Safety alert issued after haul truck rear strut injures NSW mine worker

NSW Mine Worker Injured by Swinging Haul Truck Strut

A safety alert has been issued by the Resources Regulator after a worker suffered injuries from a swinging load at an open-cut coal mine in New South Wales. This incident highlights ongoing hazards associated with heavy vehicle maintenance tasks at mining locations across the state.

According to the Resources Regulator, on September 23, 2024, mine workers were "replacing a rear suspension strut on a haul truck" at the coal mine site.

How the Incident Occurred

During this process, the strut, which was fastened by a lower pin, pivoted backward and struck a worker positioned on the access platform. This caused a severe laceration to his upper leg, underscoring the physical hazards present when handling suspended or partially secured components.

Such tasks often carry underestimated risks, particularly when heavy parts remain fastened by a single pin or point of restraint, leaving them prone to sudden, uncontrolled movement.

Regulator's Recommendations for Mine Operators

After conducting an investigation, the Regulator released a set of suggestions aimed at reducing similar hazards on future jobs. Recommendations include:

• Providing comprehensive training to workers prior to commencing tasks involving suspension struts or other components under tension.
• Reviewing risk assessments for haul truck maintenance procedures to identify potential swinging load hazards.
• Implementing additional controls, such as secondary restraints, when working near components fastened only by a single pin.

These measures align with broader health and safety obligations that apply across Australia's resources sector, where robust hazard controls remain essential for protecting personnel during routine maintenance.

Mine operators can strengthen workplace health outcomes by reviewing similar incidents, including a previous safety alert issued after a worker lost an arm in an underground mine incident, to identify recurring hazard patterns and refine site-specific procedures.

Broader Lessons for Heavy Vehicle Maintenance

Incidents involving suspended or partially restrained components are not unique to coal operations. Similar hazards have prompted alerts in other sectors, including a safety alert issued after an NT worker fell from a forklift and a separate safety alert issued after a Queensland worker died in a tractor rollover.

Businesses seeking to strengthen their compliance frameworks may benefit from structured safety software solutions, alongside documented procedures such as an electrical safety policy or an electrical safety checklist where relevant equipment is involved.

Clear workplace safety rules combined with thorough training remain among the most effective ways to prevent injuries during high-risk maintenance tasks.

Access the safety alert here.

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