RESPIRATORY PROTECTION FOR WELDERS: IS IT EFFECTIVE ENOUGH?
Welcome to the final issue of Safety Solutions for 2024! Each year seems to fly by more quickly than the last, doesn’t it? The November issue of the magazine explores environmental risk, machine and transport safety, and maintaining a focus on PPE solutions.
In recent times, some Australian states have experienced an increase in successful ‘pure risk’ WHS prosecutions; that is, prosecutions which are initiated against organisations for breaches in their duty to ensure health and safety under WHS legislation — but in circumstances where no harm has yet resulted. Richard Johnstone takes a look at case law where employees were exposed to potential risks within their working environments, and steps that were taken to mount a pure risk case against their employers even where no death or injury had occurred. New research from the University of Sydney demonstrates that there are not enough measures in place to protect welders from hazardous fumes at work. Indeed, researchers conducted a survey that reveals the vast majority of welders are exposed to welding fumes in confined spaces — suggesting that more needs to be done to protect these workers.
Finally, interesting research from Monash University reveals that the growing use of collaborative robots in the workplace may pose significant psychosocial risks to workers’ mental health; this issue also contains several case studies highlighting the ways in which organisations are improving the safety of workers in traffic and on roads. Happy reading, and I look forward to seeing
Amy Steed Editor,
HAND AMPUTATION LEADS TO $560K SAFETY SPEND
More than $560,000 will be spent by a civil engineering company after a worker’s hand was amputated by a concrete pump mixer.
On 2 October 2024, the Broadmeadows Magistrates’ Court heard Aqua Metro Services Pty Ltd had entered into an enforceable undertaking while facing two charges of failing to ensure people other than employees were not exposed to health and safety risks.
WorkSafe Victoria said it may reinstate the charges if the undertaking is contravened or withdrawn.
In February 2022, the worker was cleaning residue from the concrete pump mixer during drain rehabilitation works at Moonee Ponds when their hand became entangled in the mixing hopper, resulting in amputation.
The concrete mixer had guarding fitted; however, it had to be removed to clean the hopper area and there were no interlocks installed in case of an unexpected start-up while the guarding was detached.
WorkSafe alleged that it was reasonably practicable for Aqua Metro Services to control the risk of entanglement through measures such as the installation of an interlocked guard; the use of a high-pressure hose to remove residue; or, if the guarding had to be removed for cleaning, using a lock-out, tag-out procedure.
WorkSafe Executive Director of Health and Safety Sam Jenkin said inadequately guarded machinery put workers at significant risk.
“Unfortunately when machinery is not properly guarded it’s often a matter of when, not if, a serious and potentially life-changing incident will occur,” Jenkin said.
“The only upside to this terrible incident is that significant safety improvements will now be made within this company and the wider industry, including better support for students and vulnerable workers.”
TRUCK DRIVERS MUST BE PART OF SAFETY CAMPAIGN: ATA
A road safety campaign planned by the federal government should include truck drivers, according to the Australian Trucking Association (ATA). The government provided $10.8 million for the campaign in the 2024–25 Budget.
While the trucking industry’s safety record had improved markedly over the decades, ATA Chair Mark Parry said the National Truck Accident Research Centre’s 2024 major incidents report raised concerns.
“Our industry is much safer than it used to be. For example, there were 56 fewer fatal crashes involving articulated trucks in 2023 than in 2003,” Parry said. “The increase in safety is even more marked when you consider that the number of articulated trucks on the road almost doubled from 2003 to 2023.
“But the NTARC 2.0 report highlights issues we must address. The report found that driver inattention or distraction incidents have increased since 2022. Incidents due to inappropriate speed have increased, as have incidents involving tailgating.
“These findings show that the government’s planned road safety campaign needs to reinforce good safety practices by truck drivers as well as car drivers. We all need to be reminded to pay attention, slow down and stay back from the vehicle in front.
“The growing number of alerts from in-cab technology is also a distraction issue. Drivers need alerts that are urgent and important — such as warnings about drowsiness or lane keeping — but don’t need unimportant alerts while they are focused on driving,” he said.
