Each defendant pleaded guilty to the charge as laid.
3 An Agreed Statement of Facts, again relevant to both charges, reads:
1. ...
2. ...
3. ...
4. At all material times Waste Equipment was a wholly owned subsidiary of Clean Valley Pty Limited [ACN 003 238 882] ("Clean Valley") which operated a waste removal business (also from the premises) in the Newcastle and Hunter Valley area.
5. The Second Defendant, John Bernard Cross ("Cross") is and was at all material times the sole director and owner of Waste Equipment. Cross is and was at all material times also the sole director and owner of Clean Valley.
6. At all material times as at 22 May 2006:
(a) Waste Equipment operated a business fabricating and selling waste collection bins and waste equipment in a workshop located at the premises ("the workshop").
(b) The workshop consisted of a building measuring 54.4 metres in length by 24 metres in width by 20 metres in height. Located at the southern end of the workshop were two large steel-plated waste collection bins. One of the bins was fully painted grey in colour (with the door at the rear of the bin painted white).
(c) The other large bin was partially painted along its entire length within the internal walls of the bin. The partially painted bin was 70 cubic metres in volume and measured 10.86 metres in length at the base (with the top of the bin extending and sloping out a further 1.6 metres at the front of the bin), 2.25 metres in width and 3 metres in height ("the large waste bin"). At the rear of the large waste bin was a steel door measuring 2.25 metres in width by 3 metres in height. On the right-hand side of the door's outer edge were four locking catches running parallel with the side of the large waste bin. The catches were comprised of steel bars, measuring 25 mm in diameter, which were bent to a rectangular shape and tack-welded into the side of the door frame. The door of the large waste bin was locked in a closed position by a rotating lever that engages the catches on the door of the large waste bin. At the time of the incident on 22 May 2006, the door was held closed in an alignment by "g" clamps.
(d) Waste Equipment employed approximately seven employees in the workshop, including:
(i) Emile Pacevski - a third year apprentice boilermaker (employed by Waste Equipment for about two years);
(ii) Michael Barry - a second-year apprentice boilermaker;
(iii) Mick Ari - a second-year apprentice;
(iv) Adam Chapman - a second-year apprentice:
(v) Joel Mennie - a first-year apprentice boilermaker;
(vi) Colin Sowerby - a labourer (employed by Waste Equipment for about three months); and
(vii) Timothy Hirst - a painter and labourer (employed by Waste Equipment for 12 years),
(e) Timothy Hirst ("Hirst") had a substantial degree of autonomy in the method of performing painting work in the workshop.
(f) Cross had responsibility for the day-to-day management of the businesses operated at the premises by Waste Equipment and Clean Valley.
(g) Mr Ian Harris ("Harris") was employed by Clean Valley as the foreman of the workshop who supervised the abovementioned employees of Waste Equipment.
(h) For a period of one to two years prior to the incident on 22 May 2006, Harris' attendance at the workshop had been highly irregular owing to a back injury that he had previously suffered.
THE PRIOR SYSTEM OF PAINTING WASTE COLLECTION BINS
7. Prior to the incident on 22 May 2006, the employees of Waste Equipment adopted the usual practice of painting waste collection bins in or in front of designated painting bays within the workshop.
8. Up until the incident on 22 May 2006, the hot work performed by Waste Equipment at the premises in connection with the construction of waste collection bins, including heat-producing and spark-producing welding, drop saw cutting, grinding, oxygen and acetylene cutting or other heating operations (the "hot work") usually took place at a distance of at least six metres away from any painting work that was conducted at the same time as the hot work. Smaller waste collection bins were painted within the painting bay area. However, the 70 cubic metre waste bins were painted outside the painting bay area because they did not totally fit within that area. At the time of the accident, the bin the subject of the accident was only the third or fourth bin of that size that Waste Equipment had manufactured. It has now manufactured about ten of that size.
9. Moreover, no partition of any kind separated the painting bay from the hot work being conducted with the workshop.
10. At all material times the acceptable Australian Standard required that a hot work permit be issued before performing any hot work (i.e. grinding, welding, thermal or oxygen cutting or heating and other related heat- producing or spark-producing operations) in an area in which flammable, combustible or explosive substances may be present, which included the identification and control of any such fire hazard within 15 metres from the hot work ("hot work permit"): section 3 of the Australian Standard - Safety in Welding and Allied Processes - Part 1: Fire Precautions (AS1674.1-1997).
