Date of incident: May 2021
Notice of incident number: 22021170630006
Employers: Rebar manufacturer

Incident summary
Workers were moving a load of heavy-gauge rebar from its storage location at a workyard to the fabrication area. The load was suspended from a telehandler. The telehandler operator was manoeuvring the load of rebar into position while a worker underneath the rebar guided the suspended load by hand. The telehandler suddenly failed, and the load of rebar fell, striking and injuring the worker.

Investigation conclusions

Cause

• Telehandler was being operated over its rated capacity. The operator was using a telehandler to carry the load of heavy-gauge rebar, while the worker climbed onto some racking under a gantry crane to help guide the suspended load into place by hand. The operator extended the telehandler’s boom to place the rebar under the crane, but he extended it beyond the rated capacity of the telehandler for the load on the hook. As a result, the telehandler failed at the boom’s knuckle and the load of rebar fell and struck the worker.

Contributing factors

• Failure to follow safe work procedures. The employer did not have written safe work procedures (SWPs) for moving rebar located outside the crane’s reach. The verbal SWP for moving the rebar was not followed during the incident and was commonly disregarded, with no corrective actions provided to the workers. The operator had previously observed the supervisor conducting lifts contrary to the verbal SWP. The employer permitted the operator, who was not trained or qualified, to operate the telehandler.
• Unqualified operator. The operator had received only minimal instruction and was not qualified to operate the telehandler. However, the employer allowed him to operate the telehandler, in contravention of the employer’s SWPs and the SWPs detailed in the telehandler manual.
• Inadequate supervision. The employer failed to provide adequate supervision at the workplace. The supervisors were aware that the telehandler was being used in contravention of the operator’s manual and SWPs. In addition, the worker was allowed to walk along a structure not intended for pedestrian use, under a suspended load.

Other safety issues

• Unapproved attachments. The employer used the telehandler with an unapproved attachment, consisting of a synthetic sling and hook. The employer was aware that the telehandler was being used in contravention of the manufacturer’s instructions. The use of attachments contrary to the manufacturer’s specifications was not causal to the incident.
• Inadequate rigging. The rigging in this incident included a frayed sling and unmarked chains, which contravened the Occupational Health and Safety Regulation. Although the rigging was not compliant, the rigging did not fail and was not causal to the incident.

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