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Report - METEX - surface and UG - falling objects exposing people to harm - January 2024 to June 2025

This report provides the findings of an assessment program at surface and underground metals and extractives mines focussing on the principal mechanical engineering control plan and falling objects exposing people to harm

Sector

Metals and extractives (METEX)

Surface and underground 
Principal control plan Mechanical engineering control plan
Topic Falling objects exposing people to harm

Operation type assessed

Operation type

Number of mines assessed

Surface - dredging

1

Surface – open cut

26

Surface - processing

2

Underground

12

Total

41

Compliance notice types issued during the program

Notice type

Notices Surface

Notices Underground

Percentage of all notices issued
WHS(MPS)A s23 notice of concerns

23

11

30%
WHSA s191 improvement notice

43

36

69%
WHSA s195 prohibition notice

2

0

1%
Total

68

47

100%

Note: This data represents all notices issued during the program and may include notices other than mechanical engineering control plan topics.

Criteria assessed

Criteria assessed Operation type

Loose item containment
  1. Toe boards and under conveyor guarding are effective in preventing falling objects.
  2. Under conveyor guarding is regularly inspected.
  3. Areas are free from loose items that may pose a falling object risk such as spare or replaced components, packaging material, tools, waste, and spillage.
  4. Confirm with workers their understanding and responsibilities when implementing falling object controls, and their alignment with documented requirements.
  5. Any equipment required to implement falling object controls is available.

Exclusion zones
  1. Entry to an exclusion zone is restricted to those essential to the task being performed.
  2. Processes are in place to ensure those essential to the task entering an exclusion zone:
    • Are aware of the hazards and controls in place for the falling or swinging object risk.
    • Have the permission of the person supervising the task.
  3. Exclusion zones are established and maintained according to documented procedures.
  4. Barriers/demarcation equipment is available for use when establishing an exclusion zone.
  5. People who conduct work that poses a falling or swinging object risk can describe the falling or swinging object exclusion zone barrier/demarcation requirements
  6. People who may be required to work near a falling or swinging object exclusion zone can explain the meaning and purpose of the exclusion zone barrier.
  7. Does the mine operator provide workers with an understanding of the dangers of falling objects, how to identify the risk of falling objects and how to control the risk of falling objects.

Operator protective structures
  1. Operator protective structures are fitted to plant specified by the safety management system.
  2. Confirm Pre-start inspection form for a line item checking for condition of OPG’s (Operator Protective Guards) and that fitted operator protective structures are suitable for protecting operators from falling objects.
  3. Operator protective structures are free from defects that may compromise occupant protection 

 

Findings with issues identified - surface operation

Criteria assessed

Mine type

Findings of concern

Findings of contravention

Total findings of issues
Loose item containment

Surface

30

33

63
Exclusion zones 

Surface

23

27

50
Operator protective structures

Surface

4

0

4
Total findings with issues

Surface

57

60

117

Findings with issues identified – underground operation

Criteria assessed

Mine type

Findings of concern

Findings of contravention

Total findings of issues
Loose item containment

Underground

5

12

17
Exclusion zones 

Underground

5

0

5
Operator protective structures

Underground

0

3

3
Total findings with issues

Underground

10

15

25

Recommendations

Operators of metalliferous surface and underground mines should review their site principal control plan – mechanical engineering control plan (MECP) and the criteria assessed for the topic falling objects exposing people to harm with specific focus on:

  • Review site documented risk controls to prevent falling objects exposing people to harm for:
    • elevated structures including walkways, stairways, ladders and overhead conveyors
    • crushing and screening plant
    • mobile elevated work platforms
    • shafts and high walls
  • Ensure periodic inspection and maintenance is performed on:
    • vehicle hoists
    • cranes and other mobile lifting equipment
  • Review mine worker and contractor training, information, instruction, supervision and compliance with site procedures to prevent risks of falling objects exposing people to harm
  • Review implementation and worker compliance with ‘exclusion zones’ in particular ‘exclusion zones’ associated with operating cranes and mobile load lifting equipment on site.
  • Review site documented risk controls to prevent falling objects exposing people to harm with respect to guidance provided in Australian Standards, including but not limited to:
    • AS 1657:2018 - Fixed platforms, walkways, stairways and ladders - Design, construction and installation.
    • AS/NZS:4024 - Safety of Machinery 3600 series Conveyor Standards for all persons that design/modify, manufacture, supply, install, commission, operate, maintain or dismantle conveyor systems. Refer to: AS/NZS:4024.3610, AS/NZS:4024.3611, AS/NZS:4024.3612, AS/NZS:4024.3614
  • Review site documented risk controls to prevent falling objects exposing people to harm associated with storage racking and pallets on site.  Refer to guidance provided in Australian Standards, including but not limited to:
    • AS4068:1993 - Flat pallets for materials handling
    • AS4084.1:2023 - Steel storage racking – Design
    • AS 4084.2:2023 - Steel storage racking – Operation and maintenance
    • AS4762:2000 - General purpose flat pallets, principal dimensions and tolerances

References

NSW code of practice

May 2025 NSW code of practice – mechanical engineering control plan – Work Health and Safety (Mine and Petroleum sites) legislation

Program Fact Sheet

Control plan – mechanical engineering control plan – object falling

Related Safety Alerts

December 2023 – Haul truck engine module narrowly misses workers 

October 2022 – Dangers of lifting and pulling activities revealed

Related safety bulletins

July 2024 – Wheel assemblies detaching from mobile plant

July 2024 – Large number of hand and finger injuries reported

October 2023 – Haul truck front strut removal poses risks to workers

Industry information

SafeWork NSW – Pallet racking fact sheet