Whether the Step was Worn
52 PM51 was one of a number of trucks which the Respondent acquired second-hand in November 1999. It was built in July 1998. At the date of the accident it had done just over one million kilometres. So far as he could recall the Appellant had never driven PM51 before the day on which he was injured, though "may have driven one or two" other Transtars. The organisation of which the Respondent was part had some trucks called S-Lines, which the Appellant described as a "smaller version of the Transtar". The Appellant had driven S-Lines, and identified their steps as being "exactly the same" as the steps depicted on a photograph of a Transtar. His evidence was that he had noticed with the S-Line trucks that the "holes in the steps" over time
"… would get smoother. They wouldn't be so - they wouldn't grip your boots as well as they were when they were new."
53 He also said:
"Q. And if it got worn, what would it be like to tread on?
A. It'd just feel like a little bump in the step. It just - they - no grip.
Q. If it was in new or nearly new condition, did it grip your foot?
A. Yep."
54 In cross-examination the Appellant was reminded of his evidence of the rough edge around the hole. The evidence continued:
"Q. And that was the type of thing which wore off fairly quickly with the driver climbing up and down the steps? That's right, isn't it?
A Yep."
55 He later qualified that evidence:
"Q. Once they've been used for a relatively short period of time, those burry edges are worked off, that's right isn't it?
A. I wouldn't say in a short period of time, in a - after many - I suppose a lot of use, yeah.
Q. But after that burry edge goes, you're still left with the islands, are you not?
A. You're still left with a little bit of the islands, yeah."
56 An expert witness, Mr Bailey, was able to inspect PM51 on 13 August 2005. By that time PM51 had been sold to a new owner. Mr Bailey took a close-up photograph of the then condition of the dimples on the top step. That photograph shows a ridge around the hole of each dimple. The Appellant was shown that photograph:
"Q. And I suppose, would you say, that you didn't make a very close examination of the step on that day?
A. No.
Q. But looking at that photograph, figure 4 on page 8 of the report, it looks the same, do you agree?
A. It's similar, yes.
Q. Well are there any differences that you made?
A. I could not say whether that was exactly the same step or if it was the actual step.
Q. All right. But do you agree with me that whether or not it's the actual step, that photograph looks like the step that was on the truck?
A. Yep."
57 The cross-examination continued:
"Q. Now you've told her Honour you were wearing proper work boots with what, a polyethylene sole or something?
A. Yeah, with really good, with grip, yeah.
Q. And do you agree with me that when you put the sole of the boot onto either the top or the bottom step that it goes onto those islands we identified?
A. Mm-hmm.
Q. That's a yes?
A. Yeah.
Q. And that the sole of the boot engages with those ridges we identified in the close up photograph on top of the islands. That's right, isn't it?
A. Yes.
Q. And those islands and those ridges provide good traction when you're climbing in and out of the truck wearing proper boots, do they not?
A. If they're new, yeah.
Q. Even if that burr which is there from the manufacturing process has worn off, the islands and the ridges still provide good traction to the sole of a good work boot, don't they?
A. Not always, no."
58 The Appellant lived in Cootamundra. On the day in question he had driven PM51 from Cootamundra to Sydney, and it was when he was getting out of the vehicle in Sydney that he was injured. He gave evidence:
"Q. And indeed up until you met with your injury, you got in and out of this truck on three occasions without any mishap. That's right, isn't it?
A. Correct.
Q. And on each of those three occasions that we've been talking about, the sole of your work boot engaged with the step, didn't it?
A. Yep.
Q. And on each of those occasions it engaged with the step and you got good traction. That's right, isn't it?
A. Each time, yep."
59 Mr Brookhouse had been a regular driver of PM51 for about a year and a half before the Appellant's accident. His usual routine was to do about three trips a week in it, on each of which he would be gone about 24 hours. He gave evidence that at the place on the steps that was the normal means of passage, the surface of the steps was "smooth", but further down towards the back of the vehicle the surface of the steps was "rough". He gave evidence that he had slipped two or three times, in the smooth section underneath the front door, in the time before the Appellant had the accident. However, on those occasions he landed on his feet, and never made any formal report about it.
60 In cross-examination Mr Brookhouse was shown the close-up photograph that Mr Bailey had taken. He agreed that it had the dimples, and the hole. The cross-examination continued:
"Q. And it's got, you can see that there's no burr on those is that right?
A. Oh I could only see if I felt them.
Q. I see, but it does have a little ridge around the circumference of the hole at the top of the dimple?
A. Yes.
Q. And that photograph shows what the top step on PM51 looked like at about October 2003, do you agree with that?
A. I never took that close of a look, sorry."
61 He also said:
"Q. But even when they have that smoother feeling underfoot, you still have the dimple?
A. Yes.
Q. You still have the hole?
A. Yes.
Q. And you still have the ridge?
A. Yes.
Q. And that's what PM51 was like at about October 2003?
A. Yes."
62 Another expert, Professor Frost, (who had never inspected PM51) was shown Mr Bailey's photograph, and accepted that the step probably still looked satisfactory. He said:
"Q. But the fact that it may feel smoother underfoot doesn't mean - may feel smoother underfoot compared to those more remote areas, doesn't mean that it's unsatisfactory for safe use, do you agree with that?
