift
• use an adjustable fall-arrest system, such as a harness, with proper anchor points – train workers how to use it.

More information

• Code of practice for managing the risk of falls at workplaces
• Working at heights

Download a PDF of this release

Date of incident: 21 October 2019

While putting pickets and bunting around an excavation on a construction site in Marsden Park, a 30-year-old labourer fell three metres into the trench, suffering fractures to his leg.

_{Construction site}

The investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks of falling into an excavation at a workplace, including:

• developing a plan – in consultation with your workers and before work begins – on managing the risks of falls in and around excavations
• considering barrier fencing to further minimise accidental encroachment – perimeter barriers should be effective
• considering a suitable location for inspection, and access and egress for emergency situations
• consulting with an engineer to determine distances where shoring, benching and battering should be used – and monitor distances, particularly after rain
• using a landing platform – or scaffold towers for big excavations – to ‘in-fill’
• preparing a safe work method statement when there is a risk of falling more than two metres – and ensure workers are inducted and supervised in its implementation
• backfilling or covering the excavation.

Further information

• Code of practice for excavation work
• Code of practice for managing the risk of falls at workplaces
• SafeWork NSW falls from heights action plan

Download a PDF of this release

Date of incident: 29 November 2019

Incident overview

A fire system installer suffered fatal head injuries when he was working on a pipe as part of the installation of a fire-fighting system on the 21st floor of a construction site in Darling Harbour.

SafeWork NSW inspectors responded to the incident.SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Businesses must implement ‘reasonably practicable’ control measures to manage the risks associated with working on pressurised pipes, including:

• develop safe systems of work and apply isolation procedures that identify, lock out and tag out all energy sources while work or testing is being carried out. Where reasonably practicable provide engineering controls such as guards and removing workers from the area
• ensure end-caps are installed according to the manufacturer's specifications, including tightening fasteners to the specified torque using appropriate tools (eg calibrated manual torque wrench and correct size sockets)
• piping that is temporarily capped is to be fitted with a pressure gauge to identify any potential stored energy. Provide a vent valve or drain to release pressure prior to work commencing
• all inspections of associated pressure equipment are to be carried out by a competent person in accordance with the manufacturer’s recommendations.

Further information

• Managing the risks of plant in the workplace
• AS2118.1:2017 Automatic fire sprinkler systems – General systems
• AS2419.1 Fire hydrant installations – System design, installation and commissioning

Download a PDF of this release

Date of incident: 11 September 2019

Incident overview

A 48 year old male worker fell approximately 5.7 metres from the top deck of a mobile scaffold he was dismantling on a residential site in Sydney. He sustained serious head injuries and later died as a result of these injuries. This is the eighth incident information release we've published this year that highlights a serious incident involving a fall from heights or scaffold.

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Each year SafeWork NSW responds to incidents where workers are injured falling from a height. Most of these incidents involve falls from scaffolds, roofs, ladders, through open penetrations and from unprotected edges.

Consider reasonably practicable control measures to manage the risk of falling from a mobile scaffold. Ensure:

• The scaffold is suitable for the task and set up on a firm, level foundation.
• A copy of the manufacturer’s assembly instructions is available and instructions are followed.
• All required components are installed, including guardrails, toeboards, diagonal bracing and internal access.
• The components are inspected before assembly and in good condition.
• The workers assembling the scaffold are competent and hold a high risk work scaffolding licence (if a person or object could fall more than four metres from the scaffold deck).
• Site specific risks are identified, communicated to workers and controlled.
• A safe work method statement is prepared for all high-risk construction work Additionally, for mobile scaffolds that remain on the same work site for more than 30 days:
• Regularly inspect assembled scaffolds to determine whether all components are present, correctly installed and in good condition.
• Implement a process for replacing faulty components and/or removing the scaffold from service if found to be defective.

Further information

Refer to the following guidance materials:

• Code of practice: managing the risk of falls at workplaces
• Erecting, altering and dismantling scaffolding
• Safe Work Australia scaffolds and scaffolding work general guide
• Safe Work Australia guide for scaffold inspection and maintenance
• Working at heights
• Pocket guide to construction safety

Download a pdf of this release.

Date of incident: 3 September 2019

While being demolished, a seven-metre brick wall collapsed onto a neighbouring property in the Sydney suburb of Balgowlah. Although no-one was injured, occupants were evacuated and Public Works said the property would need to be demolished because of the damage and unstable structure

The investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with unplanned structural collapse during demolition and excavation work. Before starting demolition work:

• Collect all structural documentation for the building, such as ‘as-built’ structural drawings, geotechnical reports and designer safety reports.
• Get a competent person to give you an engineering report, if structural or geotechnical information isn’t available, if the structure has been damaged or weakened (by fire or deterioration), or if the demolition method will impose substantial stress on the building.
• Get a competent person to check the building for asbestos, make sure it’s removed and get a clearance certificate before starting to demolish.
• Consult with all relevant competent persons during the planning of the demolition works, considering the structural documentation and/or engineering investigation reports.

When planning the works, consider the:

• effect of the proposed demolition methods and sequence on the stability and integrity of the structure being demolished, and any adjacent or adjoining buildings, at all stages of the demolition
• maximum permissible wind speed for partially demolished structures
• plant to be used for the work, including the size, type, position and reach
• ground conditions and how that may affect the use of plant or other demolition methods
• safe access and safe working areas.

Also:

• Tell all relevant people when ‘hold-points’ are required during the demolition sequence, to allow for the inspection and/or testing by competent persons.
• Make sure workers are competent and have received training and instructions on the demolition methods and sequencing.

When undertaking demolition work:

• Make sure the work is supervised by a competent person and done in accordance with the planned methods and sequence.
• Use braces, propping or shoring, to make sure the building and any nearby structures are safe and structurally stable at all times.
• Use exclusions zones to protect workers from falling objects, unplanned structural collapse and moving plant – even when work has stopped for the day, or if the risk of a structural collapse exists.
• Implement fall protection devices if work is done at heights.
• Don’t work from the top of a wall that is being demolished.
• Make sure adequate controls are in place to minimise exposure to silica dust.
• Wear safety glasses, ear muffs, dust masks, gloves and long-sleeved clothing.

When removing entire wall sections using manual demolition methods that incorporate hand tools, such as jackhammers, sledge hammers, and picks, avoid weakening the wall by:

• starting demolition at the top course of bricks using a hammer and chisel
• removing an entire row before starting the next.

Further information

• Demolition work code of practice
• Excavation work code of practice
• Wall safety during excavation work guidance material
• AS 2601-2001: The demolition of structures

Downlown a PDF of this release

Date of incident: 21 August 2019

Incident overview

A 38-year-old man sustained fatal injuries when he fell through a construction site ventilation shaft in Jordan Springs, in western Sydney. The worker was clearing building material from the roof, when he fell down the shaft.

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Falls from heights are a major cause of fatalities and serious injuries in NSW workplaces. You must consider ‘reasonably practicable’ control measures to manage the risk of falls from heights.

You should:

• Give your workers a safe means of access and egress to work areas.
• Identify penetrations and install covers or guardrails
  • Use covers that are strong enough to withstand the expected load of workers and materials; fix them in place to prevent accidental removal; and mark them so they’re not mistaken for construction material.
  • Guardrails should comply with the AS/NZS 4994 series or AS 1657.
• Identify where penetrations may open once formwork is removed and install covers or guardrails before stripping.
• Put mesh into concrete slabs, as a backup to covers or guardrails.

Further information

• Managing the risk of falls at workplaces code of practice
• Construction work code of practice
• Formwork code of practice
• Formwork and falsework guidance material - SafeWork Australia
• SafeWork pocket guide to construction safety
• Erecting and dismantling formwork -  safety videos
• Falls through voids - safety video
• Specific laws about working safely at heights - WHS Regulation 2017 Part 4.4 Falls

Download a pdf of this release

Date of incident: 19 August 2019

Incident overview

A 32 year old engineer suffered multiple fractures and internal injuries on a road works construction site, when he was crushed between a reversing excavator and a stationary light vehicle. He was transported by ambulance from the Bringelly site to Westmead Hospital where he underwent surgery.

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risk of mobile plant. Use the following risk management process:

• Identify traffic hazards
  • consult with workers and mobile plant operators
  • determine where mobile plant and vehicles are in use
  • determine potential locations and circumstances where people, plant and vehicles could collide – eg. when getting off plant
• Eliminate the risk, if possible
• If elimination isn’t possible, minimise it:
  • use bollards, barriers, safety rails or exclusion zones to separate people from moving plant and vehicles
  • use alarms to warn people of moving plant – eg. reversing alarm, flashing lights
  • plan the site’s layout to minimise plant and vehicle hazards – eg. have drive-through access to minimise reversing, locate loading areas close to storage areas
  • establish traffic flow patterns, develop right of way procedures, use signs and speed limits
  • have dedicated traffic controllers
  • restrict access
  • have mobile phone procedures
  • wear high-visibility garments.
• Document procedures in a traffic management plan
• Train, instruct and supervise your workers on the control measures.

Further information

Refer to the following guidance materials for further information:

• Excavation work code of practice
• Moving plant on construction sites code of practice
• Workplace traffic management guidance material

Download a PDF of this release

Date of incident: 9 July 2019

Incident overview

A 22 year old male worker was undertaking re-roofing activities at a school auditorium in Hunters Hill when he fell approximately 8.5 metres through a penetration. The penetration had been covered with a sheet of black plastic and weighted down with sand bags, following the removal of a roof mounted air vent.The worker was transported to Royal North Shore Hospital where he was treated for a dislocated hip, broken leg and broken elbow.

The investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

• Determine the presence and condition of non-trafficable sheeting and other brittle roof sheeting such as sky lights, plastic roof sheeting or asbestos cement sheeting.
• Determine the presence and condition of safety mesh.
• When determining whether roof surfaces are safe to walk on, consider the product materials and method of fixing, including any possible deterioration in strength. (Note: products may become brittle and fixings may become less rigid over time.)

Implement these control measures to prevent workers from falling through roofs or skylights:

• Plan the work to avoid accessing unsafe or non-trafficable areas.
• Work from an elevated work platform or boom lift to avoid standing on the roof itself.
• Install temporary work platforms and roof ladders where appropriate (eg crawling boards).
• Install barriers (eg guard rails or covers) that are secured and labelled with warning signs.
• Install safety mesh when installing the roof sheeting.
• Install a fall restraint / arrest system (harness system) that has adequately-installed anchorage points, and train and instruct workers in its use.
• Ensure workers are competent in using fall restraint / fall arrest systems and  are able to assess the need to adjust the length to limit slack as they move.

Apply these measures consistently and review them as work progresses.

Further information

You can also refer to the following guidance materials:

• Our guide to working at heights includes information on managing the risks of falls, including codes of practice and guides to working on roofs.
• Managing the risk of falls in housing construction code of practice.
• Managing risks of falls in a workplace code of practice
• SafeWork pocket guide to construction safety

Download a PDF of this release

Date of incident: 25 May 2019

Incident overview

During a concrete pour at a multi-storey building under construction, the formwork collapsed, placing three workers on the deck at risk of falling up to six metres onto broken reinforcement and support frames. The workers avoided injury by grabbing onto and climbing up the reinforcement mesh and debris.

The investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW has commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Businesses must consider all ‘reasonably practicable’ control measures to manage the risk of a formwork collapse.

These include:

• A ‘competent person’ must design the formwork to retain its shape and withstand loads such as reinforcing, concrete and any associated materials and the dynamic loads imposed by pouring, agitating, the movement of people or environmental factors such as wind and rain.
• Install the formwork in accordance with the design and instructions from the designer - formwork should be rigid, watertight, braced and tied together to maintain position and shape during construction.
• Check variations to the design and ensure they are verified in writing by the designer, engineer or other competent person.
• Don’t mix components from different formwork systems unless a competent person (eg engineer), has authorised the component use.
• Put measures in place (eg bracing), to prevent vertical support feet, on inclined surfaces, from slipping.
• Before loading with weight, ensure a competent person (eg an engineer with experience in structural design -certifying engineer) inspects and certifies completed formwork and its supporting structures meet the design specifications and are structurally sound.
• Place concrete in accordance with the specified sequence and pour rate in order to maintain the stability of the formwork.
• Monitor formwork as it is being loaded to check for signs of potential failure or collapse and to ensure vertical and horizontal movements do not exceed specifications.
• Provide all workers with information and training specific to the formwork system, including:
  • details of the formwork system, tasks, activities and components
  • design intention regarding installation, use, movement, alterations and dismantling
  • control measures to minimise identified risks
  • how to inspect materials used in the formwork system.

