Multiple line-of-fire incidents bring to light the serious hazards present in mobile plant pulling tasks in NSW mines

Multiple Line-of-Fire Incidents Bring to Light Serious Hazards Present in Mobile Plant Pulling Tasks in NSW Mines

The NSW Resources Regulator has warned mines following a surge in incidents related to mobile plant pulling operations. Multiple line-of-fire incidents bring to light the serious hazards present in these tasks, with two separate cases showing how quickly routine pulling activities can turn dangerous.

In both instances, workers were fortunate to avoid injury when metal objects were propelled at high velocities due to failure of ropes or slings. Investigations disclosed shortcomings in documentation of work, a failure to adequately identify risks, and non-compliance with proper procedural protocols.

What Went Wrong: Key Findings

Reviews into these incidents identified several recurring safety gaps across NSW mines conducting mobile plant pulling activities:

• Incomplete or outdated job safety analyses for pulling tasks
• Inadequate hazard identification before work commenced
• Poor selection or inspection of ropes, slings, and related equipment
• Non-compliance with established procedural controls

"Mine operators are being urged to improve risk management by ensuring clear, updated procedures and an improvement in completing job safety analyses (JSAs) for all pulling activities," the safety warning from the regulator indicates.

Strengthening Safety Controls for Pulling Operations

Regulator emphasises the importance for workers and supervisors to comply with stringent protocols, employ correct equipment, and report any issues that arise when tasks do not align with the intended plan.

Effective safety outcomes depend on operators treating each pulling task as a distinct job requiring its own risk assessment, rather than relying on generic procedures. Selecting equipment rated for the specific load, inspecting slings and ropes before use, and maintaining clear communication between crew members are foundational controls that reduce line-of-fire exposure.

Supervisors play a critical part in reinforcing these safety expectations on site. Referring to established guidance such as the Managing Risks of Plant in the Workplace Code of Practice can help operators align internal procedures with current regulatory expectations.

Practical Steps for Mine Operators

To reduce the risk of similar incidents, operators should consider the following actions:

• Update job safety analyses before every pulling task, rather than relying on outdated paperwork
• Inspect ropes, slings, and other equipment for wear or damage before each use
• Train workers to recognise line-of-fire zones and maintain safe distances during pulling activities
• Encourage prompt reporting when a task deviates from its planned sequence

Documented safe work method statements provide a practical way for site teams to formalise these steps. Resources such as a Telehandler SWMS or a Mobile Plant Attachments SWMS can support operators in meeting compliance expectations while embedding consistent safety practices across pulling tasks.

Similar warnings have emerged in other jurisdictions, including a recent case where WorkSafe WA issued a reminder on mobile plant safety following two fatal incidents. These parallel warnings suggest line-of-fire hazards remain a persistent risk wherever pulling operations occur.

For broader guidance on reducing injury risk during equipment operation, see our article on 10 mobile plant safety tips, which covers practical measures relevant to sites managing similar equipment risks. Operators running smaller machinery may also find value in a Mini Loader SWMS when formalising site-specific procedures.

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