Q2 2021
HIGH POTENTIAL INCIDENTS Focusing on important learnings from HPI's
Thanks to this edition’s contributors
CALL FOR CONTENT
Are you an aspiring author? Are you passionate about the safety of your workmates? Do you have an idea for improving safety or efficiency in your workplace? We want to hear from you. Contribute to Lifting Matters’ vision of a safer industry by submitting your ideas and articles to editor@liftingmatters.com. We are seeking stories about recurring incidents, significant incidents, ideas about safer and more efficient ways of working, any prevalent issues, good reminders, anything of a safety related nature. You can submit a full article, anywhere from 200 to 1000 words, or you can send us ideas about what you would like to hear us discuss in future issues of Lifting Matters. If you’re from a business, we will mention you as a supporter and publish your logo at no cost to you. We can’t wait to hear from you!
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MISSED AN ISSUE? Current and previous issues are all available for download on our website. Visit the archives at: liftingmatters.com.au
From the Editor Q2, April - June, 2021 Welcome to the Q2 2021 edition of Lifting Matters.
This edition we focus on ‘what could have been’ and put High Potential Incidents (HPI’s) under the microscope. In a high-risk sector like ours, key performance improvements and organisational advancement comes from learning from High Potential Incidents. From a safety perspective, HPI’s are a way for companies and individuals to step back and take stock of a situation that could have been a lot worse but thankfully wasn’t. The team at Smithbridge Group give us a deep dive on High Potential Incident reporting and management and we delve into some statistics on mining and quarry HPI's from a report by Resources Safety and Health Queensland. Workplace Health and Safety Queensland talk us through common causes of incidents in the crane industry and best practice for incident prevention. We speak to Rod Hellwig in our Operator’s Opinion about his experience in concrete operations and to Ben Fitzgerald, owner of QLD Rigging. You can also read about a ground-breaking crane simulation training innovation coming out of New Zealand which is helping save time and improve safety in the industry through improved training outcomes. 4
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Thanks to some reader feedback we also address the cover photo from Q1 2021 in a special follow up article. Please get in touch with us! You can visit us on Facebook, LinkedIn or drop us an email any time. If you have an incident report, ideas about safer and more efficient ways of working, widespread issues, valuable reminders or anything else safety related, we want to hear from you. We look forward to working together to protect our people and save lives in the crane industry. Any contributions for our next edition are due by Friday 4 June 2021. If you prefer printed glossy copies for your crane cabs, cribs, mess hall, or reception, please send your postal address and the number of copies you require to editor@liftingmatters.com. Lifting Matters is available to view at www.liftingmatters.com.au or you can subscribe to receive an email copy each quarter. Stay safe and see you next edition!
Thank you DASHELLE BAILEY, EDITOR editor@liftingmatters.com
Contents EDITORIAL
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FEATURE ARTICLE Driving safety improvements through High Potential Incidents
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INDUSTRY INNOVATION Transforming High Risk Training in NZ with Simulator Technology INCIDENT REVIEW HPI Reviews on: - Powerlines - Insecure counterweights - Improper load restraint - Dropped loads
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SPOTLIGHT ON High potential incidents involving cranes and lifting equipment
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SPECIAL FOLLOW UP Feedback on the Q1 2021 Cover Image
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OPERATOR’S OPINION Rod Hellwig
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PEOPLE PROFILE Ben Fitzgerald
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WORKING SAFELY The importance of reporting on High Potential Incidents in the Queensland Mining and Quarry sectors
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Feature Article
Driving safety improvements through High Potential Incidents Article contributed by KEVIN BALL & BETINA DALE – SMITHBRIDGE GROUP
For over 25 years, Smithbridge Group has been known for a commitment to safety across all operations. As an organisation in a high-risk sector, the prevention of incidents and keeping the workforce safe has always been a top priority. For this reason, the Group extended its safety reporting to also focus on the potential of an incident or near miss, rather than just the outcome. This level of reporting is enabled by Smithbridge Group’s dedicated Safety, Health, Environment and Quality (SHEQ) team, who oversees systems, programs and processes across the global businesses. The team is complimented by locally based SHEQ teams within each business in Australia, New Zealand and Guam. 6
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Defining and Identifying High Potential Incidents (HPI’s) Through incident reporting and analysis processes, the Smithbridge Group determines the risk its workforce and operations are exposed to when an incident occurs by determining the most appropriate steps to take to reduce risk. This is done by applying a set of control measures consistent with the hierarchy of controls approach, common to risk management processes. As part of this “risk” approach, High Potential Incidents (HPI) are classified where an incident (including near misses) could have resulted in a serious incident if the full potential of the incident was realised. This can occur when
Feature Article the last line of defence (control) was the only thing that prevented the incident from being more serious, or when it was simply down to luck that nothing more serious occurred.
