Safety Alert

What Happened

A safety berm on the Pit 2 dump crest failed while a loaded haul truck was tipping. The berm collapsed outward, and approximately 20 cubic metres of material slid down the dump face. The haul truck was positioned correctly behind the berm line and was not affected. The berm had been constructed using soft, unconsolidated material rather than the specified compacted rock fill.

Why It Matters

Safety berms are the last physical barrier between a haul truck and a fall over the dump edge. A berm failure while a truck is tipping at the crest could result in the truck going over the edge — a fatal outcome. Berms must be constructed to specification using appropriate materials. This incident demonstrates that a berm that looks adequate may not perform when loaded.

Immediate Actions Required

1. 1All dump crest berms to be inspected for material type and construction standard — non-compliant berms to be rebuilt
2. 2Berm construction specifications to be re-issued to all operators and integrated into dump management plans
3. 3Minimum berm height requirements (axle height of the largest truck in use) to be verified at all dump locations
4. 4Implement a berm inspection checklist for Shift Supervisors as part of dump area management

Key Learning

A berm is only as good as the material it is built from. A berm made of loose, unconsolidated material will not stop a 400-tonne loaded haul truck. Always check berm condition before tipping — if it looks soft, undermined, or below axle height, stop and report it. Do not tip against a compromised berm.

Discussion Points for Toolbox Talk

• •How do you assess berm condition before tipping at a dump? What signs of weakness do you look for?
• •What is the correct minimum height for a safety berm on this site?
• •What should you do if you arrive at a dump point and the berm looks inadequate?