Further information

• Formwork information page (templates, videos and other information)
• Working at heights 
• Code of practice for managing the risk of falls in housing construction
• Code of practice for managing the risk of falls at workplaces
• Erection and dismantling formwork webinar
• Formwork and falsework guidance material (Safe Work Australia)
• Code of practice for formwork (Worksafe Queensland)
• Australian standard – Formwork for concrete

Download a PDF of this release

Incident date: 24 May 2019

Event

Crush injury while moving concrete blocks

Location

Lane Cove West

Incident overview

A worker was using an excavator fitted with forklift tines to load large concrete blocks from the ground onto a flatbed truck.

While lifting a concrete block, it moved, pinning another worker (who was helping with the lift) against the truck. The worker received a suspected fractured pelvis.

Incident date: 19 April 2019

Location

Willoughby

Incident overview

A painter working from the side of a house fell from a ladder and broke his ankle. He was taken to hospital for treatment.

The investigation

• SafeWork NSW Inspectors responded to the incident.
• SafeWork NSW has commenced an investigation to determine the cause and circumstances of the incident.

Our Prosecution Guidelines (January 2018) outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on their approach
to compliance. These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety Information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Businesses are reminded to consider reasonably practicable control measures to manage the risk of falls from heights, particularly when working on ladders.

It’s best to work from the ground whenever possible and only use ladders for simple access jobs, or for short duration light duty work.

You should also consider alternatives to a ladder, such as scaffolding or an elevated work platform.

If a ladder is the only option, the following precautions can help avoid injury:

• Choose the right ladder for the job. It should meet Australian standards and the load requirements of the job.
• Inspect the ladder for damage before each use.
• Only use a ladder if you are physically-capable of doing so.
• Set up the ladder on a flat, stable surface. If this isn’t possible then use a ladder that includes ladder safety devices like leg levellers, anti-slip gutter guards and stabilisers.
• Always maintain three points of contact when climbing or descending the ladder. This means two hands and one foot, or two feet and one hand.
• Only take small items up or down a ladder – never large or heavy items such as building materials. Only carry items that allow you to maintain three points of contact.
• Never lean or reach away from the ladder while using it.
• The combined weight of the person using the ladder and any items or tools should never exceed the working load limit on the ladder.
• A-frame (Step) ladders should only be used when locked in the fully-open position.
• If you’re using a straight ladder or an extension ladder, secure it at the top, bottom or both. If this isn’t possible then have someone hold the ladder in place while in use.
• Straight/extension ladders should be angled at a ratio of 1:4. That is, position the base of the ladder 1 metre away from the structure for every 4 metres of height.
• Do not work from the top two rungs of a ladder, and never straddle the top of an A-frame ladder.
• When climbing down, remain facing the ladder and climb to the bottom rung before stepping off.

Support

Our Coordinator Family Liaison can provide information on counseling and other support to injured workers and to close family members when a relative has died or is seriously injured in the workplace.  Contact us on 13 10 50 or contact@safework.nsw.gov.au

Visit www.coroners.justice.nsw.gov.au for information about the State Coroner.

Further information

You can also refer to the following guidance materials:

• Safe use of ladders video
• Managing the risk of falls in housing construction Code of Practice
• Managing risks of falls in a workplace Code of Practice
• Ladder safety page – Safe Work Australia
• Australian standards related to ladders

About this information release

We have issued this information to draw attention to the occurrence of a serious injury in the painting industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s
independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

Incident overview

Two formworkers were working on a multi-storey mixed-use construction in Macquarie Park. They were on a concrete slab working beside the base of scaffolding approximately 9 stories high when it collapsed, crushing both workers. One worker was transferred to hospital with critical injuries while the
other died at the scene.

SafeWork NSW conducted an investigation to determine the case and circumstances of the incident.

On 17 December 2020, the construction company was convicted for breaches against the NSW WHS Act 2011 and fined $900,000 as a result of the incident. The company was also served a Proposed Project Order, which required them to contribute a further $104,000 and establish a working group to deliver a scaffolding industry safety standard over a 12 month period.

Safety information

Businesses are reminded to consider reasonable and practicable control measures to manage the risk of scaffold collapse:

• Ensure the scaffold is stable at all times, including during erection, in situ, during and after any alterations, and when dismantling.
• Ensure the scaffold can withstand all anticipated loads, including the weight of workers, all stored material and any loads due to weather such as wind and rain (particularly where containment sheeting is used).
• Ensure dismantled scaffold components are not stored on the existing scaffold unless it is designed to withstand these loads.
• Know the duty rating (light, medium, heavy or special) and number of decks that can be loaded within a bay.
• Ensure the scaffold is adequately tied to its supporting structure, in accordance with instructions from a competent person. Consult with the scaffold designer, manufacturer, supplier or an engineer, and prevent unauthorised removal or changes.
• Develop systems of work that allow construction activities such as bricklaying, painting, rendering, glazing and cladding installation to be completed without unplanned changes to, or removal of, scaffold ties, e.g. work down from the top of the building as the scaffold is progressively dismantled,
  or relocate ties so they do not interfere with the work.
• Ensure altering or partially dismantling the scaffold does not weaken it, e.g. removing returns or adjacent bays may require additional ties or bracing on the remaining scaffold.
• Ensure only competent persons with a relevant class of high risk work licence undertake scaffolding work including making alterations.
• Protect the scaffold from damage by vehicles, plant, equipment or materials.
• Use a scaffold that is suitable for the tasks and construction process.
• Provide all workers adequate information, instruction, training and supervision regarding the control measures required to prevent the collapse of the scaffold.
• Have a competent person who holds the same or higher class of high risk work licence appropriate to the class of scaffolding regularly inspect the scaffold, to ensure it has not been modified or altered by unauthorised persons.
• Prepare a safe work method statement for all high risk construction work.

Further information

You can also refer to the following guidance materials:

• Safe Work Australia - Scaffolds and scaffolding work general guide
• Safe Work Australia – Guide for scaffold inspection and maintenance
• SafeWork NSW Erecting, altering and dismantling scaffolding – part 1 – prefabricated steel modular scaffolding
• Scaffolding collapse safety alert – 14 Sept 2018
• Dogging, rigging and scaffolding licencing information
• AS/NZS1576 Part 1: Scaffolding – general requirements
• AS/NZS4576: Guidelines for scaffolding
• Construction work Code of Practice
• Managing the risk of falls at workplaces Code of Practice

Incident date: 28 February 2019

Event

Structural collapse

Location

Moorebank

Incident overview

Eight workers were removing an asbestos roof and stacking the asbestos sheets on the existing roof.

The condition of the timber roof structure was unable to support the weight of the stacked sheets.

Part of the roof collapsed and two workers fell with the asbestos sheets to the concrete floor below. The fall was approximately four metres.

The workers were not wearing any safety harnesses at the time of the incident, however there was temporary roof edge protection and roof safety mesh in place.

Activities undertaken at the site include asbestos removal work.

Incident date

12 February 2019

Event

Bucket of excavator being loaded onto a truck hit worker

Location

Macquarie Fields

Incident Overview

While loading an excavator onto the back of a truck, a worker who was strapping down the excavator was struck by a falling object. As the operator of the excavator moved the bucket a smaller bucket inside it toppled out and struck the worker. The worker sustained injuries to his head, back and leg.

The site

The site is located at Macquarie Fields. Work being done at the site includes earth moving and construction work.

The investigation

SafeWork NSW Inspectors responded to the incident.

Our Prosecution Guidelines (January 2018) outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on their approach to compliance. These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety Information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in line with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017. Each year SafeWork NSW responds to incidents where workers have been injured while using earth moving equipment. Workers in the construction industry are commonly injured; however any worker using earth moving machinery is at risk. Businesses are reminded to consider reasonably practicable control measures to manage the risk of injury while operating, or working near, earth moving machinery. Clear, established lines of communication between the operators of plant and nearby workers is vital, and should be implemented with control measures such as barriers, exclusion zones and traffic management. Workers should be trained and supervised when working closely with plant, and all maintenance should be done by competent, accredited people.

Further information

Please refer to the following guidance materials:
Excavation work Code of Practice
Moving Plant on Construction Sites: Code of Practice
Safety Alert – Working with or around mobile plant

About this information release

We have issued this information to draw attention to the occurrence of a serious injury in the earth moving industry. Investigations are ongoing and further information may be published as it becomes available. The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

Incident date

5 February 2019

Event

Fall from heights landing on reinforcing bar

Location

Gosford

Incident Overview

A 32 year old male worker was doing formwork at a multi-storey construction site in Gosford and fell approximately 2.8 metres. He landed on a reinforcing bar and his leg was impaled.

The site

The site is located at Gosford. Work being done at the site includes formwork for a multi-storey residential construction.

The investigation

• SafeWork NSW Inspectors responded to the incident.
• SafeWork NSW has commenced an investigation to determine the cause and circumstances of the incident.

Our Prosecution Guidelines (January 2018) outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on their approach
to compliance. These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety Information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in line with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017 .

Each year SafeWork NSW responds to incidents where workers have been injured as a result of falls from heights. Most of these incidents involve open penetrations on formwork decks and unprotected edges/voids.

Workers in the construction industry are most commonly injured; however any worker working at heights is at risk.

Businesses are reminded to consider reasonably practicable control measures to manage the risk of falls from heights by ensuring open penetrations are covered and covers are secured.

Further information

Please refer to the following guidance materials:

• Managing the risk of falls at workplaces COP
• Construction work COP
• Formwork COP
• SafeWork Pocket Guide to Construction Safety
• Safework Australia Formwork Guide

About this information release

We have issued this information to draw attention to the occurrence of a fatality/serious injury/serious incident in the construction industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s
independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

The site is located at Gosford. Work being done at the site includes formwork for a multi-storey residential construction.

The investigation

• SafeWork NSW Inspectors responded to the incident.
• SafeWork NSW has commenced an investigation to determine the cause and circumstances of the incident.

Our Prosecution Guidelines (January 2018) outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on their approach to compliance. These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety Information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in line with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017 .

Each year SafeWork NSW responds to incidents where workers have been injured as a result of falls from heights. Most of these incidents involve open penetrations on formwork decks and unprotected edges/voids.

Workers in the construction industry are most commonly injured; however any worker working at heights is at risk.

Businesses are reminded to consider reasonably practicable control measures to manage the risk of falls from heights by ensuring open penetrations are covered and covers are secured.

Further information

Please refer to the following guidance materials:

• Managing the risk of falls at workplaces COP
• Construction work COP
• Formwork COP
• SafeWork Pocket Guide to Construction Safety
• Safework Australia Formwork Guide

About this information release

We have issued this information to draw attention to the occurrence of a fatality/serious injury/serious incident in the construction industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

Incident date

12 December 2018

Event

Fall from height

Location

Denham Court

Incident Overview

A worker fell from a height while installing roof & guttering on a house in Denham Court, sustaining hand and shoulder injuries.

SafeWork NSW and NSW Police responded to the incident to investigate and make the site safe.

The site

The site is located at Denham Court. Activities being done on the site included the construction of a two storey home. The site is under the control of a principal contractor. A sub-contractor had been engaged to install box guttering and roofing.

The investigation

SafeWork NSW Inspectors responded to the incident.

Our Prosecution Guidelines outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides
guidance on our approach to compliance. These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety Information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in line with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Each year SafeWork NSW responds to incidents where workers have been exposed to risks associated withfalls from heights. Most of these incidents involve unprotected edges or voids.

Businesses are reminded to consider reasonable and practicable control measures to manage the risk of falls from heights including:

• Remove the need to work from heights where possible;
• Use a suitable working platform such as scaffolds, boom lifts or scissor lifts;
• Provide adequate edge protection by using guardrails or perimeter scaffolding;
• Ensure scaffolds are inspected every 30 days and a handover certificate is issued;
• Prevent people accessing incomplete scaffolds;
• Ensure penetrations/voids are covered and clearly marked or have edge protection
• Provide workers with safe means of accessing and exiting work areas;
• Ensure ladders are secured and extend 1m past the landing; and
• Only use fall restraint or fall arrest systems when edge protection or work platforms are not reasonably practicable.

