Austcast Pty Ltd

Incident description:

A worker's arm was broken when the cast metal brake disc he was rotating came away from an open lifting hook. The lifting hook was used to lift and turn over the casting during a grinding process. The worker was removing excess material off rough castings when he started to rotate the disc in order to dress the other side. While holding the crane control pendant in one hand and guiding the disc with the other, the disc came away from the hook crushing his arm as he attempted to stop it from falling.

WHSQ investigation findings:

The injured worker had no experience as a casting dresser/fettler or in using lifting equipment. There was no documented system of work or procedure for using the lifting hook to lift brake discs, or any risk assessments conducted prior to the incident. An assessment of the hook identified that the hook opening was insufficient to properly engage the casting and there was no device to secure the cast to the hook during the lift or rotation process.

Court result:

The defendant was found guilty and fined $35,000. No conviction was recorded.

Considerations for prevention:

Obligation holders should ensure that castings being lifted and moved within the workplace are securely attached to the cranes lifting hooks during a lift. Obligation holders should consider affixing temporary lifting lugs or rings to the castings during fabrication. The cranes lifting hooks can then be securely attached to the lugs or rings while turning the casting and can subsequently be grinded off during the dressing phase.

Visit the Workplace Health and Safety Queensland website for more information on:

• managing freely suspended loads
• managing the risk from plant designed to move objects
• crane and hoist licensing requirements
• falling objects, and
• conducting risk assessments or developing safe operating procedures.