All Incidents

Light vehicle entered active exclusion zone while CAT 793 was dumping. No contact, no injuries. LV driver did not see signage due to dusty conditions. Spotter was not in designated position.

Worker fell approximately 2 metres from scaffolding. Harness was worn but not clipped to anchor point. Landed on platform below, complained of back pain. Scaffolding had green tag from previous day inspection.

Two operators reported skin irritation after contact with reagent solution. Standard PPE was worn but not chemical-rated gloves. SDS recommends nitrile gloves for this product.

Wrench dropped from Level 2 maintenance platform. Landed in walkway below. No personnel in drop zone at the time. Tool tether was not being used.

Isolation point for Conveyor C4 found with lock removed during night shift maintenance. Conveyor was energised while maintenance crew believed it was isolated. No injuries — discovered during routine verification.

Grader operator reversed without completing 360-degree check. Narrowly avoided contact with parked light vehicle behind. Reversing alarm was functional.

Minor seepage detected at tailings embankment monitoring point TSF-7. Volume estimated at 2L/hr. Within operational tolerances but trending upward from previous readings.

Water cart reversed without checking blind spot. Rear proximity alarm was not functioning. Spotter attempted to radio but driver had radio on wrong channel.

Switchboard panel cover found unsecured on Unit 3. Arc flash hazard present. Previous maintenance work order had not been closed out properly.

Unsecured load on flat-bed truck shifted during transport on haul road. Material fell onto road surface. Haul truck behind swerved to avoid debris. No contact.

Fitter strained lower back while lifting pump component. Weight was within manual handling limit but awkward lifting posture used. First aid administered on site.

Conveyor belt tracking issue resulted in belt edge damage over approximately 15 metres. Belt alignment sensor had been flagged as unreliable during previous shift but not repaired.

Night shift operator reported feeling extremely fatigued and dizzy. Had worked 6 consecutive night shifts. Supervisor observed slow reaction times during routine checks.

Minor diesel spill (~50L) during fuel transfer. Secondary containment captured majority. Small amount reached unsealed ground adjacent to bund wall.

Haul truck and water cart approached single-lane section simultaneously from opposite directions. Both stopped safely. Give-way signage was obscured by dust.

Unidentified vehicle entered camp area through unmanned gate during shift changeover. Vehicle belonged to a contractor who had not completed site induction. No safety risk identified.

Worker's foot slipped on wet grating at Level 3. Fell through gap in handrail where section had been removed for maintenance. Fell 1.5 metres. Broken wrist confirmed.

Crane load (steel beam ~2T) swung unexpectedly during lift due to wind gust. Load came within 2 metres of ground crew. Lift plan had not accounted for afternoon wind changes.

Crusher jaw liner showed premature wear and partial failure. Fragments entered product stream. No personnel exposure. Unplanned shutdown required for replacement.

Road train driver failed to stop at weighbridge. Drove through boom gate at low speed. Boom gate damaged. Driver reported not seeing stop signal due to sun glare.

Security alarm system for explosives magazine found non-operational during routine check. Last verified operational 72 hours prior. Backup system also offline due to power supply failure.

Process operator experienced heat exhaustion symptoms during plant walkdown. Core temperature measured at 38.8°C. Ambient temperature was 44°C. Operator had consumed less than 1L water in 4 hours.

Section of pit wall showed signs of instability. Cracks observed along bench face approximately 20 metres above haul road. Geotechnical team confirmed risk of rockfall. Area was active with haulage at the time of discovery.

Excavator operator commenced swing while haul truck was still positioning for loading. Bucket passed over truck cab. Operator stated radio communication was unclear.

Chlorine dosing pump malfunction led to over-dosing of treated water. Elevated chlorine levels detected at discharge point. Level exceeded licence limit for 2 hours before correction.

Hydraulic hose on forklift burst during operation. High-pressure fluid sprayed across work area. No personnel struck. Hose was past replacement date per maintenance schedule.

Entry permit for Ball Mill inspection had expired but crew was still working inside. Gas monitoring equipment battery was flat. Confined space attendant had left post temporarily.

Office worker experienced minor paper cut while handling printed reports. First aid kit used to apply bandage. No further treatment required.

Haul truck operator reported near-collision with kangaroo on haul road. Emergency braking applied. Load shifted slightly. Night visibility adequate but wildlife management controls not in place for this section.

Container being unloaded from flat-bed was set down off-centre on timber dunnage. Container toppled onto side. No personnel in vicinity. Lifting plan not followed.

Dozer operator encroached on excavator swing radius during ROM pad cleanup. Excavator operator sounded horn. Dozer operator acknowledged and retreated. Communication breakdown identified.

Hot bearing detected on conveyor drive pulley via thermal monitoring. Temperature 180°C and rising. Conveyor was carrying coal product. Fire risk assessed as high.