Further information

Please refer to the following guidance materials:

• Safe Work Australia's - formwork and falsework guideance material
• Managing the risk of falls at workplaces Code of Practice
• Maanging the risk of falls in housing construction Code of Practice
• SafeWork Pocket Guide to Construction Safety

About this information release

SafeWork NSW has issued this information to draw attention to the occurrence of a serious injury in the construction industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate officer of SafeWork NSW or the user’s
independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

Incident date

17 November 2018

Event

Fall from heights through open penetration/void

Location

Green Valley

Incident overview

A 29-year-old male air conditioning mechanic fell from the first floor of a residential construction site through a stair void. The worker suffered fatal head and neck injuries.

The site is located at Green Valley. Activities undertaken at the site include the construction of a two-story residence.

The investigation

SafeWork NSW Inspectors responded to the incident.

SafeWork NSW has commenced an investigation to determine the cause and circumstances of the incident.

Our Prosecution Guidelines (January 2018) outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on our approach to compliance. These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety Information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Each year SafeWork NSW respond to incidents where workers have been killed or seriously injured from falls from heights. Many of these incidents involve falling through penetrations.

Workers in the construction industry are most commonly injured from falling; however, any worker, working at height is at risk.

Businesses are reminded to consider reasonably practicable control measures to manage the risk of falls.

Before commencing work a business must:

• provide edge protection on all open edges where a worker can fall e.g. guardrails comprising top-rail, mid-rail and toe boards.
• cover stair voids with covers designed to withstand likely impact and static loads and fixed to prevent any dislodgement or accidental removal.
• provide workers with safe means of access and egress to work areas.

Further information

Please refer to the following guidance materials:

• Managing the risk of falls at workplaces Code of Practice
• Managing the risk of falls in housing construction Code of Practice
• SafeWork Pocket Guide to Construction Safety

About this information release

We have issued this information to draw attention to the occurrence of a fatality in the Construction industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s
independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

Incident date

6 November 2018

Event

Electric Shock

Location

Guildford

Incident Overview

A 36-year-old worker was installing a steel reinforcement bar into a wall cavity on a construction site. While attempting to position the reinforcement bar to insert into the cavity, it extended past the edge of the scaffold and touched high voltage powerlines. The worker received serious injuries.

SafeWork NSW, NSW Police Force and other Emergency Services responded to the incident.

The site is located at Guildford. Work being done at the site involves the construction of a low-rise apartment building.

The investigation

SafeWork NSW Inspectors responded to the incident.

Our Prosecution Guidelines outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on our approach to compliance. These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety Information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Each year SafeWork NSW responds to many incidents where workers are seriously injured from coming in to contact with or working too close to overhead power lines where a ‘flashover or arc’ occurs. Workers can come in to contact with electric lines directly or indirectly through materials being handled or plant being operated near overhead power lines. Regardless of the voltage, which can be as high as 500,000 volts or as low as 230 volts, the consequences can be catastrophic.

Businesses and workers in the construction industry are reminded of the increased risks when working near overhead power lines. Businesses must ensure, so far as is reasonably practicable, that no person, plant or thing at the workplace comes within an unsafe distance of an overhead power line. If it is not reasonably practicable to ensure the safe distance of a person, plant or thing from an overhead or underground power line, the person conducting the business or undertaking at the workplace must make sure that:

1. a risk assessment is done in relation to the proposed work, and
2. control measures that are put in place are consistent with:
   1. the risk assessment, and
   2. if an electricity supply authority is responsible for the power line, any requirements of the authority.

Note the requirements in the AS/NZS 4576 of a 4 metre approach distance for metallic scaffolding used near overhead power lines – where any scaffolding, hand held tools, equipment or materials may come within this 4 metre approach distance, a hazard identification and written risk assessment must be undertaken and measures undertaken to control risks to persons.

Further information

Please refer to the following guidance materials:

• Code of Practice: Work Near Overhead Power Lines
• Erecting, altering and dismantling scaffolding - Part 1: Prefabricated steel modular scaffolding

About this information release

We have issued this information to draw attention to the occurrence of a serious injuryserious injuryserious injury in the construction industry. Investigations are ongoing and more information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to make sure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

Incident date: 29 October 2018

Event

Prefabricated concrete panel fall on construction site

Location

Bexley

Incident Overview

A 21 tonne, right angle shaped, prefabricated concrete panel was being lifted by a tower crane and a mobile crane in a dual lift. The panel was approximately 9.3 metres long by 2.5 metres wide.

As the panel was being lifted into position the lifting equipment and/or lifting point failed and the panel suddenly dropped. The reason for the failure is not yet known.

A hoist rope was damaged in the incident and the cranes were subjected to shock loading. Debris from the incident landed in a public area next to the site. There were no reported injuries.

SafeWork NSW, NSW Police Force, Fire and Rescue NSW and Public Works Engineers responded to the incident.

The site

The site is in Bexley. Work being done at the site is part of the West Connex motorway project.

The investigation

SafeWork NSW Inspectors responded to the incident.

SafeWork NSW has commenced an investigation to determine the cause and circumstances of the incident.

Our Prosecution Guidelines outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on our approach to compliance. These documents set out factors that will be considered in determining the
investigative approach and appropriate outcome.

Safety Information

Persons conducting a business or undertaking (PCBUs) are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Principal Contactors and other businesses working in construction have additional and specific duties under Work Health and Safety (WHS) legislation. Those duties extend to the care of both workers and others – including members of the public. Businesses need to provide and maintain safe plant and structures
such as lifts and cranes, and risks related to structures collapsing or objects falling need to be managed..

The loads applied to prefabricated concrete elements during lifting depend on many factors. These include the orientation of the concrete element, the size and shape of the element and its centre of gravity, the location and capacity of the lifting points, and the lifting equipment and method used.

The force applied to a crane and lifting equipment can change a lot during a lift. An erection plan is needed to make sure the crane, lifting equipment and concrete element can withstand the applied loads.

The erection plan should be developed in consultation with relevant contractors, including the concrete element prefabricator. It should include drawings that have details on the types and locations of all lifting / bracing / fixing inserts and any component reinforcing.

Documents about the erection plan should be available on site. They should specify the erection sequence and orientation, the correct lifting points, clutches and the rigging details/configuration.

Lifting inserts and clutches must be compatible with each other - seek advice from the item manufacturer if you are unsure. Cranes with sufficient size to use the specified rigging and sling angles, and capacity to handle the calculated load share, must be used.

Before lifting anything, make sure the concrete has reached the required strength and the lift can be done as described in the erection plan. Do not deviate from the erection plan, without agreement of the erection designer.

Further information

Please refer to the following guidance materials:

• AS 3850.1-2015 Prefabricated concrete elements - General requirements.
• AS 3850.2-2015 Prefabricated concrete elements - Building construction.
• AS 1379 - 2007 Specification and supply of concrete (Guidance on sampling and testing systems for concrete)
• Code of Practice – Construction Work
• Code of Practice – Safe Design of Structures

About this information release

We have issued this information to draw attention to the occurrence of a serious incident in the construction industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s
independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

Incident date

11 September 2018

Event

Hit by falling object

Location

Seven Hills

Incident overview

A 10 tonne prefabricated concrete panel approximately 12m in length and 2.1m in width was being lifted off a truck using a crane and was to be rotated mid-air and moved into position as part of constructing a commercial premises. However, as it was being lifted it broke into pieces, striking and injuring
a 50 year old worker assisting with the lift.

NSW Police and Ambulance responded to the incident and the worker was conveyed to hospital and received treatment for his injuries.

The site

The site is located at Seven Hills. The activity being undertaken at the time was the construction of a commercial premises using prefabricated concrete panels. The site is under the control of a principal contractor with several sub-contractors working onsite.

The investigation

SafeWork NSW Inspectors responded to the incident.

Our Prosecution Guidelines outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on their approach to compliance.
These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Tilt-up and pre-cast panels must be designed for both erection loads and for loadings experienced when they make up part of the completed building or structure (i.e. ‘in-service loads’). The loads applied to the panel during lifting off the casting bed, transport, handling, erection, and while
the panels are temporarily braced are different from loads applied when part of the final structure. The erection designer(s) must therefore design the panel for all types of loading.  Erection crews must then ensure panels are lifted and braced in the manner specified by the erection designer(s).

Tilt-up panels should only be lifted when the concrete has cured long enough to attain the minimum required concrete strength specified by the lifting insert supplier. The minimum concrete strength for most proprietary brand lifting inserts is 25 MPa. Some inserts may require a higher
strength than 25 MPa.

Further information

Please refer to the following guidance materials:

• AS 3850.1-2015 Prefabricated concrete elements - Part 1: General requirements.
• AS 3850.2-2015 Prefabricated concrete elements - Part 2: Building construction.
• Guidance on sampling and testing systems for concrete is provided in AS 1379 - Specification and supply of concrete.

About this information release

We have issued this information to draw attention to the occurrence of a fatality/serious injury/serious incident in the prefabricated concrete industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s
independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

_{All photographs were taken by SafeWork NSW.}

Download a PDF of this release

Incident date

11 September 2018

Event

Fall through penetration

Location

Castle Hill

Incident overview

A 28-year-old bricklayer was undertaking work in a plant room of a major tunnel and civil infrastructure works project.  He stood on the temporary platform covering a penetration which has shifted under his weight causing him to fall 7.1 metres to the concourse level below. The worker sustained a broken left femur, tibia, fibula and a broken left shoulder.

SafeWork NSW and NSW Ambulance responded to the incident and the worker was conveyed to hospital and received treatment for his injuries.

The site is located at Castle Hill. Activities undertaken at the site include the construction of twin tunnels that will form part of the Sydney Metro Northwest automated rail system. The site is under the control of a principal contractor that is under the Comcare scheme with multiple sub-contractors
working onsite. The worker was an employee of a NSW bricklaying company subcontracted to undertake the bricklaying works.

The investigation

SafeWork NSW Inspectors responded to the incident.

SafeWork NSW has commenced an investigation to determine the cause and circumstances of the incident.

Our Prosecution Guidelines outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on their approach to compliance.
These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety information

Businesses and workers are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Each year SafeWork NSW respond to incidents where workers have been killed or seriously injured from falls from a height. Many of these incidents involve falling through a penetration.

Workers in the Construction Industry are commonly at risk of falling from height; however, any worker working at height is at risk of falling.

Businesses are reminded to consider reasonably practicable control measures to manage the risk of falling from heights and working near penetrations including;

• Installing barriers, such as guard rails or covers, that are secured and labelled with warning signs in areas where penetrations are present
• Covering and marking, or installing guardrails around penetrations/voids
• Providing workers with safe means of access and egress to work areas
• Conducting a risk assessment prior to working near penetrations

Further information

Please refer to the following guidance materials:

• Managing the Risk of falls at Workplaces - Code of Practice
• Trapdoors and Penetration Covers in Construction (QLD Safety Alert)
• Prosecution results following Construction falls
• SafeWork NSW guide to working safely at heights 
• Construction work code of practice 2014

About this information release

We have issued this information to draw attention to the occurrence of a serious injury in the construction industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s
independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

Incident date

10 September 2018

Event

Fall from height through roof

Location

Newcastle East

Incident Overview

A 26 year-old labourer was on the roof of a home helping remove asbestos cement corrugated roof sheeting when one of the sheets gave way and he fell approximately 4 metres.

The fall-arrest system used did not prevent the worker from hitting the wooden floor below. The worker sustained a suspected broken wrist.

SafeWork NSW and NSW Ambulance responded to the incident and the worker was taken to hospital and received treatment for his injuries.

The site is located at Newcastle East. The activity being undertaken at the time was the removal of asbestos roof sheeting on a residential dwelling. The site is under the control of a principal contractor with a sub-contractor engaged to undertake demolition and asbestos removal at the site.

The investigation

SafeWork NSW Inspectors responded to the incident

Our Prosecution Guidelines outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on their approach to compliance.
These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety Information

Businesses and workers are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Each year SafeWork NSW respond to incidents where workers have died or been seriously injured from falls from heights. Many of these incidents involve falling through roof material. Asbestos cement roof sheeting is known to become brittle with age.

Businesses are reminded to consider reasonable and practicable control measures to manage the risk of falls.

Before starting work on an existing roof, carry out an inspection (from below) to determine:

• the presence and condition of non-trafficable sheeting such asbestos cement sheeting and other brittle roof sheeting such as sky lights or plastic roof sheeting
• for residential properties, the spacing and condition of roof purlins or trusses, including any gaps in purlins
• for commercial properties, the presence and condition of safety mesh.

When determining whether roofs are safe to walk on, consider that product materials may become brittle with age and fixings may become less rigid over time.

