Safety alert issued after worker struck by stun gun

In February 2022, a worker sustained serious injuries after being struck in the abdomen by a loaded captive bolt stun gun (also known as a cattle gun, bolt gun, stun gun or stunner). Investigations revealed that the worker was part of a maintenance team and was cleaning the loaded captive bolt gun when it fired. A captive bolt gun (bolt gun) is used on animals to be slaughtered, to render the animal unconscious (without causing pain) ahead of slaughter. A bolt gun has a steel bolt that is powered by either compressed air or a blank cartridge. When it is fired, the bolt rapidly extends but is retained and then retracts. At close range, a bolt gun has the same effect on the animal as a firearm with a live bullet, but may be considered safer because the extending bolt is retained when fired.

However, all bolt guns are potentially lethal. Injuries from bolt guns can be caused by the user inadvertently activating the gun into a part of the body. Safety and operating procedures recommended by the manufacturer must be followed and all users must be properly trained in safe operation and maintenance. Taking steps to manage risks is a condition of doing business in Queensland. If an incident occurs, business owners must show the regulator that they have used an effective risk management process. This responsibility is covered by the primary duty of care in the Work Health and Safety Act 2011. Using the hierarchy of controls can help business owners 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; it’s a step-by-step approach to eliminating or reducing risks. 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.

All safety procedures recommended by the manufacturer must be followed, with all workers who operate and/or maintain mechanical stunning equipment (such as bolt guns) to receive proper training. Equipment must also be regularly checked. The Humane Slaughter Association advises workers to ensure that the muzzle is pointed away from any part of the operator’s, or any other person’s, body at all times when handling bolt gun equipment. Business owners are advised to refer to the manufacturer’s instruction sheet for the correct loading procedure and correct cartridge, and to avoid repeated use of too heavy a cartridge, or air shots, which can result in the bolt shearing and flying free of the bolt gun.

The Humane Slaughter Association also advises operators to always handle bolt guns as if they are loaded; once the bolt gun has been loaded, they should also ensure that the mechanism is in the ‘safe’ position until an animal is ready to be stunned. Operators should never leave a bolt gun unattended. In the event of a misfire, operators should not open the bolt gun breech for 30 seconds, as slow primer ignition can cause a ‘hang fire’, causing the cartridge to explode after a short pause. At the end of the day, bolt guns should be returned to the person appointed to carry out the daily cleaning procedure — this person must ensure that the bolt gun is unloaded before cleaning.

Operators should immediately report any faults in the function of the bolt gun to the maintenance person; the equipment should not be used until the problem has been rectified. When not in use, bolt guns must always be stored securely. Before carrying out maintenance on any plant, including bolt guns, operators must ensure maintenance activities comply with requirements under relevant work health and safety legislation. Effective control measures for maintenance activities are often comprised of a combination of controls; some common risk control measures can include developing a safe system of work for maintenance, repair or cleaning activities. This could include ensuring that the plant is inspected, maintained and repaired according to the manufacturer’s recommendations and specifications. Bolt guns must be dismantled, cleaned and lubricated after use, even if they are fired only a few times a day, or even less frequently. Back-up equipment must also be regularly serviced, even if it has not been used.

Workers who use bolt guns must receive information, training, instruction and supervision — this includes developing safe work procedures in accordance with the manufacturer’s instructions. An isolation procedure must also be developed, to be followed by workers when they are required to perform maintenance, repair and cleaning of plant. Isolation procedures involve isolating potentially hazardous energy so the plant does not move accidentally. It is also good practice for business owners to keep records of plant in the workplace. Records on items of plant that may be kept include information on alterations, information on maintenance and major repairs, manufacturer’s specifications and user manuals, results of tests on the plant (including safety devices), and determining what special skills are required for people who operate the plant or carry out inspection and maintenance, including preventive maintenance.

Adopting and implementing higher order controls, before considering administrative or PPE controls, can reduce the likelihood of similar incidents occurring. The control measures put in place should be reviewed regularly to make sure they work as planned.

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