[2005] NSWIRComm447
1 Two charges are brought by Inspector John Sharpin of the WorkCover Authority of NSW, the first against Boka Aluminium Windows Pty Ltd under s8(2) of the Occupational Health and Safety Act 2000 (the Act) and the second charge against Marko Franovic under s26(1) of the Act.
2 Both defendants, Boka Aluminium Windows Pty Ltd and Mr Franovic, originally raised a defence of not guilty. However, at the close of the prosecution's case, it was agreed between the parties that Boka Aluminium Windows Pty Limited (the defendant) would seek leave to enter a plea of guilty to an Amended Application for Order in matter No IRC2519 of 2003. On application, the prosecution against Mr Marko Franovic was stood over.
3 In matter No IRC2519 of 2003, it is alleged the defendant breached s8(2) of the Act in that it failed to:
Ensure that persons not in its employment, and in particular, James Gowans, Joseph Romeo, Michael Mende and Mario Musumeci, were not exposed to risks to their health or safety arising from the conduct of its undertaking while at its place of work contrary to section 8(2) of the Occupational Health and Safety Act 2000.
The particulars of the charge as relied upon in the amended Application for Order are as follows:
a) At all material times the defendant was an employer.
b) At all material times the defendant engaged contractors for the building of a factory at 19 Ash Road, Prestons, in the State of New South Wales ("the site").
c) At all material times the defendant sub-contracted A Team Concrete (Aust) Pty Ltd to perform concreting work at the site.
d) At all material times A Team Concrete (Aust) Pty Ltd used a concrete boom pump manufactured by Powercrete Australia Pty Ltd, model number T100-177-60 ("the pump"), attached to a vehicle with registration number QSV - 987 for the concreting work it performed at the site.
e) The defendant failed to ensure that proper maintenance and inspections had been carried out on the pump prior to its use by persons at the site.
f) The defendant failed to ensure that persons not in its employment did not work under or close to the boom of the pump.
4 After the plea of guilty was entered, the prosecutor filed, along with the evidence already tendered before the court, a Statement of Facts. A challenge was raised to paragraph 25 of the Statement of Facts which paragraph, after the Court heard argument, was deleted. Accordingly, the Statement of Facts now relevantly reads:
3. At all material times the defendant engaged contractors for the building of a factory at 19 Ash Road, Prestons, in the State of New South Wales ("the site").
4. At all material times Boka Investments Pty Ltd owned the site.
5. At all material times the defendant sub-contracted A Team Concrete (Aust) Pty Ltd to perform concreting work at the site.
6. At all material times A Team Concrete (Aust) Pty Ltd contracted with Concrete Civil Pty Ltd for the provision of labour hire workers at the site including Joseph Romeo.
7. At all material times A Team Concrete (Aust) Pty Ltd employed a number of personnel at the site, including:
a) James Gowans, 20 years of age, as a general labourer.
b) Michael Mende, 31 years of age, as a concrete pump operator.
c) Mario Musumeci, 34 years of age, as a leading hand.
8. At all material times A Team Concrete (Aust) Pty Ltd used a concrete boom pump reconditioned by Powercrete Australia Pty Ltd, model number T100-177-60 ("the pump"), attached to a vehicle with registration number QSV - 987 for the concreting work it performed at the site.
9. On 11 March 2002 at approximately 7.15am, James Gowans, Joseph Romeo, Michael Mende, Mario Musumeci and Salvatore Cardile were performing concreting work at the site and the pump was pouring the first concrete load of ready mixed concrete into the centre of a floor slab at the site. Mr Cardile was a director of A Team Concrete (Aust) Pty Ltd.
10. Mr Gowans was working underneath the boom of the pump and Mr Romeo was working close to the boom of the pump when the boom connection failed at the turret of the pump unit and fell to the ground striking them both.
11. A backhoe on site was used to sling and lift the boom off Mr Gowans and Mr Romeo who were then taken by ambulance to Liverpool Hospital. Mr Gowans did not recover from the head injuries he suffered and died at approximately 7.30pm on the same day. Mr Romeo suffered fractures to his neck, shoulder and ribs and remained in hospital for one week.
12. At the time of the accident, the pump was set up on one side of the floor slab of the building under construction at the site and the boom was extended to the middle of the slab. A laser guided screed was used to perform the finishing work for the concrete surface. The boom was 19 metres long, constructed of steel and weighed approximately 1.5 tonnes. A rubber hose was attached to the third section of the boom and measured approximately 3 metres in length. The pump was attached to a white UD Truck, with registration plate QSV-987. The truck had four outriggers attached.
13. Mr Cardile was the supervisor of the concrete pour at the site. At the time of the accident, Mr Gowans was holding the rubber concrete drop hose attached to the boom of the pump. Prior to the accident, Mr Cardile was holding the hose and then directed Mr Gowans to hold the hose whilst he went to talk to the agitator driver about the concrete being too wet. Mr Romeo was using the concrete vibrator close to the boom and Mr Musumeci was watching the laser guided screed work.
