Safety Alert

What Happened

A maintenance fitter sustained a lower back strain while manually lifting a 32kg pump impeller during a scheduled pump overhaul. The fitter had bypassed the overhead crane because it was occupied with another task and attempted to lift the component manually to save time. The fitter reported immediate onset of lower back pain and was unable to continue work.

Why It Matters

Manual handling injuries are the most common injury type in mining operations, accounting for approximately 35% of all recorded injuries. Bypassing mechanical lifting aids to save time is a common behaviour that consistently results in injuries. A 32kg component exceeds the recommended manual handling limit of 25kg for a single person lift.

Immediate Actions Required

1. 1Review all scheduled maintenance tasks to ensure mechanical lifting aids are available and not competing for resources
2. 2Toolbox talk on manual handling limits and the importance of using mechanical aids for all lifts over 15kg
3. 3Assess the availability of additional portable lifting equipment for the Processing Plant maintenance team
4. 4All maintenance procedures involving heavy components to specify the required lifting equipment

Key Learning

No task is so urgent that you should risk your back to save a few minutes. Mechanical lifting aids exist to protect you. If the crane is busy, wait for it or find an alternative — never default to a manual lift for heavy components. A back injury can affect you for life.

Discussion Points for Toolbox Talk

• •Have you ever bypassed a mechanical lifting aid because it was not immediately available? What happened?
• •What is the maximum weight you should lift manually? How do you estimate the weight of a component?
• •What alternative lifting solutions are available in your work area if the primary crane or hoist is occupied?