Parry urged the government to support businesses to upgrade their fleets to trucks with the latest safety technologies.
“Technologies like electronic stability control and advanced emergency braking save lives, but trucking businesses need support to buy new trucks,” he said.
“We are arguing that the government should permanently reinstate full expensing, so businesses can bring forward their fleet upgrades to improve their safety, productivity and sustainability now.”
$78K IN REPAYMENTS FOR WORKERS COMP FRAUDSTER
A man has been convicted and ordered to repay costs after he fraudulently claimed $68,502 in workers compensation while continuing to work.
Amin Dreik, 50, was sentenced in the Frankston Magistrates’ Court on Thursday, 22 August after pleading guilty to a single charge of fraudulently obtaining payments.
He was convicted and fined $10,000 in addition to the restitution order.
The court heard Dreik began receiving workers compensation in February 2021 after lodging a claim for a mental health injury due to workplace bullying while working as a factory hand, yard worker and driver at a pool heating company.
He received weekly payments until January 2022 when they were stopped after a WorkSafe Victoria investigation revealed he had been working for his own business.
The court heard that throughout this period, Dreik continued to sign certificates of capacity declaring he had not engaged in any form of employment or self-employment.
Bank records showed payments with references to vehicles to accounts in Dreik’s name from a number of businesses and four witnesses gave evidence that they had paid him for vehicle detailing work.
A surveillance investigation report provided to the court included footage of Dreik cleaning a car interior after it arrived at his premises in December 2021.
Return to Work Victoria Executive Director Jason Lardelli said fraud, while relatively rare, was deeply disappointing as it took resources away from injured workers who needed support.
“Workers compensation provides crucial support to people recovering from workplace injuries or illness and is such an important part of their recovery and return to work,” Lardelli said.
“To deliberately deceive the system for personal gain is unacceptable and anyone who does this risks prosecution and serious penalties.”
TAKING STEPS TO REDUCE WORKPLACE INJURIES
Musculoskeletal disorders are Australia’s most common workplace injury, accounting for 57% of compensation claims for serious injuries.
Body stressing caused by poorly executed lifting, pushing, pulling or bending, using computers in non-ergonomic workspaces (in an office or at home), poor posture, driving a vehicle and repetitive strain injuries can all cause work-related musculoskeletal disorders (WMSDs) — including chronic neck and back pain, shoulder stiffness and headaches.
Dr David Cahill, President of the Australian Chiropractors Association, said, “With musculoskeletal conditions (MSDs) ranked the third highest in the Australian Burden of Disease Study (2023) before cardiovascular disease, prevention and early intervention is critical.
“MSDs are the second largest contributor to disability worldwide, with lower back pain being the single leading cause of disability globally. Early diagnosis and treatment can have a significant impact on reducing the instances of WMSDs, minimise their impact to prevent the long-term burden of MSDs, and reduce workers compensation claims and overall health costs to the Australian economy.”
A range of inflammatory and degenerative conditions affecting the muscles, tendons, ligaments, joints, peripheral nerves and supporting blood vessels, WMSDs may be caused by a single workplace event. However, more commonly they result from repeated harmful workspace activities over an extended period of time.
Mental stress in the workspace can also impact workers physically and, if left unchecked, can trigger neuro-musculoskeletal disorders including tension and cervicogenic (neck-related) headaches that affect workers’ concentration, productivity, social engagement, and overall wellbeing and quality of life.
“If left untreated, WMSDs can lead to long-term chronic pain with possible life-limiting outcomes. However, WMSDs caused by physical or mental stress respond well to early diagnosis and treatment ... [which] can prevent deterioration, improve recovery, reduce severity and help prevent long-term implications including the reliance on medications for chronic pain that can be harmful,” Cahill said.
FARM SAFETY CAMPAIGN AHEAD OF HARVEST TIME
The importance of staying safe on farms is being highlighted by the WorkSafe Victoria ‘It’s never you, until it is’ campaign.