A. Well it's a matter of degree."
63 When asked about what life could be expected from a step like that, he said he had not done a life analysis on them, that they are probably left in place for lengthy periods of time, and would probably have a satisfactory working life of some years, dependent upon the type of use to which the truck was put.
64 Mr John Hutcheon was in 2003 the General Manager, Equipment and Procurement of the Scott's organisation. He accepted that steps of the type fitted to PM51 could get blunt over time. He said:
"Q. If those projecting pieces of metal formed by the punching process wear off, the step is less slip resistant isn't it?
A. I don't believe they actually wear off sir, they just become dull.
…
Q. Well I'm asking you about these projections that you've told me start off sharp and then I'm asking you about the stage where, according to you, they can get blunt. And you've agreed with me I think that reduces their effectiveness in providing purchase for a driver's boot, you've agreed with that haven't you?
A. Yes sir.
Q. Once that happens you'd replace them, wouldn't you?
A. If it's reported you'd replace it, if the people servicing the truck deem it to be unserviceable, they would replace it.
…
A. The driver had a pre-check book that he could do the pre-checks on the truck. He also had another book called a defect book, an internal defect book and he could write a defect out and pass that defect in, "Yes I've fallen off the step. Could you please look at my step. I don't think it's serviceable any more".
…
Q. You agree, don't you, that these things wear, the sharpness wears over time?
A. Yes sir.
Q. Be a good idea to have the people in the workshop keep an eye on that, wouldn't it?
A. I believe they did sir.
…
Q. What I was asking Mr Hutcheon was that the maintenance staff who do the services on these vehicles would be expected to look for a worn step and if necessary replace it?
A. Not targeting steps so anything worn that looks as though where the vehicle could fail or driver safety is --
Q. Including steps.
A Oh yes, steps.
Q. I realise not only steps, but they look - their job is to look over all the vehicle, including the steps and see if something's worn and compromises driver safety. Correct?
A. Yes sir."
65 Though Mr Hutcheon had ceased having direct day-to-day involvement with the defendant's workshop by 2000, prior to that time he tried to walk around the yard on a daily basis, and if he noticed damage to a vehicle he would advise the workshop supervisor to fix it. The workshop supervisor at the time of the accident was a Mr Morris, who was not called. However, that occurred in circumstances where orders had been made for short service of a subpoena on Mr Morris, but Mr Lidden announced he agreed that "Mr Morris would have followed a managerial line much as Mr Hutcheon's", and "I won't complain that he wasn't called by the defendant or that any adverse inference arises from the failure to call him".
66 When Mr Bailey inspected PM51, he reported:
"When assessed using boots which had polyurethane soles, there was a feeling of positive engagement with the upper surface of these steps at a time when they were somewhat contaminated with oil. Whilst assessment of slip resistance of a step can be performed by several different means, it was clear during the inspect that the upward deformed edges of the holes punched in the aluminium steps were in good condition and fairly sharp, so that they would provide positive engagement with the sole material of any conventional footwear."
67 He reported that the step as inspected by him:
"… provides well in excess of the minimum tread depth (ie 160mm vs 127mm required) between the outer edge of the step and the fuel tank, and substantial and effective slip resistance features."
68 The evidence included maintenance records relating to PM51 that spanned a period from 23 January 2002 to 23 May 2005. Those records do not disclose any step being replaced on PM51. The records came to be in evidence in a rather haphazard way - they had not been subpoenaed, but Mr Hutcheon happened to have the records which were ultimately tendered with him at the time he gave evidence.
69 There is some reason to believe that the records are incomplete. The rear of the front section of the bottom step is bent towards the ground in photographs that Mr Brookhouse took of PM51 a couple of months after the accident. So far as one can tell from those photographs, it seems as though it is the rear corner that is furthest away from the truck body that has bent down so as to be below the level of the corresponding section of the rear step, but the rear corner of the edge that is closest to the truck body is at the same level as the back section of that step. Another photograph of PM51 taken on 7 April 2005 shows the bottom step correctly aligned. Notwithstanding that, there is no record in the maintenance documents of that step being fixed, or replaced.
70 Even so, the maintenance records in evidence show that the vehicle was regularly serviced. The vehicle defect report book is a set of printed forms, each of which is headed
"ALL DEFECTS FOUND DURING THE PRE-TRIP CHECK AS PER PRE-01 OR ANY DEFECT FOUND DURING OPERATIONS WILL REQUIRE THE COMPLETION OF THIS REPORT."
71 The form identifies various components or potentially defective conditions of the truck, with provision for ticks to be placed in boxes alongside applicable ones. None of those components or potential defects relates specifically to the condition of the step, but one of them relates to "other". Defects actually reported concerning PM51 include "could you put new mudguard on", "heater not working", and "centre cab light out". Different types of standard form are provided for use in the workshop, to identify parts checked, or replaced, or repaired.