Worker accessed roof area without fall protection. Was observed by supervisor walking on fragile roof sheeting without safety mesh below. Worker stated he was unaware of the requirement.

Light vehicle overtook haul truck on single-lane section of haul road. Oncoming water cart forced LV to brake heavily and pull off road. Speed and overtaking rules clearly breached.

Chute liner plate detached and fell into crusher cavity during night shift. No personnel in area at the time. Vibration monitoring had shown elevated readings for 3 days prior.

Mechanic sustained minor laceration to forearm when hand slipped off wrench during bolt removal. Cut approximately 3cm, treated on site with wound closure strips.

Haul truck reversed beyond designated dump point on stockpile. Rear wheels came within 3 metres of crest edge. Berm was inadequate height (0.5m instead of required 1.5m).

Strong chemical odour detected in pump room. Source identified as minor leak from reagent supply line flange. Volume minimal. Area ventilation was operational.

Small rockfall (~0.5m³) from bench face landed on haul road berm. Haul truck was approximately 50m away at the time. No contact. Recent blasting may have contributed.

Gas monitor alarmed for H2S during tank inspection. Reading peaked at 15ppm (action level 10ppm). Crew evacuated immediately. Ventilation fan had been positioned incorrectly.

Drill rig being transported on low-loader failed to display wide load signage. Haul truck approaching from opposite direction had to take evasive action on narrow section.

Welder sustained minor burn to wrist when welding spark entered gap in PPE. Burn approximately 1cm diameter. First aid applied with burn gel and dressing.

Loose bolts found on grating panel at Level 3. Panel was unsecured and could have dislodged if stepped on. Area beneath is active walkway. Previous maintenance had not re-secured panel.

Return water pipeline showed minor weep at joint. Estimated loss less than 5L over observation period. Pipeline is above ground on the tailings facility access road.

CAT 793 haul truck experienced brake fade on descent from Pit 4. Operator used engine retarder and runaway ramp. Truck safely stopped. Brakes had been flagged for inspection during pre-start but truck was dispatched anyway.

Small fire on conveyor belt roller bearing. Detected by thermal camera. Auto-deluge system activated and extinguished fire within 30 seconds. Belt sustained minor surface damage.

Excavator commenced loading before haul truck was fully positioned and truck operator had given ready signal. One bucket load dumped onto truck body off-centre, causing load imbalance.

Operator experienced eye irritation from airborne dust during grinding circuit inspection. Safety glasses were worn but not sealed type. Flushed with eyewash station.

Large brown snake observed on walkway between accommodation blocks. Area cordoned off. Snake handler contacted. Snake safely relocated to bushland perimeter.

Tyre inflation cage door latch found to be defective during pre-use check. If tyre had been inflated, door could have opened under pressure. Cage taken out of service.

Haul truck operator fell asleep momentarily at wheel during ascent from pit. Truck drifted toward windrow. Operator woke and corrected. End of 12-hour night shift. Fatigue monitoring system was installed but not calibrated for this operator.

Isolation lock found to have incorrect tag — lock belonged to different work crew than those currently working on the equipment. Cross-referencing with permit showed mismatch.

Forklift operator misjudged clearance and struck storage rack while placing pallet. Rack sustained minor structural damage. No falling objects. Load was secured.

Rock fragment (~5kg) ejected from primary crusher during processing of oversized material. Fragment struck safety screen but screen had visible corrosion damage. Fragment would have entered walkway if screen had failed.

Pedestrian crossed vehicle access road without using designated crossing. Light vehicle braked to avoid. Pedestrian was a visitor who had completed induction but was unfamiliar with traffic management layout.

EWP (elevated work platform) operator raised basket beyond maximum rated height. Stability alarm sounded. Operator lowered immediately. Operator stated the height limiter appeared to be malfunctioning.

Lightning strike recorded within 5km of fuel farm during overnight storm. Automated shutdown protocol activated correctly. Manual verification found one earthing strap on storage tank not connected.

Grader blade left extended across haul road during operator break. Haul truck operator noticed at last moment and stopped. Grader was parked in active traffic area without cones or signage.

pH sensor on discharge line giving erratic readings. Manual testing confirmed normal pH levels. Sensor malfunction could have masked an actual exceedance if not caught.

Scaffold plank fell from Level 2 to ground level during scaffold disassembly. Area below was barricaded but barricade had been moved by unknown person. No one in impact zone.

Backup generator auto-started during planned maintenance on main power distribution board. Isolation procedure did not include backup generator interlock. Maintenance crew narrowly avoided energised bus bar.

Subsidence noticed on stockpile pad surface. Dozer operator felt ground shift. Area evacuated and assessed. Underground drainage pipe had partially collapsed creating void beneath surface.