11. The Occupational Health and Safety Regulation 2001 ("the Regulation"), cl 178, regulates spray painting outside the spray booth. Where it is impractical for the painting to be undertaken in the open air, cl 178 requires that the area be adequately ventilated and away from any ignition source.
12. The Regulation defines a confined space at cl 66. The large waste bin may be considered to be a confined space when the back door is closed, requiring the employer to ensure the concentration of any flammable contaminants in the atmosphere is below five per cent of its lower explosive limit and that a standby person is present outside.
13. Painting work on fabricated waste collection bins involved preparing the bins for the application of paint by initially brushing any debris and sometimes wiping down surfaces with enamel thinner to remove grease in order to promote the adhesion of the paint on the surfaces of the waste collection bins. For this purpose Waste Equipment used an industrial paint thinner known as "Ameron 445 Enamel Thinner". Waste Equipment also used a paint known as "Ameron Rustfighter 215 Lead Free". The Material Safety Data Sheets (the "MSDS") specify that vapours from the paint thinner and paint form an explosive mixture with air and should be kept away from ignition sources such as heat, naked flames and sparks.
14. The Regulation at cl 178(5) requires that personal protective equipment ("PPE") is worn while spray painting. The WorkCover Spray Painting Guide 2001 and the MSDS require that persons working with the aforesaid paint and enamel thinner wear chemical safety goggles or face shield, half face respirator with organic vapour cartridge, PVC or nitrate chemical handling gloves and PVC cover overalls. At the time of the incident on 22 May 2006 Hirst was wearing jeans, a long-sleeve shirt, as well as gloves, work boots, a respirator, glasses and a beanie. Although Hirst was wearing prescription glasses, Waste Equipment did provide access to safety glasses.
15. Waste Equipment had not provided its employees with the MSDS in respect of the paint and enamel thinner used in the workshop and had not informed, instructed or trained its employees in respect of safe distances between painting and hot work.
16. There was a fan extraction system in place to remove paint fumes from the spray booth situated on the back wall of the workshop. The manufacturer of it warrants it as being effective to a radius of six metres room the start of the pain bay area. However, it was not effective in extracting fumes from the large waste bin situated outside the spray booth.
17. Prior to 22 May 2006, Hirst had observed hot work involving the cut-off machine being performed close to the painting area resulting in sparks igniting paint or paint fumes on or around a waste collection bin. However, Cross had not seen and had not been alerted to such activity.
THE INCIDENT ON 22 MAY 2006
18. On 22 May 2006, the large waste bin was located outside the painting bay (27 metres from the front of the building and 5.8 metres from the western wall of the building at the premises) as it was too large to fit within that bay.
19. Before he left the workshop early on the morning of the incident (to replace a truck driver who had called in sick), Cross had conveyed to Harris that progressing the large waste bin towards completion was a high priority. Cross conveyed the importance of progressing work on the large waste bin because it was due for collection on 24 May 2006, two days after the day of the incident.
20. Prior to Harris leaving on the day of the incident, Hirst had instructions to sand and then paint the front half of the large waste bin and Pacevski had instructions to finish his fabrication work on the back door of the large waste bin (which involved fixing the latches to the back of the door). Pacevski began his work with the back door of the large waste bin open.
21. Cross was absent from the workshop on 22 May 2006 from no later than 7.30 am because he had to take over a truck-driving role in the absence of the usual driver who had called in sick on that day. Harris left the premises at about 1.15 pm due to his aforementioned back injury. When Harris left the workshop on the day of the incident, Harris did not contact Cross to notify him that he had left work on the day and Cross was not otherwise informed that Harris had left work on that day. The workshop employees continued their work in relation to the large waste bin in the absence of Cross and Harris.
22. At the time of the incident on 22 May 2006, Pacevski was the most senior employee working in the workshop. However, no one was formally in charge of the workshop at that time.
23. At approximately 2.20 pm on 22 May 2006:
(a) Pacevski was heating, cutting and tack-welding the catches on the door at the rear of the large waste bin using an oxyacetylene cutting device and an electric welder. The door of the large waste bin was shut with "g" clamps in order to maintain the correct alignment during the fitting process.
