Spike in falling object incidents at mines puts hundreds of workers in danger

The mining safety watchdog has issued urgent warnings after a spike in falling objects including a recent report in the state’s north which “could have been fatal”.

Resources Safety and Health Queensland has issued a new safety alert warning of a spike in ‘drop zone’ incidents, where plant, tools or equipment have fallen from height and put workers in danger. In this incident a 12m drill steel dislodged from carousel and fell to ground. The steel came to rest with one end on the deck's handrail and the other on the drill pattern (ground). Photo: Contributed

A Queensland worker safety regulator has issued urgent warnings after more than 300 workers were potentially put at risk due to falling objects at mine and quarry sites in the past two years.

Resources Safety and Health Queensland issued a new safety alert warning of a spike in “drop zone” incidents, where plant tools or equipment have fallen from height and put workers in danger.

According to RSHQ, there have been more than 300 of these incidents reported across coal, mineral mining and quarries and petroleum and gas sites since July 2023, including more than 140 in this year alone.

In this incident a dragline fan motor weighing roughly 300kg – 500kg has fallen around 6-8m from warehouse pallet racking and contacted a forklift and landed near another worker. Photo: Contributed

It was noted coal and mineral mines and quarries saw an increase in incidents involving falling objects in recent years, while petroleum and gas have seen a slight downward trend.

Many of the incidents involved poorly defined or ignored exclusion zones, untethered tools, worker complacency, lifting equipment that was overloaded, and maintenance issues with ageing or modified machinery.

In this incident during a lifting activity, the telehandler has contacted an overhead pipe. A connection of the pipework has failed, and the pipe has fallen 4.5m. Photo: Contributed

The alert urges sites to strengthen safety controls by implementing better risk assessments, clearly marked exclusion areas, regular equipment checks, preventive cleaning, installing deflection devices and tethering tools whenever people are working at height.

It also warned that workers and sites should understand proper risk identification, safety planning and worker behaviour with supervisors expected to maintain active oversight of their teams.

In this incident during the replacement of a butterfly valve, it has fallen 10m to the ground. A limited drop zone had been established but adjacent pedestrian areas were not included. Photo: Contributed

The warning comes on the back of another safety alert as RSHQ investigates a near-miss at a Bowen Basin coal mine where it says a worker was trapped between a reversing truck and a parked crane.

RSHQ Chief Inspector of Coal Mines, Jacques le Roux, said no one was seriously injured but the incident could have been fatal.

“This incident could have caused serious injury or death to the worker involved. In 2024 a coal mine worker was fatally injured after becoming trapped between two vehicles,” he said.

The image (a careful re-enactment) demonstrates the point where the tilt tray stopped after reversing and where the CMW was positioned.

“All work parties should be in constant communication when vehicles are going to be moved,” he said.

“Workers should avoid being in the line of fire.”

RSHQ said if operators could not see all areas when moving a vehicle, they should always ensure a spotter was used at a safe distance.

“Before entering any tight area between an object and a machine that has the potential to move, workers should always check that the machine is isolated and chocked,” he said.