How HPI’s can drive safety improvements As Smithbridge has a global reach, it is important the organisation shares the learnings between all locations within the group. Every location within the group has crane hire and specialised transport as integral parts of the business, therefore, the same activities are undertaken throughout the group, just at different locations. Sharing recommendations from incidents that occur in one location with the rest of the group helps Smithbridge prevent the same incident from occurring in the other locations. This is nothing new - lots of businesses with multiple locations do exactly the same thing. However, Smithbridge has a Key Performance Indicator (KPI) for the group of zero repeat HPI’s across the whole group, probably not as common. How does this work? Universal Cranes Brisbane experienced a HPI last year involving load restraint. Therefore, based on the “no repeat HPI KPI”, the Smithbridge Group as a whole could not have another load restraint incident across the group for that year to achieve the KPI. Setting a KPI is one thing but maintaining it is another. To help achieve the “zero HPI repeat”, recommendations and actions from the business unit that initially experienced the incident are reviewed at other business unit’s management meetings. The process is by no means foolproof. It does however put
the onus on each business unit to actively review HPI findings from all business units, consider the recommendations and key learnings, and adopt the control measures in their workplace. Business Unit’s are encouraged to conduct a gap analysis of existing controls against the recommended controls listed in the report. The load restraint HPI discussed in the incidents of this Lifting Matters issue led to a number of controls being implemented throughout the Group, including the Universal Cranes Load Restraint Manual.
Load Restraint Manual: Universal Cranes Reporting on, discussing and rectifying controls for HPI’s lead Universal Cranes to overhaul a critical area of operations, leading to better outcomes for load restraint. While working as Branch Manager in one of Universal Cranes’ regional depots, Phil Dayman initially had an idea for a safety initiative on Load Restraint as part of his Chain of Responsibility. When he relocated to the Universal Cranes Head Office into an Operations Manager role, Phil developed a Load Restraint Guide. The guide provided a solid foundation for many years but following a string of HPIs, near misses and incidents surrounding load restraints, gaps in load restraint management started to become apparent, even with the Load Restraint Guide in place. The initial Load Restraint Guide released in 2018 was lengthy and very detailed, making it not very user friendly and therefore unused by many in the business. The Guide was therefore again brought to the attention of the SHEQ team. LIFTING MATTERS
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Feature Article INCORRECT
CORRECT
coaming rail
coaming rail rope rail
rope rail
Original source: National Transport Commission Australia, Load Restraint Guide 2018
It was identified the load restraint incidents involved loads quite specific to crane hire and transporting of cranes, either whole or in pieces, complete with their support components like timber pads, mats and wedges, counterweights and boom sections etc. From a recent HPI investigation it was determined Smithbridge needed to develop an internal load restraint manual to cater for the specific loads carried by the business on a regular basis. Universal Cranes SHEQ Coordinator Julian Carmichael and Smithbridge Group Manager – Safety & Systems Kevin Ball took on the task to work together to revitalise, update and condense the information from the original guide to form a new Load Restraint Manual. The manual is a short and concise 13-page document which details:
• • • 8
Lashings – placement, type and quantity to be used Load restraint requirements (i.e. force required) – downforce principals and angles Load restraint methods – specific to different load types
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• •
Specific restraint techniques, methods and lashings required for different types of plant and equipment Load restraint types – when to use or not use chains, straps and tensioners
The Load Restraint Manual also provides images depicting best practice methods against clearly identified improper practice images. These images provide a clear and easily identifiable visual guide to the do’s and don’ts of proper practice and methods. The latest version was individually branded and incorporated into the Australian, Guam and New Zealand document management systems. It was so well received it began a wider dissemination journey across the Group. The Manual has now been:
•
Adopted as a best practice policy for operations among the Group globally
•
Excerpts regularly presented as part of weekly Safety Meetings
Feature Article
• • •
An online training module is in development with the content Used as a best practice guide for Benchmark, KPIs and regular auditing to ensure compliance Load restraint types – when to use or not use chains, straps and tensioners
Crane Dismantle Instruction Guide: Auckland Cranes Another example of where a focus on HPIs has enabled the group to make significant improvements to operations is the Dismantle Instruction Guide for a large mobile crane. After an incident in which a specific crane was dismantled incorrectly resulting in minor plant damage, the error was identified a precursor to a potentially catastrophic incident that thankfully never happened. To mitigate the risks, a team comprised of the Maintenance Manager, SHEQ team, Chief Executive Officer, crane operators and other staff came together to develop an
instruction guide. This guide provided step by step instructions including excerpts from the crane user guide and written directives from the operators. This was presented alongside images showing best practice versions of the crane configured in various states of dismantle. After review and approval in Auckland Cranes, the Instruction Guide was then presented to the groupwide global safety committee. Well received, the guide was then rolled out for distribution across the group and has now become a permanent addition to the procedures of that crane.
HPIs – report, discuss, act Smithbridge Group provides an excellent example of good practice in managing, monitoring and reporting on HPI’s in a high-risk industry. Reporting, investigating and acting on learnings from HPI’s and incidents allows an organisation to change its focus from being reactive, to responding to incidents proactively by examining precursors or the conditions that may lead to events.
