Objective seriousness of offences
33The charges in these matters allege that the defendant failed to ensure against the risk of personnel, in particular Mr Murrell and Mr Crawford, being struck, trapped and/or crushed by falling cases of aluminium product. It was alleged that the defendant's failures were: a failure to ensure that the plant, namely, the "bulk storage racks" were safe; that the defendant failed to provide and maintain a safe system of work at the Mayfield site in relation to the stacking, rigging, lifting and movement of "cases" of aluminium products into and/or out of and/or within the subject bulk storage racks; that the defendant failed to adequately address the risk associated with the storage of "cases" of aluminium product in the bulk storage racks at Mayfield, including the risk associated with a collapse of "cases" of aluminium product within the confines of those racks; and that the defendant failed to provide its employees, in particular, Mr Murrell and Mr Crawford with such information and/or training as was necessary to ensure the health and safety of personnel.
34The bulk storage racks were apparently installed following an incident in 1996 when a stack of unrestrained "cases" of aluminium extrusions at the defendant's Smithfield warehouse collapsed, striking and fatally injuring an employee of the defendant, Darren Gascoigne, whilst he was in the course of picking and packing stock in proximity to the subject stack of cases. As a consequence of this incident the defendant was prosecuted under the Occupational Health and Safety Act 1983 for contravention of s 15(1). The defendant incurred a penalty of $50,000 ( WorkCover Authority of NSW (Insp Ch'ng) v Ullrich Aluminium Pty Ltd t/as Ullrich Noyes Metals [1998] NSWIRComm 668. Kavanagh J described what occurred at [4] of her Honour's judgment:
[T]he deceased worker was in the process of preparing an order and placing items on a trolley. This activity took place approximately 1.5 metres from a stack of crates containing aluminium parts which were placed in two rows against the western wall of the factory. The back row of the aluminium crates stacked against the wall was approximately 2.75 metres high and the front row was stacked 1.5 metres high. Each crate contained aluminium extrusions of varying shapes and sizes. Each crate varied in weight from between 100 to 300 kilograms and was approximately 5 metres to 7.5 metres in length. The deceased had placed the trolley near the said two rows of stacked crates, when a crate became dislodged. According to Mr Noble, when he saw the stack start to fall, he called out to the deceased worker "Get out of the way quick". However, before the deceased could move out of the way, two of the crates fell against the trolley knocking both the deceased and the trolley over. According to Mr Noble the stack which fell had been standing for about a year. Over that period further crates had been added to the stack as items were used. The last time that new stock had been placed on the said rows of crates was approximately one week prior to the accident. The new stock was placed on existing stacks with the use of a forklift.
35The bulk storage racks, described earlier, could accommodate five rows of cases across the base and then stacked to the height of the end bollards that is, 2.6 metres high. In the process of selecting certain cases from the rack known as WB03 Mr Murrell and Mr Crawford used a pendant controlled electric overhead travelling "Demag" crane with fibre slings to move other cases out of the way. As it was stated in the Agreed Facts:
Mr Murrell and Mr Crawford moved pallets from stacks in the middle of WBO3 and placed those pallets onto other, adjacent, stacks within the same rack. In the immediate aftermath of the incident, in an attempt to free Mr Murrell from the collapsed cases members of the Warehouse staff moved cases within WB03.
36Mr Murrell then entered about two metres into the gap that had been created in WB03 between the stacks to retrieve a sling attached to the crane, as that sling was apparently hanging from the crane hook, in the middle of the cases, about halfway into WB03. Mr Crawford described the cases as "dodgy", "unstable, "a bit unstable" and "didn't look safe". One of the cases of aluminium product that toppled over onto Mr Murrell hit him in the chest and chin area, pinning him in a vertical position against the western-most stack. Approximately a further eight to ten cases pinned down Mr Murrell.
37It seems to me there is little difference in terms of risk between stacks of cases up against a wall and a stack up against vertical bollards or stanchions if the stack of cases is unstable and capable of falling on a person in the vicinity. The defendant knew from what occurred in 1996 that a person could be killed if an unstable stack fell on them. Even though the cases were subsequently stacked in bulk storage racks that did not eliminate the risk as the death of Mr Murrell demonstrated.