Control measures to prevent a person from falling through a non-trafficable roof or skylight include:

• plan to work from below whenever possible
• plan the work to avoid accessing unsafe or non-trafficable areas
• work from an elevated work platform or boom lift to avoid standing on the roof itself
• install temporary work platforms (crawling boards) and roof ladders as appropriate
• install barriers (such as guard rails or covers) that are secured and labelled with warning signs
• install safety mesh when installing the roof sheeting
• install a fall arrest system (harness system) which has adequately-installed anchorage points, along with training and instruction in the use.
• ensure workers using an adjustable length (traveller) fall arrest system are competent and aware that the rope line is to have minimal slack, to protect then in the event they fall through, when walking or working on roofs and are aware of the pendulum effect when using single anchorage points.

Ensure the selected control measures are being consistently applied and review the control measures as work progresses.

Further information

Refer to the following guidance materials:

• Our guide to working safely at heights includes information on managing the risks of falls, including codes of practice and guides to working on roofs.
• Safe work on roofs - Part 1: commercial and industrial buildings code of practice
• Safety Alert - Falls through skylights and plastic roof sheeting
• Australian Standard series AS/NZS 4994 – Temporary edge protection
• Australian Standard AS/NZS 1891.4 Industrial fall-arrest systems and devices Part 4: Selection use and maintenance
• Incident information releases, including Fall through plastic roof sheeting 23 August 2018

About this information release

We have issued this information to draw attention to the occurrence of a serious incident in the roofing industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s
independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

Incident date

07 September 2018

Event

Scaffold Collapse

Location

Bronte

Incident overview

Partially dismantled 4-storey scaffolding on a multi-story residential construction site in Bronte has fallen away from the building and onto the neighbouring unit complex.

No residents were in the neighbouring property at the time of the incident. There were no injuries reported.

The residents were provided with temporary accommodation and a section of the road was closed while repair work occur.

SafeWork NSW, NSW Police and the State Emergency Services responded to the incident and Engineers were on site to make the site safe.

The site is located at Bronte. Activities undertaken at the site include the dismantling of scaffolding. The site is under the control of a principal contractor with the activity being undertaken by a sub-contractor.

The investigation

SafeWork NSW Inspectors responded to the incident.

SafeWork NSW has commenced an investigation to determine the cause and circumstances of the incident.

Our Prosecution Guidelines outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on their approach to compliance.
These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Each year SafeWork NSW respond to incidents where the safety of workers, or nearby people, has been at risk from falling scaffolding.

Many of these incidents involve scaffolds with containment sheeting (eg shadecloth or mesh) which may place extra weight on a scaffold, particularly in bad weather when wind and rain can place additional live loads the materials.

A scaffold collapse not only puts workers lives at risk, but puts the public at significant risk of being hit by falling objects.

Businesses are reminded to implement control measures to manage the risk of scaffold collapse, such as ensuring:

• the design of the scaffold installation considers wind load from the scaffold containment sheeting
• provision and maintenance of sufficient ties of adequate strength for the loads, including wind load
• regular inspection of scaffold ties to check they are not modified or altered by unauthorised people (eg finishing trades who may loosen, relocate or remove ties to gain access to walls and openings)
• scaffolds are not left in a state of weakness when installing or dismantling the scaffolds (eg removing returns as they act like ties, or removing ties in preparation for dismantling).

Further information

Please refer to the following guidance materials:

• Australian Standard AS 1576 Series
• Scaffolding collapse safety alert
• SafeWork NSW Erecting, altering and dismantling scaffolding - part-1 - prefabricated steel modular scaffolding
• Safe Work Australia Scaffolds and scaffolding work general guide
• Safe Work Australia Guide for scaffold inspection and maintenance

About this information release

We have issued this information to draw attention to the occurrence of a serious incident in the construction industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s  independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

Incident date

5 September 2018

Event

Fall from form deck

Location

Blackbutt in Shellharbour

Incident overview

A 40-year-old steel fixer was subcontracted to work on steel pre-fabricated walls.

He was standing on a piece of plywood, on top of laid formwork, when it gave way and he’s fallen 2 to 2.5 metres to the floor below. The worker struck his head and sustained bruising to his left arm and grazing to his right arm.

SafeWork NSW, NSW Police and NSW Ambulance responded to the incident and the worker was taken to hospital for treatment for his injuries.

The site is located at Blackbutt in Shellharbour. The activity being undertaken is the construction of a multi-story residential building. The site is under the control of a principal contractor with a subcontractor engaged to undertake the formwork decking on site.

The investigation

SafeWork NSW Inspectors responded to the incident.

Our Prosecution Guidelines outline our approach to prosecutions and Safe Work Australia’s National Compliance and Enforcement Policy provides guidance on their approach to compliance. These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Each year SafeWork NSW respond to incidents where workers have fallen from a height. Many of these incidents involve formwork.

Workers in the construction industry are most commonly injured however, any worker working from heights is at risk.

Businesses are reminded to consider reasonable and practicable control measures to manage the risk of falls from heights including:

• The PCBU must deem the working deck is complete before allowing other workers to access the deck. the deck
• Installing barriers with signage in areas where formwork is incomplete
• Covering and marking, or installing guardrails around penetrations/voids Providing workers with safe means of access and egress to work areas.

Further information

Please refer to the following guidance materials:

• Formwork and falsework guidance material
• Incident information releases
• Managing the risk of falls at workplaces COP
• SafeWork NSW formwork webpage
• Managing the risk of falls in housing construction COP
• SafeWork pocket guide to construction safety

About this information release

We have issued this information to draw attention to the occurrence of a serious injury in the construction industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate SafeWork NSW officer or the user’s independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

Incident date

Event

Location

Incident overview

Safety information

Incident date

3 August 2018

Event

Fall from height on construction site

Location

Church Street, Parramatta

Incident overview

A 62-year-old worker was undertaking formwork at a Parramatta construction site. He was placing a joist onto the falsework bearers below when he fell approximately 3.7 metres from the ply deck he was standing on to the deck below. He sustained a broken rib and a laceration to the back of his head.

SafeWork NSW and NSW Police responded to the incident. The worker was conveyed to hospital and received treatment for his injuries.

The site

The investigation

SafeWork NSW Inspectors responded to the incident.

Safety information

Further information

About this information release

Incident date

Event

Location

Incident overview

The site

The investigation

SafeWork NSW Inspectors responded to the incident.

Safety Information

Further information

About this information release

Incident date

6 July 2018

Event

Falling object from construction site

Location

Princes Highway at Rockdale

Overview

During the demolition of an existing commercial premises, parts of the front façade fell onto the pedestrian footpath, scattering debris onto the footpath and the Princes Highway. The incident occurred during strong winds. As a result, two northbound lanes of the highway were closed. There were no reported injuries.

SafeWork NSW, NSW Police, Fire and Rescue and Public Works Engineers responded to the incident.

The site

The site is located on Princes Highway at Rockdale. The site is currently undergoing demolition and is under the control of a principal contractor. A sub-contractor had also been engaged to carry out demolition works on the site. At the time of the incident, the front façade and partial return/buttress walls were the only building elements yet to be demolished. The front façade consisted of brickwork, and glass windows and doors.

The investigation

• SafeWork NSW Inspectors responded to the incident.
• SafeWork NSW has commenced an investigation to determine the cause and circumstances of the incident.

SafeWork NSW’s Prosecution Guidelines outlines the Regulator’s approach to prosecutions and SafeWork Australia’s National Compliance and Enforcement Policy provides guidance on the Regulator’s approach to compliance. These documents set out factors that will be considered in determining the investigative approach and appropriate outcome.

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Principal contractors and other businesses working in construction and/or demolition have additional and specific duties under the WHS legislation. Those duties extend to both workers and others – including members of the public, and require businesses to ensure the risks associated with unplanned structural collapse and/or falling debris are managed so far as is reasonably practicable in accordance with the legislation.

Businesses are required to implement reasonably practicable measures to the eliminate or minimise the risks associated with unplanned structural collapse or falling debris by ensuring:

• the demolition method and sequencing is planned in consultation with the building/structure designers, or if it is not reasonably practicable to do so, in consultation with appropriately competent persons eg structural engineers.
• the building or structure to be demolished and all its components are maintained in a safe and structurally stable condition at all times until completion of the project. Temporary braces, propping, shoring or guys may need to be added to ensure that stability of the structure is maintained.
• external factors that may impact on the structural integrity of the building or structure are considered and the associated risks are managed eg vibrations from demolition activities, wind, water pooling or egress around footings or supports.
• adequate protection to members of the public are provided and maintained by installing, for example, hoarding, overhead protective structures, heavy duty scaffolding and/or or containment screening; or by implementing road closures and/or specified exclusion zones.
• measures installed to provide public protection are designed and constructed to withstand the applicable loads (consultation with an appropriately competent person may be required).
• measures installed to provide public protection are in place prior to commencing associated demolition works.
• all control measures are monitored by a competent person to assess the on-going suitability of the demolition method and sequencing and to identify signs of structural weakening e.g. movement or cracking.

Further information

Please refer to the following guidance materials:

• SafeWork NSW Code of Practice Demolition work
• Australian Standards AS 2601-2001 The demolition of structures
• Safety alert Dangers from masonry walls on construction or demolition sites
• SafeWork NSW Code of Practice Overhead protective structures

About this information release

SafeWork NSW has issued this information to draw attention to the occurrence of a serious incident in the construction industry. Investigations are ongoing and further information may be published as it becomes available.

The information contained in this publication is based on knowledge and understanding at the time of writing. Users are reminded of the need to ensure any information upon which they rely is up to date and to check the currency of the information with the appropriate officer of SafeWork NSW or the user’s independent adviser. No conclusions should be drawn from the information in this publication about the cause of the incident or the culpability of any party.

All photographs were taken by SafeWork NSW.

Download a PDF of this release

A 10-tonne bridge crane collapsed at a workshop while being operated by two workers. The crane was being used to conduct bucket flips in a manufacturing process for front end loader buckets. The process involved rotating the buckets to complete work on the underside. A bucket weighing approximately 7-tonne was being flipped using the crane when the crane and attached bucket collapsed to the floor. No one was injured in the incident.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with operating bridge cranes.

Ensure:

• the rated capacity of the crane is not exceeded, refer to the operator’s manual or crane specifications
• the weight of the load is calculated prior to being hoisted
• a test lift is conducted to ensure load security and stability
• when slinging loads, consideration must be given to:
  • the weight of the load
  • reeve and angle factors
  • size of the load
  • slinging technique
  • hoisting clearances
• the crane hook is positioned over the load’s centre of gravity to avoid dragging or snigging the load
• lateral tolerances or side loading of the crane are not exceeded
• an exclusion zone is set up around the plant and any loads
• workers do not perform work on a suspended load
• the workpiece (load) is placed on appropriate supports and remains detached from the crane while undertaking work
• crane attachments are securely attached and used to perform the tasks in the manner they were designed for by the original manufacturer
• the path of travel is clear from obstructions when a load is hoisted by a crane, and the load remains under control
• workers receive adequate training and instruction
• workers are supervised by a competent person
• workers hold valid high risk work licences for the bridge crane if the crane is operated from a cabin or a remote if it has more than three powered operations
• instructions and work procedures are translated for culturally and linguistically diverse (CALD) and migrant workers
• workers complete a site induction prior to commencing work
• a risk assessment is completed prior to commencing work
• safe systems of work are developed and followed
• appropriate personal protective equipment (PPE) is worn
• lifting equipment such as slings are inspected before and after use and discarded if damaged or if wear tolerances are exceeded
• crane pre-start and operational checks are carried out to check for defects and to ensure the crane is safe to use.

Related guidance material

• Managing the risks of plant in the workplace – Code of Practice (PDF, 1987.96 KB)
• At-risk workers
• Translated resources
• High risk work licences
• Guide for crane operators (PDF, 1225.66 KB)
• The pocket guide to construction safety (PDF, 1352.71 KB)

Further information

• Traumatic event management plan
• Speak Up Save Lives App
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 62-year-old labourer suffered burn injuries to his face and hands while using a forklift to dip scaffold components into a large skip bin filled with paint and thinners. The forklift came into contact with the skip bin, which may have caused a spark, resulting in fire engulfing the skip bin and causing extensive damage to the forklift.

Incident scene (photo source 9 news).

Safety Information

Consider ‘reasonably practicable’ control measures to manage the risks associated with working with flammable liquids whilst painting scaffold components.

