Worker’s 10-metre fall sparks warning

WorkSafe is urging all businesses that undertake work at height to reassess their safety systems after a KiwiRail employee took a near-fatal 10-metre fall in Whanganui.

The man was installing a telecommunications pole in October 2023 when he fell, suffering extensive injuries, including fractures to his ribs and vertebrae, internal bleeding, and a punctured lung. He later required surgery for blood clots that developed in his legs.

A WorkSafe investigation found gaps in KiwiRail’s approach when introducing the Oclyte telecommunications pole, a new design that differed from the wooden poles that workers were used to.

The review showed that specific risk assessments and updated procedures had not been developed for the new pole, and additional training for complex work at height had not yet been provided.

At the time of the incident, the fall-arrest system was not in use, and climbing pegs on the pole were installed incorrectly. Alternative safety measures, such as mobile elevated work platforms, were also not in place.

“When you introduce new infrastructure, you can’t assume existing procedures will be adequate. Businesses need to step back, conduct a full risk assessment, and consider the changes required,” says WorkSafe’s central regional manager, Nigel Formosa.

“Businesses must first ask whether the job can somehow be done from ground level. If you can’t eliminate the need to work at height, consider using an elevated work platform or scaffolding. Fall arrest systems should be the last line of defence – not the first option.”

KiwiRail was fined $220,000 and ordered to pay $28,500 in reparations. The worker has since made a remarkable recovery.

Protecting workers at heights

Falls from height remain one of the leading causes of serious injury and death in New Zealand workplaces, yet they are largely preventable with proper planning and precautions.

The first step in preventing falls is to assess whether the task can be done safely from the ground. If not, employers should consider engineering controls such as scaffolding, elevated work platforms, or other equipment that reduces exposure to height.

Fall-arrest systems, including harnesses and lanyards, should be viewed as the last line of defence rather than the primary method of protection.

Workers must understand the specific risks associated with the equipment and structures they are working on, and be able to use fall-protection equipment correctly.

Employers should also regularly inspect and maintain equipment, ensuring it meets current safety standards. For guidance, visit WorkSafe’s working at height resources: https://www.worksafe.govt.nz/topic-and-industry/working-at-height/