[11] At about 11.30 am on 29 March 2003 Mr Hill was operating the crane in the process of drawing one of the largest size panels of the curtain wall in to place. This panel weighed approximately 480 kg and exceeded the maximum weight that the crane could safely lift. While attempting to pull the crane with its suspended curtain wall panel back, the crane suddenly and without warning lifted at the back and began to fall over the edge of the floor breaking through a timber edge stop. Due to a deficiency in Skyrise's system of work, Mr Hill was unattached to the static line at this point. Mr Hill instinctively attempted to stop the crane lifting and was taken over the edge of the building by the crane. He fell 4 floors, approximately 15 metres to the ground.
[12] Mr Hill was on life support for 4 days. His injuries were severe and included: a jaw fractured in several places, fractures to his left and right arms and punctured lungs. Mr Hill received a tracheotomy and had a pin installed in his left hip.
Weight of the Curtain Wall Panels
[13] Sassall assembled the curtain wall panel frames at its factory in Wollongong. Sassall then sent the frames to Fabricated Glazing Pty Ltd located in Silverwater in the state of New South Wales. Between 22 January 2003 and 5 April 2003 Fabricated Glazing Pty Ltd had a works order with Sassall to glaze, palletize and then deliver the completed curtain wall panels to the site ready for installation by Skyrise. Sassall assembled 4 or 5 different size panels for this project. The size of the panels that were required for each building façade varied. There were at least 4 different sized panels required for the eastern façade of Building B. These panels included the starter panel or "full size panels" which measured 4.9 x 2.4m which were installed on Level 2. The full size panel extends from the top of the concrete floor of Level 3 above, to approximately 1.17 metres below the concrete floor of Level 2. The purpose of the 1.17 metre vertical extension was to enable the horizontal soffit, or ceiling panels, to be installed in the underside of the building. The "half size panels" measured 4.9 x 1.2 metres and were installed directly in front of the concrete columns on Level 2. The curtain wall panels to be installed on Levels 3 and 4 measured 3.7 x 2.4 metres and 3.7 x 1.2 metres, the latter being installed in front of the columns.
[14] The weight of the panels varied with their size. The panels for Levels 3 and 4 measuring 3.7 m x 2.4 m weighed approximately 387 kg. The full size panels measuring 4.9 x 2.4 weighed approximately 480 kg.
[15] On or before the day of the incident, there is no evidence that the delivery dockets attached to the crate identified the weight of the panels within. None of the curtain wall panels at the site had been labelled with their respective weights, for example by stickers attached to the glass.
[16] At the time of the incident Skyrise employees were installing the full size panel measuring 4.9 x 2.4 metres and weighing approximately 480 kg.
[17] Approximately 1 to 2 weeks before the incident, Skyrise commenced the installation of panels in the northern façade of Building B. Mr Vullo did not know of any system in place for determining the weight of the panels. Mr Vullo asked John Murphy, Sassall's Project Manager for the Curtain Wall, for the weights of the northern façade panels but he did not receive an answer. Mr Vullo saw drawings that recorded the panels' dimensions but not their weights. Based on his experience and from the dimensions of the panels he observed on the drawings, he considered the weight of the northern façade panels were within the capacity of Skyrise's lifting equipment.
[18] While installing the northern façade, some of the panels for the eastern façade were delivered to the site. Some of these panels were approximately double the size of the northern façade panels. Approximately 1 week before Skyrise finished the installation of the northern façade, Mr Vullo asked Mr Murphy for the weights of the eastern facade panels. Mr Murphy responded, " I'm waiting for it. I've asked Sassall in Wollongong ." Mr Vullo told Mr Murphy, " there's no way I'll lift them unless I know their weights ."
[19] John Sassall, Managing Director of Sassall did not know the weights of the panels. On or about 20 March 2003 he directed Sassall employee, Mike DeHossen, to prepare a weight estimate. At 11.28am on 20 March 2003 Mr DeHossen emailed Mr Sassall the weight estimate for the 3.7 x 2.4 metre panel. The weight was recorded as 387.2812 kg.
[20] Mr Sassall then telephoned Mr Murphy with this information and said that the weight was 380 kg. Mr Sassall then forwarded Mr DeHossen's email to Mr Murphy at 3.00pm the same day to confirm the weight estimate.
[21] On or about 28 March 2003 Mr Murphy told Mr Vullo that the eastern façade panels weighed 380 kg.
[22] In fact Mr Murphy, relying on the 20 March 2003 email from Mr Sassall and Mr DeHossen, had informed Mr Vullo of the weight of the 3.7 x 2.4 panels which were to be installed on the eastern façade of Levels 3 and 4, and not the full size panels measuring 4.9 x 2.4 which were the first to be installed, and which in fact weighed approximately 480kg.
