A grease injection incident at an open-cut coal mine in Central Queensland has prompted a reminder to the industry to review the safety and compliance of high-pressure lubrication equipment.

While servicing a light vehicle inside the mine’s workshop, the worker involved in the incident was lubricating a leaf spring bush assembly using an 18V cordless grease gun when the grease pump hose failed near the grease coupler. The sudden release of energy resulted in a grease injection injury to the worker’s left thumb.

According to Resources Safety & Health Queensland (RSHQ), the cordless grease gun did not meet minimum safety requirements. The flexible grease hose fitted to the tool had been modified and was not compliant with current standards, which require hose assemblies to have a safety factor of at least 4:1.

The installed hose had an assessed safety factor of approximately 1.2:1, based on a maximum working pressure of 10,000 psi. The hose failed at the connection between the hose and fitting at the coupler end, which RSHQ said is a known stress and kink point.

Additionally, spring guards were not fitted at either end of the hose, increasing the risk of failure during high-pressure operation.

RSHQ also found that the mine’s ‘Management of Change’ process was not applied to the replacement or modification of the hose. As a result, maximum working pressures were not assessed or verified, and the replacement hose was not confirmed as compliant with minimum safety factor requirements.

Following the incident, RSHQ is urging operators to take action and ensure associated risks are appropriately mitigated. This includes discontinuing the use of cordless grease guns until compliance with current standards is verified, auditing grease guns and similar fluid power equipment, reviewing inspection and maintenance programs for high-pressure hoses, assessing contractor-supplied hydraulic tooling, reviewing emergency response arrangements for injection injuries, and reviewing personal protective equipment for workers exposed to high-pressure fluid hazards.

Following a near-collision on a surface coal mine haul road, the NSW Resources Regulator is highlighting the importance of speed management and situational awareness when interacting with mobile equipment.

The regulator has released details of the incident involving a 775G rear dump truck and a grader during road maintenance activities. The incident occurred while the dump truck was travelling uphill on a haul road where the grader was operating in the middle of the roadway.

According to the regulator, the dump truck was estimated to be travelling at 55 km/h, while the grader was visible from approximately 300 to 350 metres. Despite this, the truck driver did not react until the vehicle was about 50 metres from the grader.

When braking was applied, the truck’s wheels locked, causing it to skid slightly uphill for around 50 metres. The truck came to a stop approximately 700 millimetres from the grader.

In light of the incident, the regulator reiterated expectations for equipment operators working around mobile plant. Operators are required to apply correct speed limits when approaching or operating near other equipment and to maintain situational awareness to identify hazards early and apply appropriate controls.

The regulator also outlined actions for mine operators in response to the incident. It has directed operators to review the Resources Regulator’s Technical Reference Guide (TRG) for Surface ROVOA as part of their consideration of the event.

Operators must particularly review Layer 3 of the TRG, which addresses operating procedures, including standard operating procedures, maintenance, road rules, quality control and lockout processes. The regulator also highlighted Layer 6, which focuses on measures in place to ensure equipment is operated within its design parameters, including the use of in-vehicle systems to monitor operator behaviour.

Most operators understand fines.

Many understand prosecutions.

Very few fully appreciate the impact of a Supervisory Intervention Order (SIO) until one lands on their desk.

And right now, I am seeing more of them than ever.

Under the Heavy Vehicle National Law (HVNL), SIOs were designed as a compliance tool for persistent and repeat offenders.

In practice, they are becoming a routine add-on to prosecutions including permit and dimension offences with conditions that can cost thousands of dollars to implement.

What Is a Supervisory Intervention Order?

A Supervisory Intervention Order is a court-imposed compliance regime made under section 600 of the HVNL.

It allows a court, at sentencing, to place a business under active regulatory supervision for up to 12 months.

In plain terms, it means:

The National Heavy Vehicle Regulator (NHVR) is given power to monitor, audit, demand reports, require training, and impose structural reforms on how your business operates.

Why courts and the NHVR use them

SIOs exist for one reason:

To force systemic change where a regulator believes “business as usual” is unsafe.

They are typically sought where:

• There is a serious risk breach

• The regulator alleges systemic failure

• There are repeat issues

• Management systems are weak

• Permit, loading, fatigue or dimension breaches suggest poor controls

The new trend: SIOs for permit and dimension offences

Traditionally, SIOs were reserved for more serious offences.

Increasingly, I am seeing them sought in permit and dimension matters.

Cases involving over-width, over-length, or permit non-compliance are now being treated as “systems failures”, not isolated mistakes.

That changes everything.

What used to be a fine and a warning can now become a year of regulatory supervision.

