Investigations launched after NSW mine worker suffers serious leg injury in lifting operation

The NSW Resources Regulator has launched an investigation after a mine worker suffered a serious leg injury during a lifting operation last month. This safety incident highlights ongoing concerns around crane operations and load-handling procedures at coal mining sites across the state.

The Regulator said the worker was struck on the leg by a lifting plate attached to an overhead crane. It happened at a coal mine in northern New South Wales.

“The worker had finished repairing a haul truck and was using the crane to remove the lifting plate from the axle box when it became wedged,” the Resources Regulator said in an information release.

“The crane continued to apply load, and when the plate freed, it struck the worker on the leg.”

What Caused This Leg Injury During Crane Operations?

According to the Regulator, the incident stemmed from a wedged lifting plate that remained under tension while the crane kept applying load. Once freed, the plate struck the worker with considerable force, resulting in a fractured leg.

This type of crush injury demonstrates why load-bearing equipment demands strict operational controls, particularly when components become jammed or unexpectedly release stored energy.

Why Mine Safety Investigations Matter

Investigations of this nature help identify systemic gaps in equipment handling procedures across mining operations. Findings often inform updated guidance for site operators, supervisors and frontline personnel handling similar tasks.

For mining businesses, prioritising safety isn't optional — it's a legislative and moral obligation. Robust risk assessments, documented procedures and regular equipment checks remain essential safeguards against preventable injuries.

This incident follows a separate case detailed in our report on investigations launched following another incident at an NSW mine, underscoring a pattern of lifting and crane-related hazards within the sector.

Related Safety Incidents Worth Reviewing

• Our coverage of a mine worker who suffered serious injuries after being struck by a crossbar shares similar risk factors around suspended loads.
• Another case examines how a worker suffered serious leg injuries after becoming trapped in machinery at Kilburn, reinforcing the need for stringent machine-guarding practices.

Strengthening Safety Through Documented Procedures

Employers can reduce lifting-related risks by implementing clear, task-specific safe work method statements. Our Standard Operating Procedure for Crane Lifting resource outlines practical controls for teams operating overhead cranes and similar plant.

Businesses managing heavy machinery may also benefit from reviewing our Dozer Operation SWMS and Tractor Operation SWMS, both of which reinforce safety-first operating standards relevant to plant handling tasks like this one.

Supervisors overseeing contractors on-site should also consult our Worker Contractor Manuals for guidance on aligning subcontracted teams with site-specific safety expectations.

Key Takeaways for Site Operators

• Always verify load release paths before applying continued crane tension.
• Treat wedged or jammed components as high-risk until properly assessed.
• Ensure lifting plates and attachments undergo routine inspection.
• Document lifting procedures within accessible, task-specific safety plans.

Read more here.