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Industry Innovation
Transforming High Risk Training in NZ with Simulator Technology We chatted with Stuart Hindley, owner of Major Oak Safety Training (MOST) and the recipient of the Crane Association of New Zealand’s 2019 Crane Training Company of the Year award. MOST has brought immersive simulation training, the first of its kind, to New Zealand.
The Innovation: High Risk Industry Training Simulator MOST has introduced a state of the art crane and construction equipment operator simulator for training, risk and skill analysis, and competency assessments. There are a vast range of competency tasks, situation variables and exercises all customisable to each piece of equipment. This is the first simulator in New Zealand to offer this range of training for operators and dogmen. This can be offered in a mobile format, able to go to client sites. The simulations the product offers for cranes include:
• • • • •
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flat-top and luffing tower RT mobile crawler ship pedestal crane the world’s first multi crane lift simulations
Industry Innovation The product also offers simulations for construction and mobile plant including:
• • • • •
excavator wheel loader dozer backhoe forklift
Also available is real time, in person signal/ dogman station for crane communications and hazard and risk identification. Stuart, tell us a little more about what motivated you to develop your innovative product? After spending 20 years in and around heavy plant and high risk industry, I found that training for mobile plant and crane operators has been traditionally time prohibitive and potentially disruptive to job sites. As an experienced trainer and
assessor, I saw the potential opportunities and started my own company, Major Oak Safety Training (MOST). The prospect of being able to increase the seat time for cross skilling, up skilling and introducing new skills in a safer environment for inexperienced people, while reducing the downtime and cost for industry companies was a big driver for me in creating this product. That’s fantastic! Can you give us a little more insight on what problems your innovation addresses and who might benefit from this innovation? The simulator enables upskilling and training of new and existing operators on a range of cranes and earthmoving equipment that essentially allows participants to “lift loads” without the disruption to a job site. It is also an avenue to introduce the industry to newcomers who may wonder what it’s like. This in turn will help the industry appeal to fresh talent and continue to improve its safety record. Participants benefit the most from the simulator with reduced exposure to high risk environments whilst learning basic skills, advanced skills and gaining confidence of crane operator / dogman duties. It also offers reduced costs and downtime to employers and machine owners.
Both participants and companies benefit from this form of training and I see it as a win-win for the entire industry.
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Industry Innovation Did you hit any roadblocks along the way? How did you overcome them? The simulator we bought was not initially designed to be mobile. We worked with our local engineers, Watson Engineering, to build a custom trailer and housing set up to specifically make our design portable to make it more accessible to clients.
Another challenge we are still facing is changing the mindset of the industry here in NZ, to engage and adopt new ways of training and embracing newer technologies. Simulators have come a long way and are now used widely in many industries around the world but being the first of its kind in our industry will always be a difficult task. Quite a journey! Who can access your innovation and is there a cost involved? What have your customers said so far? Any person or company can access the simulator, including other training suppliers, schools, industry associations or individuals. There is a cost involved, however, there are many different service options available from dry hire, hiring with a trainer, short courses or long-term hire. We basically want it to be utilised and accessible to the industry so as many people as possible can benefit.
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We have several large crane companies, government departments and civil companies that have all used and continue to engage with our new innovative service. Any final comments? At MOST, our aim is to enhance experience and competency levels both at the beginning of and during the career of operators. Combining this with our final assessments on real equipment in the workplace, we believe that simulation is the future for providing a risk-free confidence building training environment for candidates, increasing safety in the workplace, whilst protecting the environment and minimising operational disruptions.
Incident Review
High Potential Incident Review This issue we look into some examples of ‘near misses’ and high potential incidents (HPI’s). A High Potential Incident is an incident or near-miss that, realistically, could have under other circumstances caused one or more of the following:
• • • • •
Fatalities, Lost Time Injuries (LTI’s), injuries involving hospitalisation and injuries likely to cause permanent total work incapacity.
There is so much to be learned from HPI’s – just as much as those incidents with serious and fatal outcomes. A selection of HPI’s are described below and have been categorised into some common themes that are seen in the crane, construction, transport and mining industries.
Significant cost damage Significant environmental impact All electric shocks Incidents likely to result in major Workplace Health & Safety regulatory investigations
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Incident Review
POWERLINES
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EVENT:
TRUCK CONTACTS DE-ENERGISED POWERLINE
DATE:
2020
LOCATION:
GUAM, MICRONESIAN ISLANDS
EVENT DETAILS:
In September 2020, two operators were making a delivery of aggregate to a residential area. After unloading material, the truck dump box would not retrack. A third party was spotting for the operator and as the operator moved forward, the dump box tray of the truck came in contact with the de-energised power line. This is a HPI as the boom came within 3m of the powerlines – i.e. within the “no go zone”.
EVENT:
TOWER CRANE STRIKES POWERLINES
DATE:
2018
LOCATION:
QUEENSLAND, AUSTRALIA
EVENT DETAILS:
In November 2018, lifting equipment attached to a tower crane servicing a construction project contacted live overhead powerlines next to the site. This caused the power supply within the local area to automatically shut off. There were no injuries and it appears the crane unintentionally rotated over the powerlines under its own power. Investigations are continuing.