What conditions can look like in practice

A recent matter illustrates just how far these orders can go.

In that case, the court imposed extensive compliance conditions, including mandatory reporting, staff disclosure, compulsory training, fleet registers, subcontractor controls, and installation of monitoring systems.

The order required, among other things:

• Full disclosure of all staff and contractors

• Ongoing reporting to the NHVR

• Mandatory training in mass, dimension and loading

• Evidence of attendance and competency

• Fleet and vehicle registers

• Accreditation requirements

• Installation of dimension monitoring systems

• Pre-departure and in-route checking regimes

• External training providers

• Compliance audits

• Record-keeping systems

• Notification obligations for operational changes

All flowing from a single offence.

The real cost of an SIO

Operators often focus on the fine. The real cost of an SIO is operational.

Typical hidden costs include:

• External consultants

• Training providers

• Audit firms

• New IT systems

• Monitoring equipment

• Staff time

• Compliance managers

• Legal oversight

• Reporting administration

• Lost productivity

Over a 12-month period, it is not uncommon for compliance costs to exceed the original fine several times over.

Why these orders are so powerful

SIOs matter because they change the power balance.

Once imposed:

• The NHVR gains ongoing visibility into your business

• Non-compliance becomes a fresh offence

• Minor breaches can trigger further prosecution

The strategic risk: “Consent orders” without negotiation

Another emerging issue is how these orders are obtained.

In many cases, they are presented as “reasonable”, “standard” or “rehabilitative”.

SIOs are discretionary. They are not automatic.

Courts must be satisfied they are:

• Necessary

• Proportionate

• Linked to the offending

• Capable of improving safety outcomes

• Not oppressive

That requires proper submissions, evidence, and negotiation. If you do nothing, the regulator’s draft order usually becomes the court’s order.

If your company is facing prosecution, permit issues, or regulatory scrutiny, get advice early.

The difference between a fine and a year of supervision is often decided long before sentencing.

Operations at Newmont’s Tanami mine site in the Northern Territory continue to be suspended, as investigations into the fatal incident on February 4 remain underway.

NT WorkSafe has confirmed its enquiry into the death of a 47-year-old worker on one of Australia’s largest underground gold mines is ongoing, with initial inquiries by the regulator suggesting a potential winch failure during a lift could have been a contributing factor.

According to the NT Police Force, after being notified of the fatality at 4 pm on February 4, officers from one of the closest towns to the site, Yuendumu, which is located 270 km away, attended the scene.

“Investigations are ongoing with members from the Coronial Investigation Unit and Crime Scene Examination Unit [on site],” police said.

Tanami, the most remote mine site in Australia, supports a workforce of more than 1800 fly-in-fly-out personnel.

Following the incident, Newmont has reaffirmed its commitment to safety and its employees.

“Safety remains our highest priority, and we are committed to supporting our people,” the company said in a statement.

“Our thoughts are with the individual’s family, friends and colleagues during this very difficult time.”

In the aftermath of the incident, Newmont said its “emergency response procedures were immediately activated” with all activities at the Tanami site suspended.

As authorities work to establish a cause, the company added that it will support all investigative efforts.

“Newmont will provide our full support to assist with the investigation into this tragic incident.”

The National Heavy Vehicle Regulator (NHVR) has released details about upcoming changes to the Directional Stability Under Braking (DSUB).

The changes, coming into effect on July 1, 2026 will apply to newly built vehicles and existing in-service vehicles entering PBS for the first time.

“The Directional Stability Under Braking (DSUB) standard is being updated to modernise braking requirements under the Performance Based Standards (PBS) scheme,” said the NHVR.

“Vehicles that were PBS-approved prior to 1 July 2026 are unaffected, except for limited connectivity requirements when operated in combinations with DSUB-compliant vehicles.

“The revised DSUB standard will improve safety outcomes by increasing the use of advanced braking and stability technologies.

The new braking standard does not apply even if you re-certify or add that vehicle to a new or existing PBS Vehicle Approval (VA) after 1 July 2026.”

The changes mean that first-time PBS trailers and dollies must meet the revised DSUB requirements, including the fitment of Trailer EBS with full roll stability functionality.

Under the revised DSUB standard, load proportioning valves (LPVs) will not be permitted.

For further information, click here. The NHVR will also be holding an introductory webinar on Tuesday February 3, at 10am (AEST). To register, click here. 

A serious crush injury caused when the safety lock on an automated machine was tampered with has prompted a SafeWork SA warning.

Inspectors recently attended a worksite where a worker had become trapped in an automated computer numerical control (CNC) machine and suffered broken ribs.