38A properly conducted risk assessment, indeed, a brief consideration with a view to eliminating risk, would have revealed that storage in a rack of the type represented by WB03 would not eliminate the risk of a stack of cases falling on personnel. The defendant had an obligation following the 1996 incident to do what was reasonably practicable to eliminate the risk. It did not do so. The fact that the bulk storage racks may have represented some sort of "industry standard" provides no defence in circumstances where the employer has an absolute duty to ensure safety.
39Prior to the incident, even apart from its tragic experience in 1996, the defendant was aware that there had been collapses of cases of product within the bulk storage racks at the Warehouse, albeit these prior incidents did not result in any injury. Mr Wareham in his memo of 6 October 2006 had warned of the danger of collapse and recommended certain action be taken against that possibility. This is significant: it was not a question of whether it was reasonably foreseeable that persons might be placed at risk of falling cases of product. If it had been the defendant's culpability would be greater than it otherwise would be. But in this case the defendant knew precisely of the risk, having experienced the death of an employee in 1996 arising from the very same risk that is the subject of the present charges.
40It was at all material times clearly reasonably practicable to provide bulk storage racks for the storage of cases of aluminium product which incorporated vertical bollards and/or such other means of support and/or segregation between stacks of cases within each of the bulk storage racks designed to prevent the collapse of product, within each bulk storage rack, of the cases of aluminium product. By July 2007 new racking had been introduced for the bulk storage of cases of aluminium product at the defendant's Adelaide warehouse that utilised vertical bollards or stanchions between individual stacks of cases to maintain stability and prevent stacks from collapsing. Why it took over ten years for this new racking system to make an appearance in the defendant's warehousing operations was not adequately explained. But I note that the new racking system was installed at the Warehouse within a relatively short time of the incident on 3 September 2007.
41The system of work utilised by the defendant in relation to stacking, rigging, lifting and movement of cases of aluminium products into and/or out of and/or within the subject bulk storage racks was unsafe. From time to time the slings from the crane came to rest within the confines of the racks.
42The defendant relied upon informal and undocumented "on the job" training with respect to the manner in which the bulk storage of cases of aluminium extrusions was performed within the Warehouse. The informal work practices that were in place prior to the incident included a direction that workers were not to enter within the confines of the bulk storage racks.
43Prior to the incident, although provided with informal, oral warnings from the defendant not to walk between stacks of cases in the racks, from time to time workers entered the racks, between rows of cases, to retrieve slings that came to rest within the confines of a bulk storage rack or, alternatively, individual workers developed ad hoc responses such as leaning into the racks from the side, or using a nail attached to a long piece of wood to hook the sling and pull it out to the edge of the rack.
44Prior to the incident, Warehouse management was aware that the slings used in conjunction with the overhead travelling cranes to move the cases into, out of and within the bulk storage racks, from time to time came to rest within the racks and that, from time to time, workers entered into the racks to recover the slings.
45Prior to the incident, the defendant took no steps to put in place any formal controls on entering or leaning into the racks and to provide a safe means of retrieving the slings if and when they came to rest within the confines of a bulk storage rack. Subsequent to the incident the defendant developed a documented system of work regarding the task of removing stock from the racks. The documented work system addressed the risk of slings coming to rest within the confines of a bulk storage rack and included the provision of a hook to enable staff to recover slings without having to enter within the confines of the bulk storage racks.
46The prosecutor conceded that the defendant warned its employees not to enter the bulk storage racks and that Mr Murrell was aware of the risk of doing so. Indeed, Mr Murrell had warned Mr Crawford and others of the risk and had warned Mr Crawford and others not to enter into the racks. However, the prosecutor submitted it is trite law that the Act is "designed to protect against human errors including inadvertence, inattention, haste and even foolish disregard of personal safety as well as the foreseeable technical risks in industry": per Bauer J in WorkCover Authority of New South Wales (Inspector Twynam-Perkins) v Maine Lighting Pty Ltd (1995) 100 IR 248 at 257. See also WorkCover Authority of New South Wales (Inspector Mulder) v Arbor Products International (Australia) Pty Ltd [2001] NSWIRComm 50; (2001) 105 IR 81 at 99.