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Incident Review
The dump box tray of the truck came in contact with the de-energised power line.
POTENTIAL CAUSE FACTORS
• • • • • • • •
Low hanging power lines Spotter not paying attention Additional spotters where necessary Area not assessed prior to job Complacency Potential time factor/cost pressure Not knowing or understanding the regulations Crane movements not accounted for CORRECTIVE / PREVENTATIVE ACTIONS:
• Do site walk and check for ground conditions and overhead obstruction before moving equipment • Review spotter card with third party spotter • Safety talk with the crew on the dangers of working with equipment around energised and de-energised power lines • All powerline incidents have a high potential to injure or kill • Any inadvertent movement may have caused catastrophic damage/death. Crane operator needs to be fully paying attention at all times • Spotters are to remain in place until the job is completed. Source: https://www.worksafe.qld.gov.au/news-and-events/alerts/incident-alerts/2018/tower-crane-strikespowerlines. Internal LIFTING MATTERS
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Incident Review
COUNTERWEIGHTS NOT SECURED CORRECTLY
EVENT:
COUNTERWEIGHT FELL OFF MOBILE PLANT
DATE:
2016
LOCATION:
QUEENSLAND, AUSTRALIA
EVENT DETAILS:
In January 2016 a 13.4 tonne counterweight fell off the back of a mobile piling rig that was being assembled on a construction site in Brisbane. Two workers were nearby when the counterweight fell, one narrowly missed being struck and the other was injured.
EVENT:
COUNTERWEIGHT FELL OFF MOBILE PLANT
DATE:
2020
LOCATION:
QUEENSLAND, AUSTRALIA
EVENT DETAILS:
In October 2020, counterweights were being installed as part of the set up of a mobile crane in Gladstone, QLD. During the set up process, the slings became caught under the base weight. Once all four slings were unhooked, the workers proceeded to rope up when they noticed the counterweight had lifted and promptly began to rope down. It was already too late, the counterweight had lifted too high and then fell backwards off the crane.
Source: https://www.worksafe.qld.gov.au/news-and-events/alerts/workplace-health-and-safety- alerts/2016/ counterweights-on-mobileplant#:~:text=On%208%20January% 202016%20a,injured%20when %20the%20 counterweight %20fell. 16
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Incident Review
It was already too late, the counterweight had lifted too high and then fell backwards off the crane.
POTENTIAL CAUSE FACTORS
• The counterweight and/or engagement mechanism is not designed to minimise the risk of injuries during rigging and de-rigging operations. For example, when the counterweight is mounted on the rear of the plant, it can fall onto workers positioned behind the plant when the counterweight locking system is being released • The counterweight was secure while bolts were being installed. There is no effective method to temporarily secure the counterweight in place prior to the bolts being tightened • Workers were in the potential fall zone, behind the counterweight, when installing or removing the counterweight • Possible worker complacency led to the auxiliary equipment not being checked CORRECTIVE / PREVENTATIVE ACTIONS:
• Counterweights should be designed so a person is never required to be in a position where they have the potential to be struck if the counterweight becomes detached or falls during fitting or removal • The plant manufacturer should document safe work procedures for the fitting or removal of counterweights • Workers involved in the fitting or removal of counterweights on mobile plant are required to hold intermediate rigger HRWL • Workers are to be experienced in this activity or be adequately trained and supervised until they are considered competent
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Incident Review
IMPROPER LOAD RESTRAINT CAUSING LOAD TO SLIDE FORWARD INTO CAB OF VEHICLE
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EVENT:
TIMBER SLIDES THROUGH UTE REAR WINDOW
DATE:
2020
LOCATION:
QUEENSLAND, AUSTRALIA
EVENT DETAILS:
In September 2020, a worker was driving down a steep hill with a stillage of timber in the back of a ute. After stopping suddenly, timber off the stillage slipped out from under the strap and smashed through the back window of the ute cab.
EVENT:
STEEL BEAMS SLIDE OFF TRAILER THROUGH TRUCK REAR WINDOW
DATE:
2019
LOCATION:
OKLAHOMA, UNITED STATES OF AMERICA
EVENT DETAILS:
A semi-truck driver survived after a crash in April 2019 in Oklahoma. According to reports, the driver had to stop suddenly causing a load of steel beams he was carrying to shift and smash through into the cab of his vehicle. After the incident, the driver was trapped inside the vehicle and it took rescue crews many hours to remove him. He was taken to hospital for treatment of major injuries, but he was alert and talking after the crash. The incident remains under investigation.
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Incident Review
When the driver stopped suddenly, timber off the stillage slipped out from under the strap and smashed through the back window of the ute cab.