Tragically, six work-related deaths have occurred in agriculture this year, taking the number of workplace deaths in the industry to 38 since 2020. Fatigue, working alone and with heavy machinery, increased vehicle traffic and working near overhead powerlines are among the common risks for workers in the agriculture industry.
It’s never you, until it is has been launched again to offer practical safety solutions for farmers and encourage conversations around safety.
WorkSafe inspector Deb Domain said as the busy harvest season approached, now was the time to think about getting through it safely and efficiently.
“Stand back and think about what risks there are — if there is going to be fatigue, if you’re going to have new workers that need to be inducted properly — even do a walkthrough with somebody, they might see something that you haven’t seen before,” she said.
“Consider what job you’re doing, do your risk assessment and think about how you’re going to best protect yourself and your livelihood.”
FATAL FALL ON CONSTRUCTION SITE SEES
Charges have been laid by WorkSafe Victoria after a worker died following a threemetre fall at a Glen Waverley building site in September 2022.
The 23-year-old worker was erecting roof trusses on the development’s first floor when he fell through an unprotected stair void to the concrete floor below.
Anthony Basa, 29, trading as Big Basa Constructions, and Pearl Construction Group Pty Ltd face one charge each under section 26(1) of the Occupational Health and Safety Act for failing to ensure the workplace was safe and without risks to health.
WorkSafe alleges both failed, so far as was reasonably practicable, to control
Basa faces a further charge under regulation 327(1)(a) of the OHS Regulations for failing to prepare a safe work method statement before performing high-risk
The matters are listed for a committal mention at the Melbourne Magistrates’ Court on 25 November 2024.
STRONGER SILICA DUST PROTECTIONS FOR WORKERS TAKE EFFECT
New laws that came into effect on 1 September will provide additional protections for workers exposed to silica dust.
These news laws means all workers exposed to respirable crystalline silica dust — not just those working with engineered stone — will be able to demand multiple safety control measures such as PPE, water suppression, on-tool extraction systems, and local exhaust ventilation systems.
Workplace safety ministers from all of the nation’s states and territories met earlier this year and agreed to the new laws, which have already been in place in Victoria for some time.
A highly-publicised union campaign last year helped to secure a ban on socalled ‘killer stone’ used in kitchens around the country. But these new laws mean an additional 600,000 workers in sectors as varied as road and rail tunnelling, civil construction, quarries, mines and road maintenance will also have protection.
According to the Australian Workers’ Union, if the work being undertaken is high risk, workers can now demand a silica risk control plan from their employer, which will require work to cease if not followed. Companies will be fined if they are found to be in breach of these provisions. There is also a training requirement for workers.
THE RISE ON THE USE OF
‘PURE RISK’ WHS PROSECUTIONS
Historically, the vast majority of work health and safety prosecutions in Australia have been initiated in response to an incident resulting in injury or death to a worker or another person — that is, after the risk of injury or death has materialised in an incident that has actually caused these things. Recently, however, in some Australian states there has been an increase in successful ‘pure risk’ WHS prosecutions: prosecutions initiated for breaches of the duties to ensure health and safety in WHS legislation in circumstances where no harm has yet resulted, writes RICHARD JOHNSTONE, Honorary Professorial Fellow, Melbourne Law School, The University of Melbourne.
What are pure risk prosecutions?
For the purposes of this article, a pure risk prosecution is a prosecution initiated for a ‘risk-based’ offence — such as a breach of a general duty in the harmonised Work Health and Safety Acts (WHS Acts) or the Victorian Occupational Health and Safety Act 2004 — that occurs in circumstances that have not already resulted in death, injury, illness, actual contact with a hazardous substance or bacterium, or a ‘near miss’. The key point is that the general duties imposed upon a person who conducts a business or undertaking (PCBU); an employer; a selfemployed person; an upstream party such as a designer, manufacturer or supplier of plant, substances or structures for work; an officer and a worker do not require the occurrence of death, injury or illness as an element of the offence: they are ‘inchoate’ offences.
