The worker entered a product tank, via a hatch, to conduct routine cleaning on 17 April 2023.

At the base of the tank was a rotating auger used to transfer product from the tank to another part of the factory.

The worker’s leg became trapped in the auger resulting in his right leg being amputated below the knee as a result of the incident.

While the circumstances and findings of this incident are not finalised, this alert serves as a prompt to those responsible for plant and equipment to ensure all hazards are identified, assessed and adequately controlled to prevent injury to a person.

Rotating augers, shafts, chains and sprockets are common components on items of plant and equipment that can cause serious injuries or death, to workers and other persons who may become entangled in the moving parts.

The risks associated with any plant or equipment undergoing inspection, maintenance, cleaning, repair or construction should be assessed and appropriate control measures put in place.

Before such work commences the plant should be stopped, appropriately isolated/locked and appropriately tagged. Any stored energy should be dissipated.

Examples of energy sources include electricity, hydraulic pressure, compressed air or gas, gravity, kinetic spring tension and moving parts.

Separate controls away from the worker or immediate work area must also be isolated/locked and appropriately tagged.

Safety solutions

To reduce the risks of incidents and injuries occurring:

• Ensure a safe system of work is developed, in consultation with workers, to ensure that all power, being electrical, hydraulic, pneumatic, kinetic and gravity is isolated (locked-out) prior to, and during, work being carried out on plant or machinery.
• Ensure all relevant plant has mechanisms (locks/clasps) in place which allow power to be isolated by way of a suitable locking device that cannot be overridden.
• Ensure training is provided to all workers and/or contractors in the location of isolation points and the process on how to lock-out/tag-out plant.

SafeWork SA reminds businesses to ensure they have systems of work in place to ensure the motive power, being electrical, hydraulic, pneumatic, kinetic and gravity is isolated (locked-out) prior to, and during, any work being undertaken on the plant that requires maintenance/repairs and/or cleaning.

This system of work is to ensure that no person can re-energise power to the plant whilst a worker is carrying out routine tasks.

Further links:

• Isolation procedures