POTENTIAL CAUSE FACTORS
• Load not restrained properly • Load not stacked properly • No protective grill / mesh on back windshield of cab • Stopping too suddenly
CORRECTIVE / PREVENTATIVE ACTIONS:
• Ensure proper load restraint techniques are used and loads are stacked in a proper manner • Ensure all loads are double checked and that the correct form of lashing/ restraints are used • Install protective grills / mesh or similar to cover cab windows on vehicles • Use of defensive driving techniques to avoid having to break suddenly • Businesses must ensure that safe work practices for load restraint are in place and adhered to • Businesses to provide additional training to staff on proper load restraint practices Source: https://cdllife.com/2019/trucker-survives-after-load-of-steel-beams-slams-through-cab/. Internal LIFTING MATTERS
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Incident Review
DROPPED LOADS
EVENT:
MOBILE CRANE DROPS LOAD – STEEL PIPE
DATE:
2002
LOCATION:
QUEENSLAND
EVENT DETAILS:
In 2002 at a job site in Queensland, a mobile crane dropped its load. The crane was used to lift and suspend a 305mm diameter steel pipe vertically in the air so it could be struck with a hammer to remove wet sand that was clogging the inside of the pipe. While the pipe was being struck, the sand came free from the pipe suddenly causing the chain lifting the pipe to come loose and slip off the pipe. Both the crane operator and the worker who was striking the pipe were able to clear the area in time resulting in no injuries, however, the crane sustained minor damage. https://www.rshq.qld.gov.au/safety-notices/mines/mobile-crane-drops-load
EVENT:
TOWER CRANE DROPS LOAD OF EXCAVATOR
DATE:
2020
LOCATION:
HONG KONG
EVENT DETAILS:
In October 2020, a tower crane was lifting a large excavator into an elevator shaft of a tunnel development in Hong Kong when an incident occurred. As the tower crane slewed over the top of the shaft, it became apparent the load (the excavator) was poorly rigged and started to slip free. The excavator tilted forward during this movement, as the rigging was set too low around the load causing it to slip out of the slings, flip completely around and then drop down the shaft. There were no injuries, but both the load and the elevator shaft suffered substantial damage. https://vertikal.net/en/news/story/36364/crane-drops-load
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Incident Review
As the tower crane slewed over the top of the shaft, it became apparent the load (the excavator) was poorly rigged and started to slip free.
POTENTIAL CAUSE FACTORS
• The sand clogged inside the pipe, came out rapidly causing sudden release of about two thirds of the total load of 3t. The sudden release of energy stored in the crane rope and the lifting boom caused the empty pipe to become weightless, bounce upwards and loosen the chain around the pipe. • Instability in the load as the sand was being released. • Instability in the load as the crane slewed due to poor rigging • Centre of gravity of load either not being taken into account or changing during the lift • The hazard was neither identified nor considered before commencing either of these lifts
CORRECTIVE / PREVENTATIVE ACTIONS:
• A JSA or risk assessment should be conducted by personnel with the appropriate technical and risk management skills before commencing a job/task that is outside the scope of normal lifting operations. • A risk assessment conducted after the incident resulted in a recommendation to cease desanding pipes in this manner. • A lift study should be completed before lifting large, awkwardly shaped loads to account for changes in COG during lifting and slewing • Only qualified and competent personnel should be rigging loads
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Spotlight On
High potential incidents involving cranes and lifting equipment An example of good practice By Workplace Health and Safety Queensland
The construction division of Workplace Health and Safety Queensland puts a spotlight on safety in cranes and lifting equipment this issue. This article takes a deeper dive into the cause of incidents and discusses safe methods and practices to prevent future HPI's from occurring.
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Incidents involving cranes and lifting equipment not only expose the crane crew to a risk of injury, but also have the potential to expose other workers on site and members of the public to being struck by falling objects and overturning cranes. There have in fact been numerous incidents at Queensland workplaces this year involving cranes and lifting equipment that had the potential to cause serious injury to workers.
Spotlight On
The cause of these incidents can be broken into five broad categories:
•
failure due to incorrect slinging and rigging techniques
•
loose objects falling from loads being lifted
• • •
loads colliding with adjacent structures or plant causing items to dislodge and fall cranes not being used in accordance with the manufacturer’s instructions incorrect crane selection and siting - for example cranes selected for the task that are not suitable or do not have the capacity for the required lifts.
Shock loads placed on cranes due to lifting incidents also have the potential to cause catastrophic failure of the crane. To manage the risks arising from these types of incidents consider the following measures. Rigging and slinging techniques Right from the start, workers should be appropriately trained and verified as competent to perform the tasks, and it is vital that the crane is rigged in accordance with the manufacturer’s instructions, with rope keeper bars fitted correctly. Where practicable, utilise engineered lifting points.
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Spotlight On
These measures should be complemented by:
•
selecting the right lifting equipment, considering the potential for the lifting equipment to slip on the load, ensuring chains/slings have sufficient WLL for the load. And, when lifting with synthetic slings, use sling protection on the corners of the load unless lifting round pipe.
•
following guides provided by the designer, manufacturer or supplier and consulting with workers, with pre-start meetings discussing proposed safe methods.
•
ensuring that the doggers/riggers in control of the load are positioned safely outside of the zone where they could be struck in case of a lifting equipment failure – and implementing exclusion zones to ensure workers not directly involved in the operations are outside the lifting area and made aware of the lifting operations.