Ensure:

• a risk assessment is performed before any work is undertaken
• current safety data sheets (SDS) are obtained for all chemicals used and they are readily available to workers and all workers understand the relevant information
• instruction, training, and supervision is provided to all workers on the safe use, storage, and handling of hazardous chemicals
• appropriate personal protective equipment (PPE) is used for the task
• forklift operators hold valid high risk work licences (HRWL) - class LF
• potential ignition sources are considered, for example plant, electrical leads, portable generators
• intrinsically safe plant and equipment are used
• consideration of the receptacle/container being used to store paint and thinners for dipping scaffolding components

Related guidance material

• Flammable substances - SafeWork NSW
• Managing risks of hazardous chemicals in the workplace - SafeWork Australia
• Managing risks of exposure to solvents in the workplace - SafeWork SA
• High risk work licenses information – SafeWork NSW
• Forklift safety information – SafeWork NSW

Further information

• Traumatic event management plan - SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 56-year-old warehouse worker sustained fatal injuries when he was crushed beneath two stone slabs at a warehouse in Beresfield. The stone slabs, with a combined weight of approximately 600kg, fell from an A-frame storage system landing on top of the worker.

Safety information

This is the second incident involving stone slab storage and movement within the last 8 months.

Workers or others in close proximity to stacked stone slabs are at risk of severe or fatal injuries by being crushed, trapped, or cut by falling slabs. Stone slabs or materials which have been stacked on their edges, are at high risk of falling when being handled or moved if the sheets are not adequately supported by suitable racking or transport frames.

Consider ‘reasonably practicable’ control measures to manage the risks associated with handling and storage of stone slabs.

Ensure:

Storing the sheets or slabs

• store the sheets or slabs on an A-frame, truss, post frame or other purpose-designed racking system, and ensure that the safe load limit of the storage system is not exceeded
• once stored, use appropriate restraints to retain sheets or slabs in position and prevent later movement due to wind, impact, or other actions
• if stored on a post frame, both posts must be adequately positioned to prevent the slabs from falling forward and must be re-positioned progressively as the material is removed from the frame
• remain clear of hazard (fall) zones when lifting and handling sheets
• always stand in front of the posts which break the fall of the sheets or slabs. Never stand between the sheets or slabs and the posts
• use appropriate lifting equipment when handling sheets – do not exceed the working load limit of any lifting device
• ensure all workers are adequately trained and supervised for the tasks they are performing, the nature of the risks associated with the work, and the control measures implemented to deal with these risks
• use appropriate personal protective equipment (e.g. gloves).

Lifting and handling sheets or slabs

• remain clear of hazard (fall) zones when lifting and handling sheets
• always stand in front of the posts which break the fall of the sheets or slabs. Never stand between the sheets or slabs and the posts
• use appropriate lifting equipment when handling sheets – do not exceed the working load limit of any lifting device
• ensure all workers are adequately trained and supervised for the tasks they are performing, the nature of the risks associated with the work, and the control measures implemented to deal with these risks
• use appropriate personal protective equipment (e.g. gloves).

Related guidance material

• Hazardous Manual Tasks Code of Practice – Safe Work Australia
• Working with sheet materials safety alert – SafeWork NSW
• Storage and handling of sheet materials – WorkSafe QLD
• Workers injured by stone slabs alert – WorkSafe QLD

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

Download this Incident Information Release (PDF, 252.91 KB)

A 31-year-old worker was driving a forklift truck loaded with a pallet of sheet metal in the yard of a manufacturing plant when it collided with a fixed object and overturned. The worker sustained fatal crush injuries.

The forklift involved in the incident.

Safety information

Every year forklift trucks are involved in workplace deaths and injuries resulting in substantial financial and human costs for workers, industry, and the community. The three main reasons workers are killed or seriously injured in forklift truck incidents are:

1. being hit or crushed by a forklift
2. being hit or crushed by a load that the forklift is moving
3. being crushed in a forklift tip-over.

Before operating a forklift truck, you:

• must hold a valid high risk work licence (HRWL) - class LF
• must review the manufacturer’s instructions to ensure the forklift is operated safely in a manner for which it was designed
• must be trained on the specific type of forklift you are using so that you are familiar with the operating controls and understand any limitations
• should always conduct pre-start and operational safety checks to confirm the forklift is safe to operate
• must wear the required PPE (personal protective equipment) for the task you are undertaking and the environment you are working in
• must be fit for work. This includes not being under the influence of drugs or alcohol, and ensuring you are adequately rested
• should inspect the work area to identify any potential hazards in the work zone
• should assess the load to determine if the forklift configuration is designed to lift the load or whether a lifting attachment is better suited to maintain control of the load.

When operating a forklift, you:

• must follow any site safety rules, traffic management plans and safety instructions including any site-specific safe work method statements for the work being undertaken
• must wear a seatbelt, unless a risk assessment indicates it’s not safe to do so, and use all controls provided to prevent you being ejected from the forklift
• should drive at a safe speed, with respect to site speed limits, load size, ground, and weather conditions
• should avoid aggressive driving, braking, and steering, especially when turning
• should never turn sideways on ramps or other sloping surfaces
• ensure all loads are centred and secured
• must never overload the forklift
• should avoid driving with an elevated mast and load, unless you’re picking up or putting away the load
• should lower the fork arms to ground level, apply the parking brake, and ensure the drive controls are in neutral if you need to alight from the forklift
• should turn off the ignition and remove the key if leaving the forklift unattended.

If the forklift does tip over, attempting to jump from it is likely to cause serious crush injuries or death. In the event of a forklift tip over, you should:

• remain seated and not lean out of the forklift
• brace your feet, hold tight and lean away from the point of impact.

Businesses must:

• develop and implement safe systems of work
• ensure all workers operating a forklift have the appropriate HRWL and have received training on the type of forklift they are using
• not direct or allow a person who does not hold a HRWL to operate a forklift
• sight and hold a copy of the HRWL for all operators
• ensure the manufacturer’s instruction manual is made available to operators
• ensure all forklifts and associated equipment are regularly inspected, serviced, and maintained as per the manufacturer’s specifications
• ensure all operator protective devices installed on the forklift are maintained and used
• set up the workplace so that forklifts and people are separated, such as using barriers or guardrails
• ensure all workers and site visitors have completed a site induction
• clearly mark walkways and safe work zones
• ensure the forklift is fitted with warning devices to warn people of its movement
• ensure forklift operators only lift loads that are stable and secured on a pallet, or use an approved attachment if it is safer to do so
• ensure workers and all other people on site adhere to the traffic management plan and site safety rules
• ensure an emergency response procedure is developed and maintained, and all staff are trained in site safety procedures.

Related information

• Code of practice – Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• Workplace traffic management guidance material – Safe Work Australia
• Forklift safety information – SafeWork NSW
• High risk work licenses information – SafeWork NSW
• People working around forklifts – Safety guide (PDF, 1242.39 KB) – SafeWork NSW
• Traffic management guide – warehousing – Safe Work Australia

Download the Incident Information Release as a PDF (PDF, 285.71 KB)

Polystyrene shape moulding machine involved in the incident

Safety Information

Implement ‘reasonably practicable’ control measures to manage the risks associated with plant maintenance.

Businesses must ensure:

• all maintenance activities are carried out in accordance with the manufacturer’s recommendations
• an assessment of the guarded plant, as well as the surrounding workplace, is undertaken to ensure that no structures or objects within the workplace provide workers with an ability to by-pass plant guarding. By-passing or disabling the guarding, whether deliberate or accidental, must be made as difficult as is reasonably practicable
• procedures are in place for isolating and locking out energy sources, and for dissipating stored energy, for example, electricity, hydraulics, pneumatics, before accessing hazardous areas.

Accessing plant

• if access to the area of plant is not necessary during operation, maintenance or cleaning, the guarding should have a permanently fixed barrier
• if access is necessary during operation, maintenance or cleaning, the guarding should have an interlocked physical barrier. Access to the hazardous area should only be possible when the hazard has been controlled by others means e.g., isolation.

Operating plant

If plant needs to be operated while being maintained or cleaned, the person with management or control of the plant must ensure:

• the operator’s controls:
  • are designed for such purposes
  • are operated only by the person carrying out the maintenance or cleaning, or where that is not reasonably practicable, by an authorised person
  • allow the plant to be operated in such a way that eliminates risks or, if that is not reasonably practicable, minimises the risks so far as reasonably practicable, e.g., inching or jogging mode.

• procedures are in place to allow maintenance and cleaning, without risk to the health and safety of the person performing the work
• workers are trained in such procedures and are following them.

Subscribe to the SafeWork NSW manufacturing e-newsletter

Related information

• Work Health and Safety Regulation 2017 (Chapter 5, Division 7)
• Managing the risks of plant in the workplace - Code of Practice SafeWork NSW
• Leading safer manufacturing workplaces - SafeWork NSW
• Machine safety pack fact sheets - SafeWork NSW

Download this Incident Information Release as a PDF

A 61-year-old forklift truck operator sustained fatal injuries while moving cable drums. Prior to moving one of the cable drums, the operator alighted the forklift to retrieve a work document which was placed on the cable drum. The forklift moved forward causing the operator to be pinned between the load guard and the cable drum.

Every year forklifts cause workplace deaths and injuries resulting in substantial financial and human costs for workers, industry, and the community. The three main reasons workers are killed or seriously injured in forklift incidents are:

1. being hit or crushed by a forklift
2. being hit or crushed by a load that the forklift is moving
3. being crushed in a forklift tip-over

Consider ‘reasonably practicable’ control measures to manage the risks associated with operating forklifts.

Businesses must:

• develop and implement a safe system of work
• ensure all workers operating a forklift have the appropriate high risk work licence and have received training on the type of forklift they are using
• ensure the manufacturer’s instruction manual is made available to operators.

Before operating a forklift, you:

• must hold a current high-risk work licence (class LF)
• must have access to the manufacturer’s instructions to ensure the forklift is operated safely
• must be trained on the specific type of forklift so that you are familiar with the operating controls and understand any limitations
• should always conduct pre-start and operational safety checks to confirm the forklift is safe to operate.

When operating a forklift:

• always follow the forklift manufacturer’s instructions, site safety rules, traffic management plan and safety instructions from your employer
• assess the load to determine if the forklift configuration is designed to lift the load or whether a lifting attachment is better suited to maintain control of the load

• if you need to alight from the forklift, lower the fork arms to ground level, apply the parking brake, and ensure the drive controls are in neutral
• if left unattended, in addition to the above point, the forklift should be turned off and the ignition key removed, or the ignition control locked off to stop unauthorised use.

Practical tips to help keep workers safe:

Set up the workplace so that forklifts and people are separated, such as using barriers or guardrails.  If separation is not possible:

• clearly mark walkways and safe work zones, and make sure your workers stick to them
• ensure the forklift is fitted with warning devices to warn people of its movement
• make sure forklift operators only lift loads that are stable and secured on a pallet otherwise use an approved attachment if it is safer to do so
• make sure your forklift operators wear a seat belt (if fitted)
• make sure your workers and visitors, including delivery drivers, stick to your traffic management plan and site safety rules
• talk to all your workers, including operators and those who work near forklifts about how to work safely around forklifts.

More information

• Managing the risks of plant in the workplace - Code of practice
• Forklift safety information – SafeWork NSW
• Traffic management guide – warehousing Safe Work Australia
• General guide for industrial lift trucks – Safe Work Australia

Download this Information Incident Release as a PDF

A 29-year-old worker was seriously injured while assisting to move stone slabs/offcuts in a factory at Kogarah. The stone was stored on post frame racking. The task involved one worker operating a gantry crane while a second worker positioned the grab of the crane onto the stone. The second worker was standing in front of the stone when approximately nine slabs fell, trapping the worker from the waist down. The injuries sustained include pelvic and leg fractures, as well as serious internal injuries.

Workers or others near stacked sheet materials are at risk of being crushed, trapped, or cut by falling sheets.

The risk of severe or fatal injuries is high when materials, which have been stacked on their edges, are being handled or moved and the sheets are not adequately supported by suitable racking or transport frames.

Consider ‘reasonably practicable’ control measures to manage the risks associated with the handling and storage of sheet materials.

Storing the sheets or slabs

• store the sheets or slabs on an A-frame, truss, post frame or other purpose-designed racking system, and ensure that the safe load limit of the storage system is not exceeded
• once stored, use appropriate restraints to retain sheets or slabs in position and prevent later movement due to wind, impact or other actions
• if stored on a post frame, both posts must be adequately positioned to prevent the slabs from falling forward and must be re-positioned progressively as the material is removed from the frame.

