Investigations launched after two employees sustain injuries at NSW quarry

An investigation has been launched by the NSW Resources Regulator following a serious incident at a quarry in southwestern New South Wales, raising fresh concerns about safety management on site.

The incident happened on 13th May 2024 around 11:50 am, resulting in burn injuries for two workers as a result of cleaning fluid igniting with a cordless handheld blower. Similar events have previously prompted regulators to review investigations launched following incidents at NSW mines, underscoring why robust safety protocols remain essential across the quarrying and mining sectors.

What Happened During the Incident

"The workers were changing the lubricating oil on a Nordberg HP300 cone crusher using rags and brake cleaning fluid to remove sludge that had accumulated in the oil reservoir," the regulator says in an investigation report.

Following the incident, the first worker was taken to Royal North Shore Hospital due to burns on his face, chest, and arms. Conversely, the second worker, who sustained superficial injuries of a less severe nature, was released from hospital later that day for recovery at home.

Why Safety Management Matters in Quarry Operations

Incidents like this highlight why proper safety management systems are non-negotiable for operators handling flammable substances near equipment. Effective health and safety management involves controlling ignition sources, storing chemicals correctly, and training staff on hazardous material handling.

For professional teams responsible for site management, this incident serves as a stark reminder that even routine maintenance tasks carry serious risk when safety management protocols aren't strictly followed. A thorough review of chemical handling procedures, ignition source management, and equipment maintenance management should form part of every operator's ongoing safety management strategy.

Key Safety Management Considerations for Maintenance Work

• Ensure proper ventilation management when using flammable cleaning fluids
• Maintain strict separation between ignition sources and volatile chemicals during equipment servicing
• Implement documented safety management procedures for all maintenance tasks involving hazardous substances
• Provide ongoing health and safety training for personnel conducting cleaning and lubrication work
• Review incident reports regularly to strengthen site-wide safety management practices

Businesses seeking to strengthen their safety management documentation may also benefit from reviewing resources such as the Injuries Report Form, which supports consistent recording and management of workplace incidents.

Similar Incidents Across the Industry

This event follows a pattern of serious incidents reported at NSW sites in recent months. Regulators have also documented cases where workers sustained injuries at NSW mines after being trapped beneath coal underground, and separately, where an NSW mine worker suffered a serious leg injury during a lifting operation. Each case reinforces the need for stronger safety management commitments across the resources sector.

Professional operators handling rock-cutting or crushing equipment should also consider reviewing task-specific documentation, such as guidance for stone cutting and rock saw operations in quarry settings, to ensure safety management extends across all high-risk activities on site.

Supporting Cleanup and Maintenance Safety Management

Where cleaning fluids or solvents are involved in post-incident or routine cleanup work, operators should reference established procedures like those found in cleaning after flood and storm SWMS documentation, which offer a useful professional template for managing chemical exposure risks safely.

Read the full report on the NSW Resources Regulator's website for further detail on findings and recommended safety management improvements.