•
ensuring that all lifting equipment is inspected prior to use and is up to date at intervals as specified by the manufacturer. This is outlined in the Tower Crane Code of Practice 2017 and Mobile Crane Code of Practice 2006.
Loose objects falling from loads From the outset, ensure a safe system of work is in place to conduct, inspect and remove all loose items from loads prior to lifting (for example loose z-bar nuts on 24
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Spotlight On
formwork shutters, items above the fill line of a skip bin) and do not overfill bins or lifting boxes while avoiding items that may protrude or overhang from the bin or lifting box. Other measures include:
• •
Where possible, cover bins and lifting boxes to minimise the risk of loose objects being ejected during lifting. Do not rely on plastic wrapping or similar methods to retain objects being lifted in bulk. Loose items should always be captive inside a lifting box/cradle or should be strapped with form ply.
Loads colliding with adjacent structures or plant Before work begins, design the workplace layout to locate storage and delivery areas away from structures like perimeter scaffolding, so that loads can be lifted free of obstructions. Remember too to use tag lines to stabilise loads where required and monitor wind conditions and only lift when safe to do so. A vital preventative measure is to ensure that the dogger or rigger has clear sight of the load and can direct the crane operator as needed. Also, mobile plant equipment like concrete placing booms should be well away from the crane or the lifting
operations - and if other plant equipment that could collide with the crane or the load is operating on site, develop a safe system of work to manage the interaction. Cranes not being used in accordance with the manufacturer’s instructions A basic pre-requisite for safe work of this nature is that all operators have the appropriate high-risk work licence for the type of crane and that familiarisation training has been conducted for the specific make and model of crane. Procedures also need to be in place to follow the manufacturer’s instructions for use of the crane, particularly during setup and shutdown procedures (including erection and dismantling procedures for self-erecting tower cranes). Crane selection and siting Before work begins, ensure the right capacity crane is selected for the lifts to prevent the plant from overturning and at all times focus on the heaviest loads and maximum lift radius. Consultation should occur to verify the safest site location for the crane to be assembled, with ground conditions assessed and deemed suitable for the crane and load types. The crane operator should also request verification that the ground conditions are suitable.
The above information has been sourced from Workplace Health and Safety Queensland’s construction division. For further guidance refer to the Tower Crane Code of Practice 2017 and Mobile Crane Code of Practice 2006. LIFTING MATTERS
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Special Follow Up
Special Follow Up: Feedback on the Q1 2021 Cover Image Contributed by The Editor In the Q1 2021 issue of Lifting Matters – Crush Incidents; Preventing and Minimising the Risks, a cover photo was used from a job completed by Universal Cranes. Some concerned readers contacted us about this photo to share their feedback, so we wanted to address these concerns directly. The cover image showed a 220t Grove GMK5220 lifting a demountable containerbuilding module on a job at Roma St in Brisbane. In the image, the outrigger foot is shown without a pad underneath. This is not standard practice and may appear unsafe in isolation without some more information about the job. Therefore we would like to provide some context to alleviate concerns. The crane was situated on a suspended slab with a column directly underneath the outrigger. The primary purpose of an outrigger pad is to distribute the load over a greater area. In this circumstance, engineers determined it was more appropriate to have the outrigger foot directly on the concrete in order to concentrate the load into the column underneath. If an outrigger pad was used the load would have been distributed into the surrounding suspended slab which would be a less desirable load path for the underlying structure. 26
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Engineers, with the help of surveyors, clearly marked the ground of the site to show where the crane could safely drive and outriggers could safely be placed. Despite the practice being safe, Lifting Matters would like to apologise for any misleading impressions this may have caused. We were really thrilled with all the feedback we received. At the end of the day, we are here to start conversations about safety in our industry, so we were really encouraged that our readers directly engaged with us with their concerns.
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Operator’s Opinion
Operator’s Opinion Rod Hellwig ROD HELLWIG
CONCRETE DIVISION MANAGER – SMITHBRIDGE GUAM
Rod, pictured left, at the Smithbridge Guam concrete plant.
Rod has recently joined Smithbridge Guam as Concrete Division Manager, bringing with him 20+ years’ experience in business and process improvement roles across a range of manufacturing and service-based industries.
It’s a pleasure to speak with you, Rod. Can you give us a bit of background on yourself? I have spent the last 20 years working in manufacturing and service-based industries within Australia and overseas. Some of the industries I’ve worked in include engineering plastics, cardboard, plastic bottles, steel, concrete and particleboard manufacture. My main focus has always been people, business and process improvement and I have worked in roles from OHS, logistics and manufacturing manager to customer service, sales and general management. Having 5 years’ experience with Holcim Concrete in Australia with a business improvement focus, I came to Smithbridge Guam to lead the team and build a strong, efficient and well-regarded concrete division within the business. I look forward to the challenges ahead. 28
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What is the most common action or behaviour you witness in the field that leads to high potential incidents or near misses? Any ideas on how we can prevent incidents or near misses in the future? The most common behaviour is the lack of planning and taking what you do seriously. It is the lack of planning and understanding of the surrounding environment that can (and will) lead to high potential incidents / near misses, or even worse, actual incidents.