Lifting and handling sheets or slabs

• remain clear of hazard (fall) zones when lifting and handling sheets
• never stand between the sheets or slabs, and the posts - always stand in front of the posts which break the fall of the sheets or slabs
• use appropriate lifting equipment when handling sheets - do not exceed the working load limit of any lifting device
• ensure all workers are adequately trained and supervised for the tasks they are performing
• use appropriate personal protective equipment (e.g. gloves).

More information

• Hazardous Manual Tasks Code of Practice – Safe Work Australia
• Working with sheet materials safety alert – SafeWork NSW
• Storage and handling of sheet materials – WorkSafe Qld

Download this Information Incident Release as a PDF

A 34-year-old worker was killed after being crushed between two steel girders. As one of the girders, nearly 30 metres long and weighing almost nine tonnes, was being lifted by chain slings, it shifted, crushing the worker.

The two girders and bridge crane involved in the incident

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with lifting large or heavy loads.

Before any lift, make sure:

• the licensed dogger or rigger determine a safe lifting method, by calculating mass and selecting lifting equipment and slinging techniques
• the plant, attachments and lifting gear have been designed for that specific task, and inspected and maintained according to manufacturer’s recommendations
• the attachments and lifting gear are appropriate for the item of plant, and properly fitted
• exclusion zones are established and maintained to protect everybody from falling objects and moving plant
• all crane operators and users of lifting equipment are appropriately trained and correctly licensed (where required).

During the lift, make sure:

• no-one places themselves within the vicinity of a suspended load
• there are no obstructions and you can always see the load during the lift - if the load is outside your view, the lifting process must be directed by a licensed dogger or rigger
• all loads are lifted, carried and stored in a manner that ensures the safety of the plant, and the security of the load and any attachments.

More information

• Code of practice for managing the risks of plant in the workplace
• Code of practice on how to manage work health and safety risks

Date of incident: 5 May 2020

A 31-year-old worker was killed when his forklift tipped over and crushed him, as he was driving down a driveway.

This is the second forklift fatality in NSW during the past five months.

Safety information

Before operating a forklift, you:

• must hold a current high-risk work licence (class LF), be familiar with the operating controls and know the limitations of the forklift
• should always complete a pre-start safety check, such as:
  • fluid levels (hydraulic oil, brake fluid and water)
  • seat and seat belts
  • steering, brakes, park brake, lights and operating controls
  • hydraulic operations, such as lift, tilt and sideshift
  • tyre condition and pressures (if applicable)
  • fork tynes and attachments
  • load-rating plate and safety decals
  • test drive and function tests.
• should check that regular maintenance and servicing has been carried out
• must not be not be under the influence of drugs or alcohol, or suffering from fatigue, injury or illness,

When operating a forklift, you must:

• wear a seatbelt, unless a risk assessment indicates it’s not safe to do so and other controls prevent you being ejected from the forklift
• drive at a safe speed, noting site speed limits, load size, ground and weather conditions
• avoid aggressive driving, braking and steering, especially when turning
• never turn sideways on ramps or other sloping surfaces
• avoid driving on an incline with the load facing downhill
• never overload the forklift
• never drive with an elevated mast and load, unless you’re picking up or putting away the load
• ensure all loads are centred and secured.

When the forklift is left unattended, the ignition key should be removed, or ignition control locked off to stop unauthorised people from using it.

If the forklift does tip over your instinct may be to jump. This is likely to cause serious crush injuries or death. In a forklift tip over, you should:

• remain seated and don’t lean out of the forklift
• brace your feet, hold tight and lean away from the point of impact.

More information

• Forklift safety advice
• Industrial lift trucks guidance material

Date of incident: 19 February 2020

A 34-year-old worker was shovelling ice into a horizontal screw auger conveyor at a poultry processing plant at Tahmoor when his leg became trapped.

The investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Consider ‘reasonably practicable’ control measures to manage the risks associated with working on or around machinery.

Make sure you separate workers from moving machinery by having:

• permanently fixed guarding, where access is not required during operation
• interlocked guarding, where access is required during operation

If these options are not practicable, make sure the guarding can only be removed by using a tool.

Also, make sure the guarding:

• is solid and securely mounted
• is difficult to by-pass or disable, whether deliberately or accidentally
• can be removed for maintenance and cleaning tasks – but the machine can’t be restarted until the guarding is replaced
• doesn’t create a new hazard
• doesn’t make the machine more difficult to operate, which may result in the guard being removed or disabled.

Further information

• Guide to machine safety
• Machine guarding safety pack (factsheets, posters, toolbox talk form)
• Machine safety videos
• Code of practice for managing the risks of plant in the workplace

Download a PDF of this release

A 53-year-old worker fractured his femur and pelvis after being crushed by unrestrained glass sheets, which fell from an A-frame, when a sheet he was cleaning shattered while suspended from a crane.

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.The investigation

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Consider ‘reasonably practicable’ control measures to manage the risks associated with working with glass. Make sure:

• you never attempt to restrain glass by hand
• you use a rack or transport frame to securely store, cradle, lift, transport and restrain glass sheets
• all glass sheets are restrained
• you never stand in front of glass sheets when loading or unloading from a rack, trolley or A-frame
• you always have a plan when lifting glass sheets – consider the work area, and the size and weight of the sheets
• you use the right mechanical aid – glass lifting grab, clamp, vacuum or suction cup lifter –depending on the size and weight of the glass sheets
• you keep mechanical aids in good working order
• no-one works under a suspended load or in any potential fall zones
• workers not involved in moving, cleaning or storing glass are kept away from the work area.

Further information

• Storing and handling glass video safety alert
• Unpacking glass sheets safety alert
• Code of practice for hazardous manual tasks

Download a PDF of this release

Two maintenance workers were doing electrical work using a forklift and workbox at a manufacturing site in Barooga in the Riverina region. The forklift accidentally lifted the workbox, crushing one worker between the workbox and the underside of the roof. The worker sustained fatal head injuries.

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Consider ‘reasonably practicable’ control measures when using plant not specifically designed to lift people, such as forklifts fitted with workboxes. Make sure:

• the workbox is fitted with overhead protection if there is a risk of collision
• the forklift driver holds a current, valid licence
• the forklift data plate includes the workbox model number
• the workbox is securely attached to the forklift, according to manufacturer’s instructions
• workers are trained to use the workbox safely and follow emergency procedures, so occupants can be rescued if necessary
• the forklift is on a hard, flat, level surface, with the park brake applied, controls in neutral and the mast is vertical
• the path is clear of overhead obstructions – do a test lift with an empty workbox
• the forklift driver stays at the controls when someone is in the workbox
• workers wear a safety harness in the workbox, if there is a risk of falling from a height.

Further information

• Forklifts safety advice
• Industrial lift trucks guidance material
• Clause 219 – Plant that lifts or suspends loads
• Clause 220 – Plant not specifically designed to lift or suspend a person
• AS 2359.2-2013 Powered industrial trucks - Operations
• AS 2359.1:2019 Powered industrial trucks – General requirements

Download a PDF of this release

A 32-year-old man sustained fatal injuries when he became caught in a timber pallet-making machine at a factory in St Marys.

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risk of plant in the workplace.

Use the following risk management process:

• Identify all foreseeable hazards associated with machinery, including mechanical hazards, such as entanglement, impact and cutting, and non-mechanical hazards, such as ergonomic, electrical, dust, confined spaces and the like.
• Manage the risks associated with these hazards.
• Use the most effective machine guarding, such as permanently fixed guards or interlocked guards, that don’t rely on human behaviour – make sure the guards can’t contact moving parts.
• Control access to dangerous areas, screen harmful emissions, minimise noise and prevent ejected parts from striking people.
• Program machine re-setting, particularly during maintenance, to prevent unexpected start-up or movement.

When working with machinery:

• Do a pre-start check before using, to confirm it’s safe.
• Make sure all guards are working.
• Use it for the purpose it was designed.
• Follow operating procedures when setting-up, operating, cleaning and maintaining.
• Don’t remove guards or bypass safety devices.
• Isolate the machine and make sure all stored energy has dissipated before accessing hazardous areas.
• When doing maintenance in ‘jogging mode’, make sure guards remain in place and are effective in managing risks.

Further information

• Managing the risks of plant in the workplace – code of practice
• Machine safety fact sheet
• Machine guarding safety video

Download a PDF of this release

A 56-year-old worker sustained fatal injuries when he was struck by falling objects after a semi-trailer reversing into the warehouse collided with a laden steel storage rack causing it to fall.

Pictures of fallen storage rack and materials within a warehouse taken from different angles.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with moving vehicles and steel storage racking systems.

Ensure:

• the layout of the workplace and the system of work allows for adequate separation between the vehicle path, people and fixed objects
• you use bollards, barriers, safety rails or exclusion zones to separate people, workers & equipment from moving plant and vehicles
• you use warning devices to warn people of moving plant, for example reversing alarm, flashing lights, proximity sensors
• there is a plan at the site to minimise plant and vehicle hazards, for example have drive-through access to minimise reversing, or establish clearly defined loading areas close to storage areas
• there are established traffic flow patterns developed for the right of way procedures, use signs and speed limits
• there are dedicated trained traffic controllers to assist with reversing plant and vehicles
• exclusion zones are in place to workers and others in areas where there are reversing plant and vehicles
• visible safe working load signs are fitted which display the maximum unit load for each pallet beam level and bay
• the total weight of unit loads stored on each bay does not exceed the maximum unit load
• you never make any modifications to racking systems unless first approved by the manufacturer, supplier or qualified engineer who has knowledge and experience in similar work
• racking systems are always installed in accordance with the manufacturers guidelines and all bolts are used to fasten the racking system to a secure base
• collision protection is installed such as upright protectors and end-of-rack protectors
• a traffic and pedestrian plan is developed and maintained
• information, training and instruction is provided to all workers, including contractors or visiting drivers so that they know the traffic rules for the workplace.

Statistics

The transport, postal and warehousing industry has a high rate of injuries and fatalities and compared to all NSW industries, it has a higher percentage of major workers compensation claims.

Hazardous manual tasks are the most frequent cause of claims, accounting for approximately 43 per cent of all claims followed by falls, being hit by or hitting objects and vehicle accidents.

For every 1,000 workers in the sector, on average, 41 workers sustain a workplace injury or disease leading to a claim compared to 28 workers in all industries in NSW.

Transport, postal and warehousing accounted for the largest number of fatalities in NSW between 2003 and 2015.

Ref. Transport, postal and warehousing (Top injuries)

Related guidance material

• Code of Practice - Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• Safety around your vehicle (SAYV) glove box guide
• Self-Assessment Checklist - Safety Around Your Vehicle (PDF, 166.32 KB)
• Traffic Management Guide for Truck Drivers (PDF, 76.41 KB)
• Pallet racking fact sheet
• AS4068: 1993 Flat pallets for materials handling
• AS4084. 1:2023 Steel storage racking – Design
• AS 4084.2:2023 Steel storage racking – Operation and maintenance
• AS4762: 2000 General purpose flat pallets, principal dimensions and tolerances
• Traffic management: Guide for Warehousing
• Traffic Hazards Checklist
• Traffic Control Measures Checklist
• Transport, postal and warehousing

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 31-year-old worker was in the process of tipping out refuse from a tipper truck at a waste management facility. The worker was outside of his vehicle clearing a blockage when he was struck by a compactor operating on site, sustaining fatal crush injuries.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with moving plant interactions.

• Identify traffic hazards
  • consult with workers and mobile plant operators
  • identify where mobile plant may interact with pedestrians or other vehicles
  • determine potential locations and circumstances where people, plant and vehicles could collide – eg. when workers are required to alight from their vehicles.
• Eliminate the risk, if possible.
• If elimination isn’t possible, minimise the risk by:
  • Designing the layout of the workplace so that workers are not required to exit their vehicles and to minimise the interaction between pedestrians and mobile plant and other vehicles.
  • Use physical barriers and/or exclusion zones to separate workers from mobile plant and vehicles.
  • Ensure there are clear, reliable communication systems in place.
  • Ensure all workers and other site users are aware of the traffic flow pattern, site rules, control measures and communication systems.
  • Any area where the mobile plant and/or vehicles are required to reverse poses an additional risk and higher levels of controls should be implemented for example: scheduling work so that vehicles and pedestrians are not operating simultaneously in the one area.

At most sites, a combination of control measures will be required to effectively manage the risks associated with mobile plant.

