A coal mine worker was injured in a serious surface incident involving a forklift tipping bin at a Central Queensland site, prompting recommendations for mine operators to review exclusion zones, equipment management and working-alone arrangements.
According to Resources Safety & Health Queensland (RSHQ), the incident occurred while the worker was preparing to empty a tippler bin containing scrap metal into a larger skip bin using a forklift.
With the tippler bin positioned on the ground in front of the forklift, the worker exited the cab and “put themselves in the line of fire” by entering the bin’s exclusion zone to check whether there was sufficient capacity in the larger skip bin. Shortly afterwards, the tippler bin’s pivot mechanism released, causing the bin and scrap-metal debris to topple, striking the worker’s leg and injuring them.
The worker was working alone at the time and was later located by colleagues.
RSHQ’s investigation identified a number of contributing factors, including the lack of established exclusion or ‘No Go’ zones around the tippler bins, and drop zones or line-of-fire risks were not identified in training materials. Risk assessment and risk management processes of the bins were also found to be ineffective.
Additionally, equipment controls were identified as an issue, with no non-destructive testing conducted on the tippler bins, no maintenance schedule in place, and damaged and largely illegible warning placards on the plant.
The investigation also found the tippler bins had been reintroduced into service following a previous incident in 2009 without following the site’s introduction-to-service process or completing due diligence to confirm the equipment was fit for purpose.
In response to the incident, RSHQ’s recommendations include reviewing exclusion zones, drop zones and line-of-fire controls, as well as assessments of similar equipment across sites. The recommendations also cover site introduction processes, risk management systems, operating procedures, training, maintenance practices, mobile plant suitability and protocols for working alone. Senior Site Executives are also advised to review the effectiveness of their investigation system for the close out of actions and the monitor/review process following incidents.
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