[23] Skyrise did not check or confirm the weight before commencing work.
Lifting System
[24] Skyrise had a '3-floor configuration' system for lifting the panels and each window fixer had a different job. Mr Hill was on Level 4 to set up, position and operate the crane. Mr Hill would manually position the floor crane central to fixing brackets, (which had been pre-cast into the concrete floor slab). He did this by measurement and scoring a line on the concrete slab. The crane was raised off its four feet by use of the hydraulic pallet jack lifter system and pushed into position. The first position was to place the jib of the crane out over the edge of the floor a distance of approx 1.2 metres; this was achieved when the front feet of the crane touched a timber edge stop. The crane was then lowered back onto its feet.
[25] Relevantly, Step 6 of Skyrise's site specific Safe Work Method Statement dated 22 October 2002 for "Crane Set Up and Use for Panel Installation" identified the risk of the crane rolling off the building. The control measure to eliminate that "Class 1" risk, being potential to cause death or permanent injury, was "Placement of steel wheel chock [attached to static safety line vide lanyard] against previously installed bracket." Mr Vullo states the reason why the timber beam was placed at the edge of the building, contrary to the control measure in Step 6 of his SWMS, was because it was, " easier for the guys to move into place because it was not as heavy as the steel ."
[26] When the crane was in position, Mr Hill lowered the pendant control down to Mr Church on Level 3. Mr Church used the pendant control to lower the hook of the hoist to working height to Mr MacCue on Level 2 where the panels were stored. Mr MacCue attached the lifting chains and hooked up the panel. Mr MacCue then pushed out the panel to the edge of the building using 2 trolleys. Mr Church then raised the hook, lifting the front end of the panel off the front trolley, which Mr MacCue would pull out of the way. The panel was then raised into the vertical position, hanging approximately half the width (1.2 metres) of the panel away from the edge of the building. The panel was then spun so that it was the right way around. Mr Church then gave a command to Mr Hill using a two way radio to pull the crane back towards the centre of the building so that the panel was close to the brackets. At this stage the crane's feet were lifted off the floor with aid of the hydraulics. When the panel was pulled back into position, the crane was then lowered back onto its feet. Mr Church then lowered the panel to align it with the bracket and secured it. They then levelled the other end of the panel, clamped, drilled and fixed it off. The slings were then unhooked.
[27] Mr Vullo was also working in the area and was in control of overall supervision.
[28] Skyrise owned the crane used to install the curtain wall panels. It was a purpose built device consisting of an electric powered chain hoist attached to a metal frame with a fixed jib measuring approximately 3 metres in length ("the crane"). The crane was in turn welded to a 1.5 tonne pallet jack lifter, to make the crane mobile. This was so that the crane operator could move the crane backwards and forwards to manoeuvre the panel. With this system the crane operator could move the crane forward to the edge of the building, extending the jib over the edge to allow sufficient room to swing the hoisted panel around when parallel with the required level, and then backwards to the centre of the building to bring the panel flush with the side of the building and aligned with the brackets and secured.
[29] The lifting frame had been tested by All Safe Lifting Equipment on 20 December 2002 and had been certified with a "Working Load Limit" (WLL) of 400 kg. The lifting frame had marked on it, "WLL 400kg". The WLL (also known as the Safe Working Load (SWL)) is the total amount of weight suspended at the end of the jib (including the panel and hoist), which may be lifted safely. The jib of the crane had a WLL of 400 kg or 250 kg depending on the setting. On the day of the incident this was set at the 400 kg capacity.
[30] The electric powered chain hoist had also been tested and certified at a testing centre on 5 February 2003 with a "SWL" of 500kg. Before the incident, Mr Vullo tested the hoist himself to confirm that it could lift 500 kg.
[31] The hoist and tackle weighed approximately 32 kg and is part of the load on the jib. Therefore the most a curtain panel could weigh in order for the crane to lift it safely, was approximately 368 kg, being 400 minus 32.
[32] The curtain wall panel being lifted at the time of the accident was the full size panel, which measured 4.9 m x 2.4 m and weighed approximately 480 kg, not 380kg as Sassall had advised. The jib was therefore being used to lift an additional 112 kg, approximately 28% over its WLL of 400 kg.
[33] The curtain wall panels measuring 3.7 m x 2.4 m weighed approximately 387 kg. The jib would be required to lift approximately 419 kg, (including the hoist and tackle), therefore an additional 19 kg, approximately 5% over its WLL.
[34] Mr Vullo understood that the WLL of his crane was 400 kg and that hoist and tackle weighed approximately 30 kg. The All Safe report for the crane stated that the Proof Load of the crane was 500 kg. The purpose of a Proof Load is to allow for a margin of error or other factors which may affect the stability of the crane. All Safe had tested the proof load to a factor of 1.25, or a margin of 25% above the WLL.