• Maintain and review control measures. Control measures need to remain effective, particularly if the workplace is changing. Systems should be in place to:
  • assess the effectiveness of current control measures
  • allow reporting and feedback on the effectiveness of the control measures
  • ensure workers are implementing control measures correctly
  • identify upcoming changes to the workplace environment (layout, shared services etc) or work procedures (new equipment or processes, worker training etc) before they occur, and assess the potential impact on control measure,
  • identify and assess possible alternate control measures (eg. new technology).
• Provide supervision and ongoing training.
• Regularly observe your workers to check they are following safe work procedures. Conduct informal discussions or toolbox talks with them to talk about specific health and safety issues.

Statistics

Safety around moving plant is a SafeWork NSW regulatory priority with a focus on reducing workplace safety incidents related to moving plant, and forms part of the SafeWork NSW Strategic Plan 2024-2029. Moving plant and vehicles such as excavators, forklifts, utes, and trucks create a risk to workers when reversing, loading, and unloading. Incidents, such as workers or others being hit by moving plant or vehicles, can cause injury and death.

Related guidance material

• Code of Practice - How to manage work health and safety risks (PDF, 556.72 KB)
• Code of Practice - Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• Working with or around mobile plant safety alert – SafeWork NSW
• Workplace traffic management guidance material
• Findings report: Earthmoving Plant in Construction 2022-2023

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A 28-year-old worker sustained serious injuries while unloading a tipper truck when the vehicle’s load cascaded down from the front of the raised trailer. The tailgate opened without warning, striking the worker, pinning him against a wall while the load engulfed him. He sustained serious injuries.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with loading and unloading trucks.

Tailgates on tipper bodies may not be designed to bear loads during tipping. This means if the tailgate is closed while the tipper body is raised, there is a risk the tailgate will suddenly and unexpectedly open.

The movement of materials within a tipper body, either under transportation or operation of the tipper, may place excessive forces on the tailgate. The weight of tailgates may expose workers to possible crushing or shearing hazard.

Ensure:

• workers have access to the manufacturer’s information to ensure the tipper truck is operated correctly
• an exclusion zone is set up around the truck during loading/unloading processes to separate plant, cargo and machinery from people
• never enter an exclusion zone, approach, or work close to, the rear tailgate while the tipper body is inclined. This includes when undertaking cleaning and maintenance work
• the vehicle selected to transport loads is suitable for the task
• fasteners and load restraint systems are used as intended to prevent loads from moving or falling
• fasteners and load restraint systems are inspected before use and regularly maintained by a competent person
• hazards in the work environment where the loading/unloading of materials will take place, are identified and if they cannot be eliminated, are managed in accordance with the hierarchy of control measures
• workers have been provided with the necessary information, training and instruction so they are competent in the safe use of tipper truck
• the tipper truck is regularly inspected and maintained by a competent person
• a site induction is completed prior to unloading
• an effective communication system is in place between the truck driver and other workers during the loading/unloading process for example, hand signals or two-way radios
• workers do not place themselves between the load and the truck or other equipment
• a work plan is developed in consultation with all workers involved in the task that details how the task is to be performed
• a traffic management plan is in place and all workers attending the site are provided with this information
• workers wear appropriate personal protective equipment for example, high-visibility clothing.

Related guidance material

• Work Health and Safety Act 2011
• Code of Practice - How to manage work health and safety risks (PDF, 556.72 KB)
• Code of Practice - Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• A guide to work health and safety in the road freight transport industry
• Safety around your vehicle (SAYV) glove box guide
• Safety Alert - Working with or around mobile plant
• Load-Restraint Guide 2018
• National Heavy Vehicle Regulator - Law and Regulations

Further information

• Traumatic event management plan
• Speak Up Save Lives app
• Mental health at work - NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A worker was helping a driver to unload stock from a flatbed truck when he fell approximately three metres from the truck’s tray. The worker was seriously injured when he landed on a pile of aluminium and the concrete ground.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with loading and unloading trucks.

Ensure:

• you develop a work plan in consultation with all workers involved in the task. This should detail how to perform the task
• you provide information and training to drivers. This should include a safe system of work and loading and unloading procedures
• a safe system of work is established and workers only move objects from ground level where possible
• if working from ground level is not possible, ensure that a safe system of is developed to access the tray for work to be undertaken
• an exclusion zone is set up around the truck during loading/unloading processes to separate plant and machinery from people
• before loading or unloading materials, identify and eliminate hazards
• a traffic management plan is in place and all workers attending the site are provided with this information
• workers wear appropriate personal protective equipment, for example high-visibility clothing
• ensure workers are trained and competent in using plant and machinery (such as cranes), as well as lifting equipment. This includes holding High Risk Work licences where required
• the vehicle selected to transport loads is suitable for the task
• lifting equipment is used to remove objects from trucks, such as a forklift or crane
• temporary platforms, guard rails or fall arrest systems are used to minimise the risk of falling if workers are required to complete tasks at height
• fasteners and load restraint systems are used
• loads are pre-configured to allow easy access and removal during the unloading process
• plant and machinery are regularly inspected and maintained by a competent person
• the truck is immobilised and cannot move during the loading/unloading process, for example the handbrake and stabilisers are deployed
• workers do not place themselves between the load and the truck or other equipment.

Related guidance material

• Code of Practice – Managing the risk of falls at workplaces (PDF, 2326.56 KB)
• Code of Practice - How to manage work health and safety risks (PDF, 556.72 KB)
• Code of Practice - Managing the risks of plant in the workplace (PDF, 1987.96 KB)
• A guide to work health and safety in the road freight transport industry
• Safety around your vehicle (SAYV) glove box guide

Further information

• Traumatic event management plan – SafeWork NSW
• Speak Up Save Lives App – SafeWork NSW
• Mental health at work – NSW Government
• Subscribe to SafeWork NSW newsletters and updates

A flammable liquid fire at a service station saw workers and others exposed to a risk of injury when an uncontrolled fuel and/or vapour was ignited. The fire occurred while fuel was being unloaded from a road tanker into underground storage tanks, destroying the service station buildings, forecourt canopy and fuel dispensers, the prime mover and fuel tanker trailer and three cars.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with the loading and unloading of petroleum products (class 3 PGII flammable liquids).

Ensure:

• All transfer equipment is inspected and tested in accordance with manufacturer recommendations to minimise the risk of fuel leakage
• Safe systems of work are established for the transfer of bulk fuel at service stations
• All workers involved in the delivery of fuel, including service station attendants and road tanker drivers, are trained in the procedures for safe transfer of bulk fuel
• An exclusion zone is established and enforced during fuel unloading to prevent the introduction of ignition sources into the hazardous zone
• Road tanker drivers are adequately supervised until they are deemed competent to complete the tasks unsupervised
• Emergency procedures are established, and workers are trained in these procedures.

Related guidance material

• Australian Code for the Transport of Dangerous Goods
• AS/NZS 60079.10.1 Classification of areas - Explosive gas atmosphere
• AS1940: 2004 Storage and handling of flammable and combustible liquids
• AS4979: 2008 Flammable and combustible liquids – Precautions against electrostatic ignition during tank vehicle loading

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• Subscribe to SafeWork NSW newsletters and updates

A 57-year-old delivery driver sustained fatal injuries when two rolls of electrical conduit he was delivering fell from the truck as he was unloading it. Two of the conduit rolls, weighing approximately 250-300kg each, landed on top of the worker.

The delivery truck loaded with rolls of electrical conduit at the incident scene.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with loading and unloading trucks.

Ensure:

• the vehicle selected to transport loads is suitable for the task
• fasteners and load restraint systems are used as intended to prevent loads from moving or falling
• fasteners and load restraint systems are inspected before use and regularly maintained by a competent person
• hazards in the work environment where the loading/unloading of materials will take place, such as overhead electric wires or unstable ground, are identified and eliminated, or risks to health and safety are controlled
• workers are trained and competent in the use of plant and machinery (e.g., cranes), as well as lifting equipment, and hold High Risk Work licences where required
• plant and machinery are regularly inspected and maintained by a competent person
• the truck is immobilised and cannot move during the loading/unloading process e.g., handbrake and stabilisers are deployed
• an exclusion zone is set up around the truck during loading/unloading processes to separate plant and machinery from people
• an effective communication system is in place between the truck driver and other workers during the loading/unloading process e.g., hand signals or two-way radios
• workers do not place themselves between the load and the truck or other equipment
• a work plan is developed in consultation with all workers involved in the task that details how the task is to be performed
• information and training are provided to drivers on a safe system of work and loading/unloading procedures are adhered to
• a traffic management plan is in place and all workers attending the site are provided with this information
• workers wear appropriate personal protective equipment e.g., high-visibility clothing.

Related guidance material

• How to manage work health and safety risks – Code of Practice (PDF, 556.72 KB)
• Managing the risks of plant in the workplace – Code of Practice (PDF, 1987.96 KB)
• Construction Work – Code of Practice (PDF, 1014.41 KB)
• A guide to work health and safety in the road freight transport industry
• Safety around your vehicle (SAYV) glove box guide
• Working with or around mobile plant safety alert – SafeWork NSW
• Falling objects in construction fact sheet (PDF, 122.91 KB)

Further information

• Traumatic event management plan – SafeWork NSW
• Mental health at work – NSW Government
• Speak Up Save Lives App – SafeWork NSW
• The pocket guide to construction safety (PDF, 1352.71 KB)
• Subscribe to SafeWork NSW newsletters and updates

A 52 year old truck driver was fatally injured on the Macleay Valley Way at Clybucca, in northern NSW. The location is commonly used as a changeover point for heavy vehicles travelling between Sydney and Brisbane.

On the night of the incident, several heavy vehicles were parked on the shoulder of both sides of the road. The worker, who was not wearing high visibility clothing at the time, was struck by an oncoming heavy vehicle. The heavy vehicle was driving in the middle of the road at the time of the incident.

All transport operators should:

• conduct risk assessments of heavy vehicle changeover locations
• identify suitable control measures such as:
  • safe locations for undertaking tasks that are related to heavy vehicle changeovers
  • ensure the area has sufficient lighting when it’s dark
• provide training and instruction to workers on the hazards associated with work tasks and safe systems of work for heavy vehicle changeovers
• provide workers with personal protective equipment (PPE) and information, training and instruction for its proper use, wearing and storage
• have systems in place to monitor compliance with safe work procedures.

All drivers should:

• when coupling and uncoupling trailers, park the prime mover and trailer on a flat, level and hard surface in a safe location
• follow reasonable instruction, policy and procedures from the transport operator
• operate vehicles and conduct work tasks in accordance with Work Health Safety laws and the National Heavy Vehicle Law
• wear appropriate personal protective equipment (PPE) required for the tasks to be undertaken.

Statistics

The transport industry is one of NSW’s highest risk industries. Common causes of serious injury or death in the transport, postal and warehousing industry are:

• working at heights
• hazardous manual tasks
• being hit by moving objects
• being trapped between stationary and moving objects.

More information

• National Heavy Vehicle Regulator - Master Code
• Transport for NSW - Heavy Vehicle Driver Handbook [PDF] (refer pages 82-87)
• SafeWork NSW - Safety Around Your Vehicle Glove Box Guide [PDF] (refer pages 12,14,16)

Download this Incident Information Release as a PDF

A 71-year-old male sustained fatal injuries while loading a car onto a tilt tray truck in Singleton NSW.  It is believed that the car came off the tilt tray causing the worker to fall and strike his head on the pavement.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with tilt truck operations including uncontrolled movements of vehicles. Ensure plant, structures, systems of work and sufficient training and instruction are provided to ensure work can be carried out in a safe manner.

Tow truck operators must:

• Ensure drivers are competent to undertake the work and hold a current Tow Truck Drivers Certificate and Drivers Licence
• Ensure the tow truck’s required equipment is available, inspected and maintained in accordance with the manufacturer’s recommendations
• Ensure the truck and equipment deployed is appropriate for the vehicle being retrieved
• Make sure workers are provided with training and instruction to safely use appropriate recovery systems
• Routinely monitor and review all control measures

Workers must take reasonable care for their own health and safety, and comply with any reasonable, policy, instruction, or procedure of the tow truck operator for which they are working.