An early example of a successful pure risk prosecution was the English case of R v Board of Trustees of the Science Museum [1993] 1 WLR 1171. The museum was prosecuted for a breach of the employer’s general duty to persons other than employees in the United Kingdom Health and Safety etc at Work Act 1974 after WHS inspectors found that its air conditioning cooling tower contained the bacterium that causes legionnaire’s disease. The prosecution alleged that the air-conditioning system failed to institute and maintain a regime of regular cleansing and disinfection, failed to maintain in operation an efficient chemical water treatment regime and failed to monitor its efficiency.
In reasoning that has been accepted and adopted by Australian courts,1 the Court of Appeal of England and Wales rejected a submission that the prosecution had to establish an actual danger , as distinct from
the mere possibility of danger , and accepted that members of the public were exposed to risks to their health and safety because of the possibility that the bacterium might escape into the atmosphere outside the museum. In other words, the prosecution had to establish that the bacterium was present in the airconditioning system and that there was a ‘risk’ of it escaping, but not that it was present in the atmosphere outside the museum and capable of being inhaled. A person can be ‘exposed to risk’, and in breach of the general duty, because of their proximity to a risk and in the absence of a finding of any mechanism by which the risk could have ‘come home’.
In summary, the general duties in the Australian WHS statutes, and some duties in the WHS regulations, create inchoate offences, which means that the WHS regulators can initiate a pure risk prosecution for breach of those duties where a person to whom the duty is owed has been exposed to a risk to their health and safety and the person owing the duty has not taken reasonably practicable measures to eliminate, or at least minimise, the exposure.
Why initiate pure risk prosecutions?
From a regulatory policy perspective, pure risk prosecutions are an essential component of a responsive enforcement strategy using an escalating hierarchy of sanctions — as is found in the Australian WHS statutes and in the National Compliance and Enforcement Policy — because they signal to duty holders that the regulator is willing and able to use all sanctions (most notably prosecution) in the hierarchy to reinforce the need for systematic WHS management and safe systems of work, even where there has not yet been an incident resulting in injury or death. Fur-
ther, pure risk prosecutions enable the WHS regulator to prosecute contraventions of the general duties for all kinds of hazards and redress the historical pattern of prosecuting mainly for safety issues such as dangerous plant and working at height. They are also an important component of a general deterrence strategy to draw PCBUs’ attention to addressing hazards at work proactively (and before any harm occurs) through a systematic approach to managing WHS.
Finally, the legal framework for regulating WHS in Australia has institutionalised a primary preventive framework for businesses and undertakings, officers, workers (and their representatives) and WHS regulators to take proactive action to prevent, at source, workrelated death and physical and psychological illness or injury by, to quote the Safe Work Australia website, “applying a risk management approach to eliminate or minimise risks so far as is reasonably practicable”.
How do WHS regulators find out about pure risk scenarios?
Because ‘pure risk’ scenarios are not ‘incidents’ falling within the ambit of section 38 of the WHS Acts, and therefore there is no legal obligation to report them to the WHS regulator, how do they come to the attention of the regulator? The WHS inspectorates are likely only to find out about the possible WHS Act contravention if:
• a PCBU voluntarily reports the circumstances to the regulator, which occurred in one of the New South Wales pure risk prosecutions: SafeWork NSW v Ambulance Service of NSW [2023] NSWDC 134;
• a worker or someone else makes a complaint to the regulator about defective systems of work, or dangerous work activities;
• workers realise that the work was dangerous and refused to work, or other workers intervene and advise the exposed worker(s) to stop working, and inspectors are notified, presumably through a complaints process, and possibly through the issue resolution process in the WHS Acts (section 89); or
• an inspector attends a workplace in the course of a programmed proactive, or random, visit: for example, if WHS inspectors observe unsafe systems of work, unguarded plant, defective scaffolding or inadequate fall protection; or if inspectors find out about a dangerous scenario while at a workplace in response to a report of an unrelated incident.
Constructing pure risk cases
How do WHS investigators investigate WHS offences if there is no incident to examine? And how do investigators and prosecutors demonstrate the reasonably practicable measures a business should have implemented to address a hazard?
