Incident alert

An upgrade project at a block plant included installation of two vertical strapping machines.  The coils of plastic strapping that feed the machines weigh approximately 70kg, therefore, a jib crane with electric hoist and lifting attachment is required to lift the coils onto their holders.

As part of the commissioning of the jib crane, two service engineers were carrying out deflection tests, an activity which involves putting a weight on the lifting hook and travelling the trolley across the runway beam.  One engineer was at height in a mobile elevated work platform inspecting the beam, while the other engineer controlled the movement of the trolley via a pendant control at ground level.  As the engineer at ground level operated the trolley to travel slowly across the beam, the engineer inspecting the runway beam had hold of the beam, with his hand too close to the trolley and the trolley trapped the end of his index finger.  The resulting wound had to be closed with dissolving stitches.

Key Findings

• PPE - The Injured was wearing the correct PPE including gloves.
• Training - Both Service Engineers are competent and approved vendors; however, they are not assigned to MP Connect for individuals.
• Compliance - A Permit to Work was issued and specific risk assessment and method statement (RAMS) completed.
• Risk Assessment - RAMS did not identify risk of hands being ‘in the line of fire’ or highlight the need for effective communication.
• Supervision - Ensure periodic supervision checks are carried out on contractors.

HOW COULD THIS HAVE BEEN AVOIDED

• Encourage contractors to adopt a STOP & THINK mentality by carrying out pre job risk assessments before tasks commence and again if there is a change in working method.
• Ensure risk assessments and method statements consider key activities where coordination and communication needs to be clear; both engineers should have communicated with each other before operating the crane to ensure they were clear before carrying out the deflection test.
• Ensure we STEP IN / Take 5 Together if we see anyone who may be at risk of injury.

KEY REVIEW POINTS

• Do the RAMS/SSoW detail how of to carry out commissioning procedures.  In this case, the procedure of how to carry out a deflection test in detail.
• Do contractors need 2-way portable radios when carrying out tasks at different height levels.
• Ensure pre job risk assessments are carried out (e.g. Take 5) before tasks start to ensure all hazards and risks have been identified and necessary precautions are in place.