14. The concrete boom pump was being operated by Mr Mende, an employee of A Team Concrete (Aust) Pty Ltd, with 10 years of experience in operating such pumps. Mr Mende was operating the concrete boom pump from a cable remote unit and was adjacent to the passenger side front outrigger which enabled a full view of the outboard end of the boom.
15. Marko Franovic, a director of the defendant, was present at the site on 11 March 2002 and observed persons working under the boom of the pump.
16. On 11 March 2002 Wayne James attended the site and undertook a factual inspection, a copy of which is annexed and marked "A". Inspector James also took 17 photographs at the site, copies of which are annexed and marked "B".
17. On 11 March 2002 Inspector Sharpin issued a notice to A Team Concrete Pty Ltd under section 70 of the Occupational Health and Safety Act 2000 for the pump to be taken to the WorkCover TestSafe facility in Londonderry for testing purposes.
18. Various tests and calculations were performed on the pump and boom by David Ng, Head of the Mechanical Unit, TestSafe Australia, Reza Eftekhar, engineer employed by WorkCover and Michael Cheng, engineer employed by Workcover. The tests were to address the boom metallurgical material composition, the rotational force movements and other static and induced stress forces on the boom. Rexroth Pty Ltd conducted tests on the hydraulic components of the boom.
19. An engineering report was prepared by Michael Cheng on 30 April 2002 which concluded that the boom detached from the turret of the pump unit at the main trunnion connection. This was caused by the two trunnion retaining rings fracturing. One ring had approximately 45% fatigue fracture areas and the other ring approximately 20% fatigue fracture areas which had been growing for a considerable time prior to the accident. The ring with the 45% fracture front broke first causing an immediate overload failure to the other ring and the collapse of the concrete boom assembly. Mr Cheng also concluded that a proper inspection and maintenance program should have been able to detect the cracks before they grew to a critical size. A copy of photograph number A7 from the report is annexed and marked "C".
20. Reza Eftekhar, senior engineer of WorkCover, also prepared a metallurgical engineering investigation report dated 28 April 2002. Mr Eftekhar also concluded that the immediate cause of the accident was the two fatigue fractures in the trunnion retainer rings. Mr Eftekhar believed the fractures had been in place for a long time and could have been detected via inspection by a competent person. The reason for the fractures developing was found to be the inappropriate mechanical properties of the rings due to an error in material selection. This inappropriate material selected was brittle and pre-disposed to the initiation of fractures. Copies of Figure 1 and Figures 4 to 9 from the report are annexed and marked "D".
21. Opinion is divided as to how the presence of the cracks that caused the failure of the trunnion rings could have been detected. Mr Leonard, Managing Director of Concrete Pump Parts Pty Limited, believes that a magnetic particle crack test or dye penetrant crack test undertaken by an expert is required to identify the presence of such a crack.
22. Following the accident, documents were obtained from the pump, which included the WorkCover NSW Code of Practice for Pumping Concrete and a safety manual issued by Schwing America, a concrete boom manufacturer.
23. The safety manual from Schwing America includes directions to:
a) Avoid standing directly under or over the boom or the system pipeline.
b) Have the boom inspected by a certified boom inspector on a regular basis.
c) Ensure proper and timely maintenance of the boom.
d) Inspect the boom for cracks and how to test for cracks in the boom.
A copy of the safety manual is annexed and marked "E".
25. . . .
26. A log book was not kept and inspections were not carried out on the pump in accordance with AS 2550.15 - 1994 "Cranes - Safe Use - Concrete placing equipment" and the Code of Practice "Pumping Concrete".
27. The Australian Standard, AS 2550.15 details the maintenance inspection and assessment requirements for concrete placing equipment. The standard requires non-destructive inspection of all critical areas for evidence of cracking to be performed on an annual basis. A copy of the Australian Standard is annexed and marked "F".
28. The Code of Practice for pumping concrete requires that all concrete placing booms and pumps be inspected once a year by a competent person and the results entered into a log book. A copy of the Code of Practice is annexed and marked "G".
29. On 14 April 1997 Scahill & McCloskey Consulting Engineers provided by letter a boom inspection certification. The certification provided that the boom satisfied the requirements of AS 1418 -15(1994), the Australian Standard for cranes and concrete placing equipment and if the boom was regularly maintained it would continue to operate satisfactorily.
30. The defendant's safety management plan required that an inspection and maintenance history for items of plant be provided prior to the commencement of use of the plant on the site. The defendant did not comply with this requirement in relation to the pump.
31. The defendant was provided with a job safety analysis and work method statement from A Team Concrete (Aust) Pty Ltd for the work to be performed at the site. The job safety analysis and the work method statement did not require that the workers performing concreting work avoid working under or close to the boom of the pump.
5 Mr D.B. O'Neil, of counsel, appeared for the prosecution. Reliance was placed by the prosecution on the Statement of Facts drawn from the primary documents already before the court.
6 Mr M.K. Scott, of counsel, appeared for the defendant. Mr Scott relied upon an affidavit from Mr Franovic, Director of Boka Aluminium. Mr Scott also tendered, on behalf of the defendant, a video and various documents which revealed the company's safety policy.