Tow truck drivers should:

• Make sure you have the necessary training and experience to identify hazards associated with uncontrolled movement of vehicles
• Ensure the weight of the vehicle being retrieved does not exceed the Safe Working Load (SWL) of the tow truck, its winch or equipment such as hooks or towing eyes
• Check the Safe Working Load (SWL) for the truck and cradle is not exceeded when using the towing cradle for single vehicles or using the tilt tray and cradle when towing two vehicles. This includes towing a car and caravan in the case of a breakdown recovery

When preparing a vehicle for tow:

• Park the truck on level ground. When this is not possible, be aware of the vehicle limitations and what to do when parking on a gradient
• Use chocks behind the wheels to prevent uncontrolled movement
• Always apply the parking brake when exiting the vehicle
• Know the components and limitations of the braking system
• When lifting a vehicle onto the tow truck, use designated plant and equipment to secure to appropriate connection points, check the braking systems and steering controls for damage
• At all times stand to the side of vehicle when connecting a winch to vehicles

More information

• Working with or around mobile plant – SafeWork NSW\
• Managing the risks of plant in the workplace – Code of Practice
• Uncontrolled movement of vehicles - SafeWork NSW
• Working with super tilt heavy vehicle recovery trucks & trailers – SafeWork NSW

Download the PDF of this Incident Information Release as a PDF

A 50-year-old mechanic suffered fatal crush injuries in Tumut, whilst working on the brake line of a tipper truck. The worker was situated underneath the truck when it rolled forward over the worker before coming to rest after colliding with another parked tipper truck.

Safety information

Businesses must implement ‘reasonably practicable’ control measures to manage the risks associated with uncontrolled movements (e.g. roll aways) of vehicles, including trucks, cars, buses, vans, forklifts, tractors, mobile cranes and the like.

You must:

• when acquiring vehicles, consider models and options that eliminate or minimise the risk of uncontrolled movement
• park the vehicle on level ground. Where it is not reasonably practicable to park the vehicle on level ground, be aware of the limitations of the vehicle including the maximum slope of the supporting surface and what to do when parking on a gradient
• always apply the parking brake when exiting the vehicle
• appropriately chock the wheels of vehicles and trailers before conducting inspection or maintenance activities to prevent uncontrolled movement
• ensure the vehicle is inspected and maintained in accordance with the manufacturer’s recommendations
• be familiar with the components and limitations of the braking system that may cause unintentional release of the brakes
• consider implementing aftermarket controls that minimise the risk of uncontrolled movement of vehicles, (e.g. include seat sensor interlocked brakes or fail-safe braking systems)
• where it is not reasonably practicable to employ engineering controls, implement other controls such as alarm systems and/or operating procedures
• develop site specific parking locations and procedures in consultation with workers
• ensure workers have the necessary training, experience and supervision to identify hazards and control the risks associated with the uncontrolled movement of vehicles
• routinely monitor and review all control measures.

More information

• Code of practice for managing the risks of plant in the workplace
• Safety alert; Working with or around mobile plant
• Safety alert: Uncontrolled movement of vehicles safety alert

Date of incident: 28 September 2020

A 70-year-old truck driver was fatally crushed while unloading a 400-500kg excavator sieve bucket from a semi-trailer. The bucket was lashed to the semi-trailer. When the chains holding the bucket were released, the bucket slid and toppled off the truck, crushing the worker between the bucket and a bridge beam on the ground next to the truck.

Safety information

Businesses must implement ‘reasonably practicable’ control measures to manage the risks associated with loading and unloading mobile plant equipment.

You must:

• check that the load has not shifted during transportation before releasing the transportation restraints
• develop and document a Safe Work Method Statement (SWMS), in consultation with your workers, for unloading plant and equipment with a crane. Make sure all relevant workers understand and implement the SWMS.
• where necessary, sling the load to lifting equipment, such as a crane, prior to releasing the transportation restraints
• determine the weight or centre of gravity of the load, and the slinging technique to be used. A Dogging High Risk Licence is required for this type of work
• establish exclusion zones to make sure people are not placed within potential fall zones

More information

• Plant, machinery and equipment information
• Code of practice for managing the risks of plant in the workplace
• WorkSafe Qld video on unloading mobile plant

View the latest incident information releases at Incident Information Releases

Date of incident: 10 August 2020

A 52-year-old tow truck driver was fatally crushed by a prime mover as it rolled off a tilt tray semi-trailer in Newcastle. The incident occurred as the truck driver was loading the prime mover he had purchased onto the tilt tray semi-trailer. It appears that when the driver raised the tilt tray to place tie down chains around the chassis of the prime mover, it rolled backwards off the tilt tray and crushed him. NSW Police are preparing a coroner’s report.

Businesses must consider ‘reasonably practicable’ control measures to manage the risk of uncontrolled movements of vehicles.

You should:

• park the vehicle on level ground. If not, be aware of the vehicle limitations and what to do when parking on a gradient
• use chocks behind the wheel to prevent uncontrolled movement
• always apply the parking brake when exiting the vehicle
• make sure the vehicle is inspected and maintained in accordance with the manufacturer’s recommendations
• understand the components and limitations of the braking system
• when recovering or towing vehicles, use designated connection points and check the braking systems and steering controls for damage
• when connecting recovery equipment to vehicles, do not place yourself between potential crush points
• make sure workers are provided with training and instruction on assessing and using recovery systems
• develop site specific parking locations and procedures in consultation with workers
• make sure you have the necessary training and experience to identify hazards associated with uncontrolled movement of vehicles
• routinely monitor and review all control measures

Further information

You can also refer to the following guidance materials:

*Working with or around mobile plant
*Code of Practice – Managing the risks of plant in the workplace
*Uncontrolled movement of vehicles safety alert | SafeWork NSW

View the latest incident information releases at safework.nsw.gov.au

Date of incident: 16 September 2019

A 65-year-old driver suffered fatal injuries when struck by two steel pipes as they were being unloaded from a heavy-vehicle trailer in Moorebank. A telehandler, operating from the opposite side of the truck, was used to unload the pipes.

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with unloading heavy loads.

Before entering any work area, delivery drivers should be inducted into the site-specific rules and procedures, then directed to an exclusion zone that allows mobile plant to be used safely.

Before unloading, make sure:

• fasteners and load restraint systems are working as intended, and are in good condition – restraint systems should prevent loads from moving and control pipes from rolling off the truck bed or against a truck-mounted post, barrier or frame
• workers are competent, have received training and instructions on loading and unloading stock safely, and have appropriate high-risk work licences if necessary
• the appropriate plant is used to lift and transport the stock, and attachments are compatible and properly fitted.

When loading or unloading, make sure:

• workers don’t place themselves between the load and the truck, trailer, lifting equipment or any other pinch point
• workers don’t work on the opposite side of the trailer (other than when seated in the cab of a backstop forklift).

Further information

• Machinery and equipment safety page
• Forklift safety page
• Forklift load handling safety video
• Forklift information sheet for owners and operators
• Industrial lift trucks – general guide
• How to manage work health and safety risks - code of practice
• Guidance for transporting and stacking wide loads
• Managing the risks of plant in the workplace - code of practice
• Moving plant on construction sites

Download a PDF of this release

Date of incident: 2 April 2020

A 54-year-old truck driver was crushed by a loading ramp and died, while unloading earthmoving equipment from a low loader.

This is the second death in NSW in the past six months involving a truck driver being crushed by loading ramps.  In November 2019, a similar incident occurred.

If you operate and maintain low loader trailers, make sure:

• you assume a loading ramp can fall on someone at any time, unless properly restrained
• you don’t rely on hydraulics or other lowering devices to prevent a ramp falling
• those involved in the task are properly informed, trained and supervised
• pre-start checks are done, including inspecting and testing the hydraulic system
• measures are in place to prevent anyone being in the ‘swing arc’ area when ramps are lowered, raised or unsecured
• procedures are in place to deal with hydraulic malfunctions, loss of hydraulic oil, hydraulic oil leaks, damage to hydraulics or structural failures
• ramps are used according to manufacturer’s instructions
• ramps and other equipment are regularly inspected and maintained by a competent person
• there are signs at the rear of the vehicle, warning people to stay clear of ramps
• workers can’t be struck by a falling ramp.

More information

• Code of practice for managing the risks of plant in the workplace
• Hydraulics safety information
• Truck and trailer ramps

Download a PDF of this Incident Information Release

A 51-year-old man was crushed by his truck in Marsden Park when it rolled down a slope as he was fitting a dog-trailer to it. It’s the second serious truck roll-away incident in NSW in the past seven months.

The Investigation

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with uncontrolled movements (e.g. roll-aways) of vehicles, including cars, trucks, buses, vans, forklifts, tractors, mobile cranes and the like.

Make sure you:

• park the vehicle on level ground, or be aware of the limitations of the vehicle and what to do when parking on a gradient
• apply the parking brake when you get out of the vehicle
• have the vehicle inspected and maintained according to the manufacturer’s recommendations
• know the limitations of the braking system and what may cause the brakes to release
• consider installing seat-sensor interlocked brakes, a fail-safe braking system or anything that will prevent uncontrolled movements of the vehicle
• install an alarm system, or implement operating procedures or other low-level controls if you can’t use engineering controls
• when acquiring vehicles, consider options that eliminate or minimise the risk of uncontrolled movements
• develop site-specific parking locations and procedures in consultation with workers
• train your workers
• monitor and review control measures.

Further information

You can also refer to the following guidance materials:

• Code of practice for managing the risks of plant in the workplace
• Working with or around mobile plant safety alert
• Uncontrolled movement of vehicles safety alert

Download a PDF of this release

Date of incident

5 November 2019

Incident overview

A 55-year-old truck driver sustained fatal injuries after being crushed by a hydraulic powered ramp on a trailer connected to the prime mover he was driving. The incident occurred as the truck driver was attempting to unload two vehicles from the trailer in an industrial area in Ingleburn. After removing the safety chains from the ramps, one of the ramps has fallen, fatally crushing the driver.

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety Information

Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.

Businesses must implement ‘reasonably practicable’ control measures to manage the risks associated with hydraulic systems:

Always assume a loading ramp can fall on a person at any time unless properly secured by a restraint device. Never rely on the trailer hydraulics or other lowering devices to prevent a ramp from falling.

Persons involved in the operation and maintenance of loading ramps on trailers must ensure:

• persons undertaking the lowering and raising of loading ramps have received adequate information and training and are supervised to the extent necessary for safe operation
• appropriate pre-start checks of trailers are conducted, including a visual inspection of the hydraulic system and where practicable, test the operation of the hydraulic system
• effective control measures are put in place to prevent workers and/or members of the public being in the ‘swing arc’ area when ramps are being lowered or raised, or when the ramps are in the raised position but not secured
• procedures to deal with hydraulic system malfunctions, loss of hydraulic oil, hydraulic oil leaks, damage to hydraulics or structural failures are in place and followed
• ramps are used in accordance with the manufacturer’s instructions
• ramps and their ancillary equipment are regularly inspected and maintained by a competent person
• clearly visible signs at the rear of the vehicle warning people to remain clear of ramps at all times help to highlight the risk
• workers should never stand or move past where they could be struck by a falling ramp

Further information

You can also refer to the following guidance materials:

• Code of Practice – Managing the risks of plant in the workplace
• Hydraulics safety information – WorkCover Queensland
• Truck and trailer ramps  - WorkCover Queensland

Download a PDF of this release

A 67-year-old man suffered fatal injuries when crushed between containers at Port Botany. He was working near a forklift carrying a 12-metre long shipping container, when the container hit a stationary container, causing it to slide and trap the man between it and a nearby stack of containers.

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.

Safety information

Consider ‘reasonably practicable’ control measures to manage the risk of lifting and transporting shipping containers.

Make sure:

• the site has adequate space and light to operate plant safely around the containers
• the environmental conditions – heat, cold, rain, wind, ventilation – don’t hinder safety
• exclusion zones are established and maintained around containers and mobile plant, to protect workers from falling objects and moving plant - as set out in your traffic management plan
• plant and equipment is fit for purpose, inspected and properly maintained, in accordance with manufacturer’s recommendations
• operators are competent and hold the relevant high risk work licence for the work they are doing, such as the operating reach stackers, forklifts or cranes.

Further information

• AS 3711.10 - Freight Containers – Handling and storing standards
• Workplace Traffic Management – general guide
• How to manage work health and safety risks - code of practice
• SafeWork NSW Code of practice – Managing the risks of plant in the workplace

Download a PDF of this release

Incident overview

A truck driver was standing next to his truck as a forklift was used to load it with pine timber packs at a workplace in Bathurst. One of the timber packs fell off the tray, striking the truck driver. The driver sustained a serious head injury and later died as a result of his injuries.

• SafeWork NSW inspectors responded to the incident.
• SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.