A key factor enabling pure risk prosecutions has been that from the 1990s governments and WHS regulators have expanded the range of hazards addressed in the WHS regulations, codes of practice and guidance material, so that there is now detailed guidance about compliance with the WHS general duties available to employers and, significantly for this article, for inspectors, prosecutors and the courts. Consequently, prosecutors have been able to use provisions in WHS regulations, codes of practice and Australian standards to demonstrate to the court the reasonably practicable measures that should have been implemented to address a hazard.
Second, in one case which examined WHS risks from deficiencies in an ambulance service’s systems and processes for handling restricted drugs (SafeWork NSW v Ambulance Service of NSW [2023] NSWDC 134), the prosecutor successfully referred the court to guidance provided by expert bodies, including the National Safety and Quality Health Service Standards , the Scheduling Policy Framework for Medicines and Chemicals endorsed by the Australian Health Ministers Advisory Council, the NSW Health Drug and Alcohol Withdrawal Guidelines and the Operation Tone Report by the Victorian Independent Broad-Based AntiCorruption Commission.
A third approach was to refer to measures introduced by the defendant in response to a statutory notice. For example, in SafeWork NSW v Dial-A-Dump Pty Ltd [2023] NSWDC 260 the prosecution relied on the reasonably practica-
ble measures ensuring health and safety that were introduced to comply with a prohibition notice and two improvement notices issued by SafeWork NSW after its investigation of circumstances that exposed two workers to serious risks to their health and safety.
In some cases, the court referred to a combination of these approaches: see, for example, SafeWork NSW v N Moit & Sons (NSW) Pty Ltd [2023] NSWDC 205.
When it came to investigating and proving possible contraventions of the WHS Act, rather than focus on the details of an incident to prove that the defendant had contravened provisions of the WHS Acts, in the pure risk prosecutions the prosecutors focused on one or more explanations of:
• failures to develop a systematic approach to WHS management;
• failures to have a documented safe system of work;
• failures to implement documented procedures; and
• defects in WHS procedures or systems of work, including actual failures to assess risks and/or to implement suitable control measures; and actual failures to supervise, instruct, provide WHS information to, and/ or to train workers (including failures to provide an asbestos register to another party, or a failure to notify others of hazards and risks).
Pure risk prosecutions are consistent with the notion of primary prevention, and the inchoate nature of the WHS offences, and are a reminder that PCBUs need proactively to eliminate risk, as far as is reasonably practicable, before any harm occurs at work.
1. See, for example, Thiess Pty Ltd v Industrial Court of NSW (2010) 78 NSWLR 94; [2010] NSWCA 252, [51]; Boland v Safe is Safe Pty Ltd & Munro [2017] SAIRC 17.
AI industry spreadsheet software
3 Dot Digital has integrated V7 Go software to improve work and safety practices in the architectural, engineering and construction (AEC) industries.
V7 Go enables businesses to harness generative AI models such as GPT, Claude and Gemini at scale from a single interface with simple prompts.
The software offers an easy, no-code interface and built-in features like AI citations and human-in-the-loop feedback. Users can enjoy a familiar ‘spreadsheet-style’ experience, with large language models available in every cell of their spreadsheet. Every cell in a V7 Go project can accept raw data, images, PDF documents and audio files, instead of just plain text. This means AEC industry spreadsheets can now take minutes instead of days to complete, while operated by a single user. The technology also helps to eliminate the “drag and drop” of thousands of lengthy tender proposals.
According to the company, this software integration can reduce manual effort by more than 50% for site inspections, hazard and safety reports, and audit/compliance regulatory tracking. It can also remove 40% of repetitive knowledge work tasks.
3 Dot Digital 3dot.digital/
Worksite storage system
The DEWALT TOUGHSYSTEM 2.0 DXL storage system offers portable, stackable storage to enhance efficiency and safety on the job site.
The DXL range, which is compatible with the TOUGHSYSTEM 2.0 range, includes heavy-duty drawers, a rolling base and a work top. These components provide a durable, mobile workshop solution suitable for worksites, workshops, garages or any location where equipment is used and security is paramount.