We need to take the time to scope, plan, test and then act. Our industry needs to get better at learning how to say “no” without feeling obligated.
Operator’s Opinion
Just remember, the near miss you walk past could become the next person hurt.
There is no one magic thing that prevents incidents. However, we can train people in planning, processes and thought patterns that will work towards preventing these types of things happening. Spending more time with our people will allow us to truly understand the messages we send about speed and efficiency. What do you feel is the most important safety issue affecting your particular role in the industry today? For some reason we still have industries that hold business and profitability over people’s development, safety and training. There is a lack of true mentorship or apprenticeship. For my entire career, one thing has remained true: People trust in those who they respect. We need to bring this core value back to the forefront. Any final thoughts to share? I stopped what I was doing today because of the importance of this topic and made sure I spent time to share my experience and concern. We, as leaders, must demonstrate safety, not just talk about it. The trend of blaming complacency for our own shortfalls needs to stop. Just remember, the near miss you walk past could become the next person hurt.
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People Profile
People Profile Ben Fitzgerald Ben has nearly 20 years’ experience in the lifting and rigging industry and shares with us how his business Queensland Rigging Hire is committed to keeping their customers safe through quality rigging products. Thanks for your time Ben. Can you give us a summary of your professional journey so far? My career in the lifting and rigging industry began back in 2002 when the company I was working for started to import round and web slings to supply to our existing customers at the Port of Brisbane. I learned a lot about the Australian Standards, importing and retailing this equipment. I started as a storeman / delivery driver and after 11 years with the company, I was Queensland State Manager with 9 staff, turning over millions of dollars annually and consistently outperforming every other state in Australia. I am forever grateful to the owners and management of this company for teaching and giving me so much. From 2012 – 2014 I started a role growing the Queensland operations for a rental company. During this time, I was heavily involved in LNG projects in Gladstone and learned a great deal about lift operations and engineered lifts. In 2014, I started in a national sales role with a lifting and rigging wholesale supply company on the Gold Coast. Here I learned a great deal about the manufacturing of lifting equipment, 30
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Ben, Owner (pictured centre) alongside business partner and wife Jess and new team member Trey (right) Queensland Rigging Hire
wire rope and also about synthetic ropes including dyneema and how it is starting to revolutionise the industry. These two roles allowed me to build a network with many of the lifting & rigging companies in Australia, big and small and I met a lot of good people whom I’m still close with now. Finally, in January 2017 Queensland Rigging Hire (QRH) was born. With my wife Jess by my side, we decided to take the giant leap and go out on our own. I have been extremely blessed to have made some strong allies in my past, a number of whom assisted us in the early days as we were making our mark in the industry. QRH helps our customer base with project work, short term and last-minute equipment rental, with reliable and consistent supply, which was previously a gap in the market. We do not sell or inspect lifting equipment, we only dry hire, which puts us in a unique position to be able to service most markets directly including lifting and rigging suppliers, crane companies, construction companies and major project contractors. My motto
People Profile
is “do what you do and do it well” and as a company, we do not deviate from this business model which gives us a competitive advantage as we are solely focussed on our strength: lifting and rigging equipment. You have had a great career so far by the sound of it! What are some things that you do in your role and company to help make the industry a safer place? The most important thing for me, is to make sure everyone goes home to their family each night safe. We work in a high-risk environment and it should never be taken for granted. As a company owner and employer, it is our duty to make sure our staff, our customers and ourselves are always working safely. We have customers that have had life changing injuries and it opens our eyes to respect the risks involved. Queensland Rigging Hire is continually striving to increase our performance in these areas through training, toolbox talks and on the job learning. We have recently invested in new software to help us keep in control of our growing fleet, which takes care of our inspection and test certification, as well as maintenance records and service history. Queensland Rigging Hire test everything and supply both equipment registers and inspection certification with every order dispatched, which has been well received by our customer base. We are regularly asked to supply equipment while our customers gear is being tested or repaired, which minimises downtime and loss in productivity. We
also put a huge effort into ensuring our equipment is supplied according to the manufacturer’s specification and relevant Australian Standards and Codes of Practice. Whenever we have come across something that we think could be unsafe or compromised we always work with the manufacturer or NATA accredited local lifting companies before bringing any rigging back into service. Constant inspection by all parties using lifting equipment is essential before and after use, as well as when safety concerns arise during use. If in doubt, tag it out. How do you help to build an effective safety culture? Continual improvement is a huge part of our business and we try extremely hard to be proactive in offering our staff and customers a safer experience. The simple things like replacing timber crates and pallets with custom modular stillages to store and transport equipment to and from site safely are particularly important to us. I believe we are judged not only by our successes but also our shortcomings and we are always on a journey of continual improvement. A highlight for me is the investment we have put into our first staff member Trey, and how much he has learned in the last 18 months with us. Having come from outside of the industry and knowing very little, Trey has forged a very good understanding of our business model and the high standard of service and safety that our customers expect with every order (big or small) and we are very proud of his achievements.