47It was further submitted for the prosecutor:
Further, in light of the failure of the defendant to devise, provide and enforce the use of either a sling designed so as to ensure that the sling did not come to rest within the confines of a rack, or some safe means of recovering a sling when it did come to rest within the confines of a rack, it is submitted that the fact Mr Murrell stepped into the rack to recover a sling from where it had come to rest is not a matter which should be seen by the Court, with respect, to mitigate to any significant degree the culpability of the defendant.
Rather, the prosecutor submits, with respect, that in the absence of any meaningful response by the defendant to the fact that its slings came to rest, from time to time, within the confines of the defendant's racks, should be seen to [sic] further evidence [sic] the lack of a diligent and proactive response to safety.
It is submitted that, without more, the general, informal warning(s) given to workers in the face of a known and serious risk to safety - even one that was known to the worker - was in all the circumstances of this case an entirely inadequate and unsatisfactory response. See, for example: Gardner Bros Pty v McAuliffe (1986) 15 IR 477 at 479
48The fact that the defendant knew of the risk of entering a rack and had warned personnel not to enter into the racks must be a mitigating consideration. In that respect, the error or negligence of an employee may reflect on the degree of culpability of the employer for the purposes of sentencing: Riley v Australian Grader Hire Pty Ltd [2001] NSWIRComm 31; (2001) 103 IR 143 at [15].
49However, I agree with the prosecutor that the fact the defendant had issued an informal warning to employees and by that means Mr Murrell was aware of the risk, an informal warning was a most inadequate means of ensuring employees and others did not enter the racks. The defendant knew that slings did come to rest from time to time within the racks and it knew that personnel were entering the racks to retrieve the slings. In circumstances where the defendant knew death could result from exposure to the risk of falling cases of product it was imperative that the defendant had in place a system of work that was designed to achieve all that was reasonably practicable to ensure personnel did not enter the racks. An informal warning fell well short of that requirement.
50At the very least the defendant should have provided personnel with a written work method statement, or safe operating procedure, with respect to the rigging, lifting and/or movement of "cases" of aluminium product into and/or out of and/or within the bulk storage racks at the Mayfield site that:
(a) described how the work was to be carried out, step by step;
(b) identified the work activities assessed as having risks;
(c) identified the subject safety risks; and
(d) described the control measures that were to be applied to the subject work activities to control the identified risks, including but not limited to the control measures to be applied for the purpose of controlling and/or minimising the risk of workers being struck by and/or crushed by "cases" of aluminium product whilst the employees were engaged in the tasks of rigging, lifting and moving product in to and/or out of and/or within the bulk storage racks at the Mayfield site.
51In relation to information and training some workers in the Warehouse who used the overhead cranes in the course of their employment, including Mr Murrell, did not receive formal, documented training in the use of the overhead cranes; nor were there any formal systems of work in place to ensure that Mr Murrell, and Mr Crawford were competent in the use of the overhead cranes. There was no requirement for operators of the overhead crane at the Warehouse to be assessed and certified under the Occupational Health and Safety Regulation 2001. Prior to the incident, the defendant did not audit the task of operating the overhead crane.
52The defendant should have provided, but failed to provide, Mr Murrell with adequate training and information with respect to the safe use and operation of the subject crane to lift, move and/or stack cases of aluminium product. It is noted that after the incident, the defendant introduced formal documented, skills-based competency training for all workers required to use the overhead cranes in the course of their employment. This training is provided by an appropriately qualified third party trainer and upon successful completion of the training, the third party trainer undertakes a competency based assessment and certification of the subject trainees. It is also noted that subsequent to the incident, the defendant developed a documented procedure for the task of removing stock from racks.
53The defendant failed to carry out any formal risk assessment relating to the use of the bulk racking system at the Warehouse. In my opinion, this contributed significantly to the presence of the risk. A formal risk assessment would have revealed the obvious danger of unstable stacks collapsing and would have revealed that from time to time slings came to rest inside the racks. It would have been a small step in the assessment process to work out the possibility of workers going inside the rack to recover the sling and place themselves at risk, with the potential result being another death.