[35] Skyrise had not previously installed panels as large as the full size panels for the eastern façade. Mr Vullo packed the crane feet with steel chocks where the floor was uneven to stop the crane from rocking. Before commencing work on the eastern façade, at 7am on 28 March 2003 Mr Vullo held an informal meeting with his employees. At this meeting Mr Vullo told the group, " The weight of these panels is getting up to the maximum limit so be extra careful ". He also told Mr Hill to take the lifting slowly.
[36] 18 full size panels were to be installed on the eastern façade of Building B. The incident occurred at approximately 11.30am, with Skyrise having already installed all but 2 of the full size panels.
[37] There is no evidence of any structural or mechanical failure of the lifting equipment other than the overweight load it was lifting, that is, the full size panel weighing approximately 480kg. As Mr Hill was pulling the crane back into the centre of the building for the panel to be fixed into the brackets, he saw the wheels of the crane lift up. The over-weighted crane was dragged to the edge of the building and cracked the wooden timber stop at the edge of the floor. Mr Hill states, " I attempted to stop it ." He fell with the crane, 15 metres over the edge of Level 4 of the building to the ground. Mr Hill was wearing a 2 metre lanyard but was not attached to the static line when he fell.
Static Line and Safety Fence
[38] The reason why Mr Hill was not attached to the static line was because he had to unclip his lanyard from the line in order to pull the crane back far enough into the building. The 2 metre lanyard he was wearing did not enable him to reach far back enough. Mr Hill should have had an inertia reel system which would have allowed him full mobility to move the crane while still attached to the static line.
[39] Skyrise's safety system relevantly comprised a 1 metre high wire mesh safety fence approximately 2.15 m from the edge of the floor. Skyrise installed a static line running through the centre of the concrete columns, approximately 1.15 metres from the edge of the building, the line being approximately 2 metres high above the floor.
[40] Step 4 of the SWMS dated 22 October 2002 identified the Class 1 risk of falling off the edge of the building. Step 4 required the workers to "put harness on and attach oneself to the static safety line". The control measure stated, "Worker to be inside the safety fence and have both feet on the ground whilst reaching over to attach the lanyard to safety line. Once attached the worker is to open the safety fence, walk through and close the fence behind him/her."
[41] Given the proximity of the fence to the static line, it was impossible for the worker to comply with Step 4, that is, to stand behind the closed fence before attaching to the static line. The workers therefore opened the gate to the fence before attaching to the line, during which time they were within a Class 1 danger zone.
[42] The lanyard and harness worn by the worker was required to be attached to the static line when operating in the area between the safety fence and the edge of the floor, a distance of approximately 2.15 metres. A 2 metre long lanyard attached to the static line 1.15 metres from the edge would allow a worker to go to the edge of the floor and to go to a distance of approximately 1 metre inside the safety fence.
[43] There was a gate or opening in the safety fence at the point at which Mr Hill was to pull the crane backwards into the centre of the building to draw the hoisted panel into position. Mr Hill would pull the crane back towards the centre of the floor and through the gate of the safety fence to a distance of approximately 4.1 metres (which includes the length of the crane) from the edge of the floor. However, the safety system only enabled the worker attached to the safety line to come in about 3.15 metres from the edge of the floor (safety line in 1.15 m + 2 m lanyard). Therefore the 2-metre lanyard while attached to the static line was not long enough to enable the crane operator to pull the crane far back enough to lift the curtain wall panel into position.
[44] Mr Hill could only pull the crane back far enough through the open safety fence, was by unclipping his lanyard from the static line.
[45] Skyrise's risk assessment directly considered this point. Mr Vullo states that it was only after the accident that he realised that Step 4 of Skyrise's SWMS was deficient. He stated that, " when we moved away from that line it was relatively safe because we were far enough away from the edge not to be hooked up. We thought that the because the crane, which was 3 metres inside the edge, was in front of the worker, that they would be safe…"
[46] Five, 5 metre retractable/inertia reel lanyards were available on Level 3 with the panel crew at the time of the incident. For the reason Mr Vullo gives as outlined in paragraph 45, and that the workers said that they found the inertia reel system uncomfortable to wear, Skyrise did not enforce a system for its workers to wear the retractable / inertia reel lanyard.
[47] While operating the crane under this system of work, Mr Hill was at all material times in a class 1 danger zone.
Action since the incident
[48] Since the incident, Skyrise have replaced the manual floor crane system with a crawler crane, which is operated by a licensed crane operator with a certified Dogman giving the directions. A set of scales is rigged up to weigh each type of panel to be installed and the panel crew is trained to check the weight themselves. The weight is then documented and recorded on a sticker affixed to the panel. Skyrise also ensures that retractable lanyards are used when the safety fences are down.
Previous History