An unsafe situation exposed a maintenance worker—one of two workers assigned to the task—to a line-of-fire hazard while they were carrying out alternator repairs on mobile plant in a workshop.
The maintenance workers attended a pre-start meeting and completed a task-based risk assessment, identifying dangers that included manual handling, suspended loads and line-of-fire hazards. A forklift operator used their machine’s tines to lift the front of the mobile plant. One of the maintenance workers positioned themselves partially beneath the suspended mobile plant while they attempted to install an axle stand. Another worker observed the unsafe situation, instructed the maintenance worker to move from beneath the suspended mobile plant and notified a supervisor, who intervened immediately.
The supervisor assessed the situation and identified that the mobile plant didn’t have adequate support. The team corrected the lifting arrangement by installing appropriately rated axle stands from a safe position and maintaining distance from the line of fire. They safely lowered the mobile plant onto the axle stands and removed the forklift.
Takeaways
- Avoid working beneath suspended loads. Workers must not position themselves beneath loads that approved equipment doesn’t fully support.
- Use lifting equipment for its designed and approved purpose only.
- Secure vehicles with appropriately rated and correctly sized supports before undertaking work beneath them.
- Exercise dynamic risk management. Workers must continually assess risks, not just appraise them at pre-start meetings.
- Empower workers to stop and supervisors to intervene when they observe unsafe situations.
Summary
This incident reinforces the importance of strict line-of-fire controls during maintenance activities involving heavy equipment. Even when workers identify hazards in planning phases, unsafe situations can arise if they don’t implement controls properly. Continuous supervision, correct equipment selection and a strong safety intervention culture are essential to prevent serious harm.
