The NSW Resources Regulator has released details of its investigation into an incident that left a contractor with serious leg injuries after a fall from a stationary excavator in the state’s Hunter Valley.
The worker fell about four metres while pressure cleaning near the right-hand boom cylinder on a platform at the front of the machine on September 22, 2025. While cleaning the boom cylinder mount, the worker leaned against the platform’s gate stanchion, which failed at its base, causing the fall.
The contractor sustained multiple fractures to the legs, along with other injuries.
The investigation found that the failed guardrail and gate assembly was positioned next to the boom cylinder and supported an aftermarket access platform. Modifications to the original equipment manufacturer’s design had removed one of two stanchion posts, reducing structural support.
Additionally, the guardrail design did not meet AS 5327 earthmoving machinery access system requirements. Investigators also identified a weld flaw or crack at the base plate connection, which allowed the stanchion post to fail when load was applied.
According to the regulator, despite regular inspection regimes, including shift, fortnightly and three-monthly checks, the defect was not detected.
The regulator also noted that the access point was located in an area exposed to ongoing rock impacts. At the time of the incident, the ladder was damaged and missing at least two lower rungs, but had not been taken out of service.
Following the incident, the NSW safety watchdog is urging mine operators, excavator suppliers, and people modifying plant to pay closer attention to inspection and defect management of access systems, adopt stronger change management processes when modifying plant, engineer verification of modifications, and use risk assessment tools such as Take 5 and job hazard analysis to manage working at height risks.
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