An examination of the equipment found that the electrical interlock device used to prevent the machine’s door from being opened while in operation had been overridden with a home-made metal key – exposing the worker to dangerous moving parts. Inquiries are continuing.

SafeWork SA reminds businesses that disabling the safety features of CNC machines and any other automated tools can have serious consequences and is a significant breach of work health and safety laws.

Employers must ensure that safety devices such as electrical interlocks, light curtains, pressure mats and guards are not overridden and/or bypassed to undermine the safety features of any plant and equipment.

Regulation 208 (3) of the Work Health & Safety Regulations (2012) (external site) states the person with management or control of the plant must ensure that the guarding is solidly constructed, securely mounted, well maintained and not easily bypassed.

Penalties for failing to comply with the regulations attract maximum penalties of $6000 for an individual and $30,000 for a business.

Safety solutions

To reduce the risk of incidents and injuries, employers must:

• Ensure plant with safety devices is regularly inspected and tested by a competent person to verify the safety devices are operating in accordance with the manufacturer’s requirements.
• Implement a system of work for the testing of safety devices prior to the operation of the plant. This may involve a daily checklist or similar system of work.
• Ensure all workers required to use plant which has safety devices installed, are provided information, instruction and training on the correct operation of the devices.
• Ensure workers and/or other persons do not deliberately bypass or override safety devices fitted to plant and equipment.

SafeWork SA Executive Director Glenn Farrell said safety locks and guards on machinery provide a physical barrier that when utilised appropriately and maintained provides a highly effective means of preventing injury or death.

‘Failing to have adequate control measures in place on items of plant, such as safety locks, can have significant life changing consequences for a worker,’ he said.

Warning about dangers of improper use of high-power lasers

SafeWork SA has identified a growing concern regarding the unsafe use of Class 3B and 4 lasers in entertainment venues, particularly in laser light shows.

Lasers can add visual appeal to events but they can also pose potential risks to the health and safety of staff, performers and audiences if they are not used and managed properly.

Class 3B and 4 lasers are classified based on their potential to cause harm to eyes and skin burns, with Class 4 lasers being fire hazards if they are not properly controlled and positioned.

Emissions from lasers may be visible and non-visible light and are commonly used at concerts, festivals, and events for light shows, projections, and special effects.

Regulation 223 (5) of the Work Health & Safety Regulations (2012) (external site) states the person with management or control must ensure workers operating laser equipment are trained in the proper use of the equipment.

Safety solutions

A person conducting a business or undertaking (PCBU) must identify and assess all risks associated with the use of high-power lasers and ensure that lasers are not directed:

• In a manner that the laser beam could interact with a person
• Towards a surface that the beam could reflect off
• Towards a surface or substance that has the potential to ignite

All lasers require correct labelling to warn of the hazards involved with the radiation source as per Australian requirements.

If a business identifies that they have Class 3B or 4 lasers, they should consider if that category of laser is appropriate for the location and activity undertaken.   A lower class of laser can produce a similar effect without the associated risk.

Further information

• Laser classifications | Safe Work Australia(external site)
• Lasers | ARPANSA(external site)

AS/NZS IEC 60825.3:2022 Safety of laser products, Part 3: Guidance for laser displays and shows | Standards Australia Store

Two separate explosive fires causing serious burns to workers have prompted SafeWork SA to warn employers about the dangers of cutting into used storage drums.

In both of the recent incidents, the drums had previously contained flammable substances but had been empty for a long period of time.

In January 2025, a worker in Murray Bridge was cutting into a 166-litre storage drum with an angle grinder to repurpose it.

The drum – although empty – had previously contained oil.

Sparks from the angle grinder and residual vapours caused an explosive fire, resulting in serious burns and lacerations to the man’s hand, arm and torso, requiring treatment at a nearby medical clinic.

In March 2025, a worker in Tailem Bend was cutting into a storage drum with an angle grinder to repurpose it.

The drum had previously contained a carcinogenic and flammable liquid and was clearly labelled with a red flammable liquid diamond warning.

Sparks from the angle grinder caused an explosive fire, resulting in serious burns to the man’s torso.

He was taken to Adelaide for medical treatment.

SafeWork SA is urging employers and workers to stop, think and assess the risk before modifying a storage drum that has been used.

Even drums that have been empty for a long period of time are likely to contain residual substances or vapours and should not be exposed to heat.

The heat and sparks from tools can cause a fire, explosion or release of hazardous vapours. Rinsing drums with water or other cleaning substances does not eliminate the risk.

