A worker narrowly avoided injury after a roll of geotextile material fell approximately 1.6 metres from a trailer during unloading activities.
Workers were unloading seven rolls of geotextile material from a delivery trailer using an IT loader fitted with tynes. After identifying difficulties accessing the load safely, they adopted an alternative retrieval method that required work inside an area designated as a no-go zone under the Safe Work Method Statement. While a spotter released a centre tie-down strap from the opposite side of the trailer, stored tension in the load restraint system released unexpectedly and caused a geotextile roll to fall to the ground.
The incident shows how tasks can rapidly expose workers to falling-load and line-of-fire hazards when conditions differ from the planned work method and work teams do not reassess hazards and controls before continuing. Workers can increase their exposure to uncontrolled load movement when they change task sequences, enter exclusion zones or continue work without escalating unexpected conditions for review.
Takeaways
- Plan unloading activities carefully: Assess the sequence for releasing restraints to maintain load stability throughout unloading.
- Follow approved work methods: Conduct unloading activities in accordance with the Safe Work Method Statement and approved procedures.
- Stop and reassess work: Review hazards, controls and approval requirements when conditions differ from the planned task.
- Recognise stored-energy hazards: Treat tensioned straps, chains and load restraint systems as potential sources of unexpected energy release.
- Maintain exclusion zones: Position workers outside potential fall zones and areas where loads may move unexpectedly.
- Escalate concerns early: Engage supervision when workers cannot access or unload a load safely using the planned method.
- Exercise stop-work authority: Pause the task when workers encounter conditions that differ from the risk assessment or prevent them from maintaining controls.
