According to the state's Mineral Mines and Quarries Inspectorate, the 14mm synthetic fibre rope failed when the breaking strain was exceeded during installation of a new conveyor belt at the plant.

Workers were using the rope to pull out the old conveyor belt, with one end of the rope attached to the belt and the other attached to a loader.

The loader was providing the motive force to pull the old conveyor belt off the conveyor structure.

However, during the move a gravity take-up unit pulley jammed, when the links of a safety chain used to lift it became stuck between the pulley end and the conveyor structure.

The increased tension caused the rope to snap and then whiplash into the man's face.

He later had surgery to remove one of his eyes.

Key issues

There was no exclusion zone set up despite the risks of equipment failure during hauling and loading type operations being well known.

Workers must stay well clear of items such as cables, ropes and chains when they are under tension.

Purpose-built equipment such as a winch, winder or reeler was not used when replacing the conveyor belt, and workers were not wearing appropriate personal protective equipment to protect them from flying materials or objects.

Recommendations

The inspectorate made a number of recommendations to prevent similar incidents from occurring. They include:

• Separation. An exclusion zone should be in place when using cable, ropes or similar types of haulage equipment under tension. The exclusion zone should account for any rope or cable stretch under load, plus a significant allowance as a margin of safety, particularly when using synthetic fibre ropes. The exclusion zone must be clearly defined and, where possible, physically prevent entry into the exclusion zone;
• Substitution. Preference should be given to purpose-built equipment such as winches, winders and reelers when installing or replacing conveyor belts. This type of equipment allows for a more controlled belt pull-on process and can be operated by personnel at a safe distance. Winches may be fitted with load cells to ensure wire cable breaking strain is not exceeded;
• Substitution. Some traditional synthetic fibre ropes like nylon and polypropylene are prone to whiplash or failure due to their elasticity. Newer synthetics and natural fibre ropes can mitigate this problem. Ropes should be checked and replaced on a regular basis;
• Engineering. Belt pull calculations should be carried out prior to a belt installation to determine the correct rated capacity of haulage equipment. Wireless load cells are now available to ensure breaking strain of haulage equipment is not exceeded while workers remain safely outside the exclusion zone. Load cells can also help detect abnormal conditions during belt haulage activities, prompting an inspection of jam and wedge points;
• Engineering. Winch line dampeners are effective at reducing rope lash on failure, provided they are used as per manufacturer's instructions;
• Administrative. Safe work instructions related to conveyor installation or replacement should be reviewed to ensure the risk of catastrophic equipment failure is identified and appropriate controls are in place; and
• Personal Protective Equipment. As a last line of defence, eye protection should be worn when carrying out tasks where there is a risk from flying material or objects.