Safety checklist

Before reusing a drum, check what the drum was previously used for:

• Did it ever contain a flammable or combustible liquid, or gas?
• Did it ever contain a hazardous chemical?
• Does the drum have a hazardous chemical label on it?
• Is there a hazard diamond on the drum?
• Is there a single word such as “danger” or “warning” on the drum?
• If the answer to any of these questions is ‘yes’ or ‘I don’t know’, do not apply heat to the drum.

Keep the drum away from oxyacetylene torches, naked flames or sparks from grinding and welding equipment.

Assess the storage drum before starting work

Before making that first cut, check:

• the Safety Data Sheet and the manufacturer’s instructions and precautions before performing any work on the container
• the container has been properly cleaned and certified vapour-free by a competent person
• that there are safe work processes in place to manage the hazard and ensure all workers understand and are properly trained on these processes
• controls are in place to extinguish any flames that may eventuate.

Working with or near storage drums

• Never conduct hazardous work without proper training and supervision
• Never assume every worker is fully aware of the risks involved in the task
• Never weld, grind or do any other hot work activity near empty drums
• Do not use drums as a welding or work platform
• Store empty drums with bungs removed in a well-ventilated place away from other work areas. Removing the bung will not guarantee all hazardous residues and vapours have been naturally vented.
• Do not cut or apply heat to these drums.

SafeWork SA is warning people who work with cement and concrete about the dangers of alkaline burns after a home handyman sustained serious leg injuries.

The Mid North resident was laying a cement base for a garden shed when wet cement seeped through his pants, causing serious burns to both legs.

He was airlifted to Adelaide by the Royal Flying Doctor Service for treatment at Royal Adelaide Hospital’s Burns Unit where he underwent skin grafts on both legs to treat the deep burns.

Cement or concrete with a pH level greater than 12 is highly alkaline and poses a serious risk of burn upon contact with the skin.

The setting of cement or concrete is an exothermic reaction, releasing a lot of heat. This, together with excessive sweating, and wearing wet or damp clothing can exacerbate the severity of cement or concrete burns.

Cement or concrete burns, also known as cutaneous alkali burns, may start as redness or irritation but can quickly progress into more severe conditions.

Unlike thermal burns, the damage might not be immediately noticeable, which can delay treatment and increase severity.

These burns are most common in the construction industry where workers frequently handle concrete or cement without sufficient protection. Burns often happen to:

• Workers pouring cement or concrete for foundations or footpaths may have prolonged contact with the wet mixture, especially if they kneel or sit on it.
• Masons and bricklayers develop burns when handling mortar or cement without gloves or protective clothing.
• DIY enthusiasts working on home projects like patio installations experience burns if they handle cement or concrete without proper skin protection.

Symptoms of cement or concrete

Cement or concrete burns on the skin can manifest in various ways and may depend on the individual’s sensitivity to alkaline substances.

Stages of cement or concrete burns

• Early Stage: Characterized by mild irritation, redness and inflammation, and delayed discomfort.
• Intermediate Stage: Involves blistering, crackling, and peeling of the skin, swelling, and colour change from red to pink to whitish-grey.
• Advanced Stage: Progresses to full-thickness burns, dead skin, and tissue loss, as well as scarring and loss of mobility. Severe cases have the potential for life-threatening consequences if left untreated.

Injury management

Prompt removal of wet cement from the skin is crucial. All clothing that is in contact with the affected area must be removed and the burns irrigated with copious amounts of saline or water. Powdered cement or concrete should be brushed off the wound before water is applied.

How to prevent cement or concrete burns

Construction workers and do-it-yourself enthusiasts are reminded to read labels and safety information about the products they are using before commencing work and follow instructions.

People working with cement or concrete should wear the appropriate personal protective equipment (PPE) and practise good hand hygiene.

Handling cement or concrete

Read Safety Data Sheets (SDS) if available: Before starting any cement or concrete-related task, review the SDS for information on handling, hazards, and emergency response procedures. This helps you understand the specific risks associated with the cement or concrete mix you’re using.

Mix cement or concrete carefully: When mixing cement or concrete, do so slowly to minimize splashing. Wear gloves and goggles to protect yourself from accidental splashes that could reach your skin or eyes.

Handle wet cement or concrete with tools: Avoid direct skin contact and whenever possible, use tools like trowels, shovels, or cement or concrete spreaders to minimize direct contact with wet cement or concrete. This reduces the chances of burns and skin irritation.

Limit exposure time: Try to limit your time working with wet cement or concrete to reduce the risk of burns. The longer the skin is exposed, the higher the risk of injury.

Keep a clean work area: Maintain a tidy workspace to avoid accidentally tracking wet or dry cement or concrete onto your skin, tools, or clothing. Clean any spills immediately and be mindful of where the cement or concrete is being mixed or poured.

