Safety alert issued after worker killed by hydraulic hook lift system

Workplace Health and Safety Queensland is investigating an incident that led to a young apprentice being killed after being trapped under part of a hydraulic hook system on a heavy rigid truck at a mechanical workshop. Early enquiries indicate that the apprentice, and another worker, were repairing the truck’s hydraulic hook lift system (also known as a hooklift or roll on roll off system). To access the area which needed fixing, the boom of the hook lift system was raised and a safety prop used. However, hydraulic fluid had leaked, causing a fall in pressure. That led to the hook lift boom lowering unexpectedly. For reasons yet to be established, it appears the safety prop failed and the young man suffered fatal crush injuries.

Equipment that uses hydraulics to assist in its movement has the potential to cause serious injury or death. It is used across industries for trucks and transport, construction plant and equipment, farming machinery, manufacturing equipment and amusement rides. Serious crush injuries can result from normal movement of the hydraulic equipment and when the hydraulic systems fail, from falling loads or unexpected moving parts. Plant arms or equipment can cause injury through rapid or slow movement, with or without the person being aware of the danger. Hook lift devices are located on the rear of vehicles and are designed primarily for loading, unloading and tipping of containers or waste bins.

Business owners are advised to use the hierarchy of controls to help decide how to eliminate and reduce risks in the workplace. The hierarchy of controls ranks types of control methods, from the highest level of protection and reliability to the lowest. Business owners must work through the hierarchy of controls when managing risks with the aim of eliminating the hazard, which is the most effective control.

Before accessing any parts of the plant (including hydraulic hook lift systems) for cleaning, maintenance or repairs, all hazards must be identified and adequately controlled. Inspection should be conducted in accordance with a regular maintenance system to identify potential problems not anticipated during plant design or task analysis. Inspections should also identify any deficiencies in plant or the equipment associated with the use of the plant (such as wear and tear, corrosion and damaged plant parts). Adverse effects of changes in processes or materials associated with plant, along with inadequacies in previously implemented control measures, should also be identified.

The WHS Regulation 2011 includes specific duties for persons conducting a business or undertaking (PCBUs) involving the management or control of plant, including requirements to manage the health and safety risks associated with plant. The person with management or control of plant at a workplace must ensure maintenance, inspection and, if necessary, testing of plant is carried out by a competent person. A safe system of work should be implemented to manage the risks associated with the inspection and maintenance of the plant (including hydraulic hook lift systems). The plant must be maintained and repaired according to the manufacturer’s specifications.

A safe system of work can include, but is not limited to, ensuring the plant, or part of the plant, that could move is adequately secured to prevent unexpected movement. This can include installing mechanical locks to support parts suspended by hydraulic systems, using props, blocks or chocks in accordance with the manufacturer’s safety instructions, or using purpose designed and engineered support stands, jigs or cradles.

PCBUs are also advised to consult with the manufacturer, workers and others involved in the work to obtain feedback on the plant’s associated work processes and safe work procedures. When operating machinery that uses hydraulics, PCBUs should never place themselves or others in a position where they could be crushed if hydraulics fail, or are inadvertently used. When working on equipment, PCBUs should assess how it could shift if it were to move unexpectedly and find alternative ways to access the equipment to maintain it, keeping workers out of the danger zone.

PCBUs should always read the instructions provided by the manufacturer and follow all safety directions; if a back-up safety system is provided on the plant, PCBUs should ensure it has been correctly installed and is always in use before entering a high-risk zone. If a safe system is not provided on the machine, PCBUs should use an alternative system specified by the manufacturer — the alternative system should be load-rated, with adequate strength to withstand safely any loads that could be applied to it. Workers working on, near or under hydraulics must be adequately trained and supervised, with a safe work procedure outlining the potential risks of working on or near hydraulic equipment and the likely consequences of hydraulic failure.

PCBUs must ensure that there is sufficient space for safe access to the plant for maintenance and repairs activities, and that broken or worn equipment is never operated. An isolation procedure should also be developed and followed by workers when they are required to perform maintenance, repair and cleaning of plant. Isolation procedures involve isolating potentially hazardous energy, so the plant does not move or start up accidentally. Isolating plant may also ensure that entry to a restricted area is controlled while the specific task is being carried out.

Workers who use the plant must receive information, training, instruction and supervision; this includes developing safe work procedures, in accordance with the manufacturer’s instructions, that are suitable and adequate to the nature of the work to be carried out, the nature of the risks associated with the work and the control measures implemented to deal with these risks. Any remaining risk must be minimised with suitable personal protective equipment (PPE). For example, by providing workers with steel cap boots, hearing protection and protective eyewear. The control measures put in place should be reviewed regularly to make sure they work as planned.

Business owners must ensure that the work environment, and the way young employees do their job, is safe and healthy, regardless of the type and terms of their employment. Employers of young workers should understand young workers’ risk profile; ensure a safe and healthy workplace; provide information, training, instruction and supervision; and develop a positive workplace culture. Business owners should consider the tasks they assign to new and young workers given their skills, abilities and experience. Before a young person begins work, a PCBU should identify the gaps in the worker’s knowledge and assess their ability to work safely (competency should be tested). It is not sufficient to accept a young worker’s assurance that he or she is experienced and competent. Young workers must actively participate in the way that work health and safety is managed, which means taking induction and training seriously, using the risk management process for work tasks and asking for help before starting a task they’re not familiar with or comfortable carrying out.

Image credit: ©stock.adobe.com/au/Noel