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Working Safely
The importance of reporting on High Potential Incidents in the Queensland Mining and Quarry sectors Excerpt from the Queensland Mines and Quarries Safety Performance and Health Report 2019-2020, publication by Resources Safety and Health Queensland. © State of Queensland, 2020
Lifting Matters is all about bringing safety to the forefront of the conversation and making it accessible to everyone. The crane industry can learn from a variety of other sectors with similar style operations and we are always on the lookout for safe practices to share. This article examines a recent yearly report publication on how HPI’s have been used in the Mining and Quarry industries to track, report and act on to improve future safety outcomes.
A high potential incident (HPI) is an event, or a series of events, that causes or has the potential to cause a significant adverse effect on the safety or health of a person. It remains the case that the vast majority (96 percent in 2019-20) of HPIs do not involve injury to a person.
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The inspectorate considers HPIs to be an important lead indicator for measuring the effectiveness of safety and health systems. Dr Sean Brady is a forensic engineer who specialises in the investigation of incidents, defects and failures in the mining and construction sectors, who recently advised
Working Safely
a recommendation that the regulator should adopt HPI as a measure of reporting culture within the industry – a recommendation the regulator has now actioned. The reporting of high potential incidents to the regulator is an indicator of an industry with a mature reporting culture, strong oversight and an appetite to share learning in the interests of improving safety outcomes. It is the expectation of the inspectorate that the HPI frequency will rise as more incidents are recognised, reported and acted on. Industry is encouraged to review internal reporting systems to ensure they promote fulsome, accurate and timely notification of incidents. Overall, the high potential incident frequency rate increased in the 2019-2020 financial year by 3 percent. There was notable variation across sectors with the number of incidents reported in surface mineral mines and quarries both lower than last year. The reduction in incidents reported for surface minerals is matched by a reduction in hours worked, meaning the frequency rate remains unchanged at 10 incidents per million hours worked. The reduction in reported incidents for quarries comes despite almost identical hours worked year on year meaning the frequency fell from 27 to 22 incidents per million hours worked. Reported incidents increased in surface coal (up 7 percent), underground coal (up 16 percent) and underground mineral mines (up 24 percent) in the reporting year. However, worked hours also increased leaving the frequency rate unchanged for
surface coal at 21 per million hours worked. The increase in worked hours had a marked effect for underground coal which recorded a 13 percent in the HPI frequency rate, from 30 to 34 incidents per million hours worked. The rise was 27 percent in underground mineral mines where the frequency rate increased from 11 to 14 reported incidents per million hours worked. The most frequently reported HPIs for coal mines were:
• • •
Fire on vehicle or plant Unplanned movement of vehicle or plant Collisions involving vehicle or plant
For mineral mines and quarries, the most commonly reported HPIs related to:
• • •
Unplanned movement of vehicles Fire Unplanned movement of earth or rock
This is broadly consistent with the trend over the past four years and demonstrates that the value of effective HPI reporting and investigation cannot be overstated; these hazards and the failed and absent controls feature time and again in serious accidents and fatalities and are therefore obvious focus areas for industry to review incidents and controls.
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Working Safely
In 2019-20, the number of high potential incidents reported by mineral mines and quarries decreased from 391 in 2018-19 to 374.
Focus Areas In 2019-20 mineral mines and quarries inspectors have maintained a focus on:
• • • •
Falls Collisions Entanglement Respirable dust
In all instances where unacceptable levels of risk have been identified, compliance action has been taken. In 2019-20, the number of high potential incidents reported by mineral mines and quarries decreased from 391 in 2018-19 to 374. As noted above, in response to Dr Brady’s recommendation, the regulator has adopted HPI as a measure of reporting culture within the industry. By encouraging the reporting of high potential incidents, 34
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the regulator expects that early warning signals of incidents and fatalities will be captured, disseminated widely and acted upon appropriately (including through investigation, root cause analysis and risk mitigation performed in alignment with the hierarchy of controls). This provides the best opportunity to identify hazards before they cause harm and ensure they are effectively controlled. During the 2020-21 year, inspections will examine the reporting culture of mineral mines and quarries to ensure that mines are reporting high potential incidents and thoroughly investigating events to ensure effective controls are identified and implemented to prevent recurrence. This will include targeted inspection of sites whose level of HPI reporting is outside of industry norms. Industry are reminded that failure to notify an inspector of an incident is an offence under Queensland law and the inspectorate takes a dim view of sites who fail to report or report inaccurately.
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Content deadline for next issue: 4 June 2021 Next issue available: July 2021
Disclaimer – This newsletter is not an exhaustive list of all safety matters that need to be considered. Whilst care is taken in the preparation of this material, Lifting Matters does not guarantee the accuracy and completeness of this information and how it applies to your situation. Lifting Matters will not be responsible for any loss, damage or costs incurred as a result of errors or omissions in relation to the material in our publication or for any possible actions ensuing from information contained in our publication. Any views or opinions represented in this publication are personal and belong solely to the author and do not represent those of people, institutions or organisations that the publisher may or may not be associated with in a professional or personal capacity unless explicitly stated.