Use water wisely: Ensure that plenty of clean water is available at the worksite for immediate rinsing in case of accidental contact with cement or concrete. Having a designated rinsing station can help workers quickly wash off any wet cement or concrete from their skin.

Inspect equipment before use: Inspect your tools, mixing containers, and protective gear before use. Uncleaned or damaged equipment can increase the likelihood of spills and splashes and expose you to cement or concrete unnecessarily.

Dispose of waste properly: Properly dispose of cement or concrete waste to prevent further exposure. Be mindful of environmental guidelines when disposing of unused cement or concrete or washing down equipment.

Appropriate PPE

Long-sleeved shirts and pants: Long-sleeved shirts and pants made of durable materials, such as cotton or protective fabric blends, shield your skin from direct contact with cement or concrete and a water-resistant top layer should also be worn. For example, protective waterproof chaps should be worn over clothing.Ensure that your garments fit properly and cover your body adequately for the best protection.

Gloves: Wearing work gloves is essential to protect your hands from coming into direct contact with wet cement, which can cause skin irritation or chemical burns. Opt for gloves made of materials specifically designed for cement or concrete work, such as rubber or nitrile. These gloves provide a barrier against the chemicals in cement or concrete and help maintain your grip on tools and materials.

Safety goggles: When working with cement or concrete, it is important to protect your eyes from potential splashes or airborne particles. Safety goggles with snug fit and shatter-resistant lenses safeguard your eyes from any cement or concrete debris or chemical substances that may cause eye irritation or injury.

SafeWork SA is warning operators of mobile plant of the significant risks to workers and pedestrians following 14 deaths in the past five years.

Powered mobile plant includes forklifts, tractors elevating work platforms, delivery vehicles, order pickers, earthmoving equipment, prime movers, cranes and other industrial equipment and machinery that is designed to be easily transported and used at various locations.

In South Australia over the past five financial years (2020–21 to 2024–25), SafeWork SA received 81 notifiable serious injury notifications involving powered mobile plant.

These incidents resulted in:

• 14 fatalities
• 67 serious injuries, including:
  • 51 people struck by operating mobile plant
  • 25 serious injuries linked to forklifts, 16 to motor vehicles, 8 to trucks, and 6 to cranes
  • 9 injuries due to vehicle roll-aways.

The industries with the highest number of notifiable incidents were:

• 14 Transport, Postal and Warehousing
• 9 Construction
• 8 Wholesale Trade
• 6 Agriculture, Forestry and Fishing
• 5 Retail Trade.

Legislative responsibilities

Under the Work Health and Safety Act and Regulations, businesses must eliminate or, where not reasonably practicable, minimise risks to health and safety associated with mobile plant.

This includes:

• consulting with workers on hazard identification and risk control
• providing adequate information, training, instruction, and supervision
• ensuring all workers, including contractors and visitors, understand and follow site-specific traffic management procedures.

Risk Management and Control Measures

Identify Hazards

In consultation with workers and plant operators, identify:

• where mobile plant is used
• where interactions with pedestrians or other plant may occur
• potential collision points with people, other plant, or structures.

Eliminate Risks Where Possible

• design site layouts to physically separate pedestrians and vehicles (e.g. separate entry points, overhead walkways)
• schedule work to avoid simultaneous operation of plant and pedestrian access in the same area.

Minimise Risks with Control Measures

If elimination is not practicable, implement a traffic management plan that includes:

• substituting high-risk plant with safer alternatives (e.g. pallet jacks instead of forklifts)
• installing physical barriers, bollards, exclusion zones, and safety rails
• using audible and visual alerts (e.g. reversing alarms, flashing lights)
• designing site layouts to reduce plant movement and reversing
• establishing clear traffic flow, signage, right-of-way rules, and speed limits
• deploying spotters or traffic controllers where necessary
• restricting access to essential personnel
• requiring high-visibility clothing for all personnel in shared zones
• preventing vehicle roll-aways by implementing shutdown procedures before exiting the vehicle that include:
  • engaging the parking brake
  • parking on level ground wherever possible
  • undertaking maintenance checks that include inspection of braking systems and parking mechanism
  • ensuring workers are trained to recognise and respond to roll-away risks.
• preparing a Safe Work Method Statement (SWMS) for high-risk construction work activities involving powered mobile plant.

Maintain and Review Controls

Control measures must be regularly reviewed to ensure ongoing effectiveness, especially in dynamic environments such as construction sites. Systems should be in place to:

• monitor and assess control effectiveness
• encourage reporting and feedback
• ensure compliance with procedures
• anticipate and manage changes to site layout, equipment, or processes
• evaluate new technologies or safer alternatives.