(b) Hirst was spray painting the internal walls at the rear of the large waste bin near the closed door on which Pacevski was working.
(c) No hot work permit had been issued prior to the commencement of Pacevski's work.
(d) There was a build-up of paint spray and fumes within the large bin.
(e) Pacevski could not see Hirst behind the door of the large waste bin.
(f) As Pacevski was oxy-acetylene cutting the top catch on the door, he noticed flames emerging about two feet over the top rim of the large waste bin. Pacevski could small paint fumes. He then ran up the ladder to the platform next to the door and saw Hirst standing at the door of the bin engulfed in flames that extended to about one foot from his body. Pacevski jumped into the bin and began patting down Hirst with his welding gloves on. Mr Barry arrived and turn a fire hose on Hirst while Hirst was screaming.
(g) Adjacent to the right rear corner of the large waste bin was an open-top 20-litre drum with the label "Ameron Coating Rustfighter 215" with the flammable liquid 3 red diamond sign containing about three or four litres of paint thinner, which was also on fire. The drum was hosed down and kicked outside the open door.
(h) Hirst was subsequently taken to hospital by ambulance.
24. As a result of the incident, Hirst suffered severe third degree burns to 90% plus of his body. He was taken initially to John Hunter Hospital and transferred by air ambulance to the Royal North Shore Hospital where he was admitted into intensive care. Hirst underwent a surgical operation to cut burnt skin on the front of his chest and abdomen to relieve pressure on the chest and organs and allow him to breathe. He was in an induced coma for 3.5 months. He was placed in intensive care at Royal North Shore Hospital for seven months and underwent multiple skin graft procedures, operations and extensive physiotherapy. He was subsequently hospitalised at Ryde Hospital Rehabilitation Centre from December 2006 to May 2007, and returned to Hunter Valley Private Hospital for a further 1.5 months. Hirst has extensive scarring covering the whole of his body from the top of his head to the dorsum of his feet and burn amputations of the thumbs and fingers of his left and right hands. His impairment has been assessed as 95%. Hirst has been unable to work since the incident.
CHANGES TO THE SYSTEM OF WORK AFTER THE INCIDENT
25. On 23 May 2006, Inspector Garry Sandall issued a Prohibition Notice to Waste Equipment to eliminate the risk of injury from carrying out spray painting in close proximity to welding, heating and oxy-acetylene cutting (No 150275). On 24 May 2006, Inspector Sandall issued three Improvement Notices to Waste Equipment.
26. After the incident on 22 May 2006, Waste Equipment instituted a system at the workshop whereby spray painting and hot work are performed during separate shifts, rather than in conjunction with each other.
PRIOR CONVICTIONS
27. Neither of the defendants have any prior convictions under the Occupational Health and Safety Act 2000.
CO-OPERATION WITH WORKCOVER
28. The prosecution acknowledges the co-operation of the defendants at all stage of this matter.
29. The following supporting documentation is annexed:
(a) Factual Inspection Report of Inspector Garry Sandall dated 13 July 2007.
(b) 1-23 colour photographs taken by Inspector Garry Sandall on 22 May 2006.
(c) Australian Standard - Safety in Welding and Allied Processes - Part 1: Fire Precautions (AS1674.1-1997).
(d) Material Safety Data Sheet for Ameron 445 Enamel Thinner.
(e) Material Safety Data Sheet for Rustfighter 215 Lead Free.
(f) WorkCover Spray Painting Guide 2001.
(g) Prior Conviction Certificates for Waste Equipment and John Bernard Cross.
4 The prosecution was represented by Mr D.W.M. Chin of counsel. The prosecution tendered a bundle of documents, including an agreed statement of facts, factual inspection report, photographs, Australian Standard No 1674.1-1997- Safety in Welding and Allied Processes, a safety data sheet for 445 Enamel Thinner, Information regarding Rustfighter 215, a spray painting guide and the Prior Convictions Records for both defendants.
5 The defendants were represented by Mr S.J. Rushton SC and Mr J.S. McLeod of counsel. Reliance was placed upon an affidavit of Mr John Cross sworn 24 April 2009, the net profit figures for Clean Valley Group (comprising Waste Equipment Pty Limited and Veetol Helicopters Pty Limited) and profit and loss statement for Veetol Helicopters Pty Limited and a bundle of statements and references in support of Mr Cross.