The DXL System comprises four products; deep drawer, shallow drawer, 4-wheel dolly and work top. Each features auto-stacking latches for quick connectivity with each other and previous TOUGHSYSTEM modules, allowing users to create and customise combinations that meet the specific tool and accessory needs of each job. The system is also available in a 5-in-1 tower pre-stacked combination modular workstation.
Suitable for accommodating larger tools and equipment, the deep drawer features removable dividers for customisable organisation and heavy-duty aluminium carry handles for convenient transportation. The deep drawer includes an integrated locking bar with a metal secure lock mechanism for secure storage, providing quick and easy lock/release and acting as a deterrent to theft. The locking aluminium drawer levers prevent accidental opening during transit.
Stanley Black & Decker Inc www.stanleyblackanddecker.com
Powered air purifying respirator
The SR700 PAPR is an easily operated battery-powered fan device designed for protection against mechanically and thermally generated particulates. Fitted with two Sundström SR510 P3 filters and SR221 pre-filters, it provides efficient respiratory protection against wet and dry particles including dust (silica dust), smoke, aerosols, spray, bacteria, viruses, fumes, mould and fibre such as asbestos. This respiratory system meets the new silica dust regulations introduced by Workplace Australia.
This compact and lightweight fan unit can be used with any Sundström soft and hard head-tops or full-face masks, giving the user flexibility to choose suitable protection depending on the work and environment at hand. Alternatively, by using the SR507 adaptor, it can be connected to filtered air supply through a hose to the facepiece, which is effective when used during extended periods of hard work in warm conditions.
Features of the SR700 include acoustic and optical alarms, two battery alternatives (standard and heavy duty). It can run for approximately 8 hours’ time at a flow rate of 175 L/min and approximately 5 hours at 225 L/min.
It is AS/NZS 1716 approved and IP67 rated (can be worn in decon shower).
Safety Equipment Australia Pty Ltd www.sea.com.au
Automation is predicted to increase annual productivity growth in Australia by 50–150%, according to the National Robotics Strategy. The global cobot market is also booming, reaching a staggering US$50 billion since 2018.
Growth has predominantly been driven by increasing automation needs in sectors like manufacturing, automotive, electronics, health care, and food and beverages.
However, while cobots are often hailed for their abilities to increase efficiency and speed — as well as reducing the physical risks posed to workers — less is known about the hidden psychosocial risks employees may be facing.
A research team from the Monash University Business School has been investigating the potential harms posed by these cobots.
What have the researchers found?
According to Professor Herman Tse and his team, the growing use of collaborative robots in the workplace may pose significant psychosocial risks to workers’ mental health and their job security. Despite this, there are ways for organisations to smooth the transition.
“Workers often perceive cobots as potential threats to their job stability, especially when collaboration between humans and machines is minimal; lower collaboration may be perceived as a strategy to automate work and replace operators with machines. This perception can lead to increased stress and decreased trust in new technologies,” Tse said.
To support a smooth transition of cobots in the workplace, and reducing these risks, the study emphasises the urgent need for organisations to consider employees’ perception of collaborative robots
PSYCHOSOCIAL RISKS TO WORKERS? DO COBOTS POSE
and the stresses that arise from their growing use. It is hoped this would lead to a broader organisational understanding about the importance of involving workers in the implementation process of cobots.
The research team found engaging employees through participatory change management and consultation can significantly reduce psychosocial hazards and improve overall acceptance of new technologies.
What should employers do to reduce the risk?
• Engage workers: Involve employees from various units in the planning and implementation stages to address concerns and gather feedback.
• Enhance consultation: Provide clear communication about how cobots will impact job roles and responsibilities, and include workers in decision-making processes.
• Conduct risk assessments: Develop comprehensive risk assessments to identify and address potential psychosocial hazards associated with cobots.
“Cobots enhance productivity and address labour shortages, making them attractive for both large and small businesses, and advancements in cobot technology will further boost their adoption in Australian workplaces,” Tse said.
The team’s findings underscore that while cobots offer significant benefits, including reducing physical strain and enhancing productivity, their introduction must be handled with care to avoid unintended psychosocial consequences.
By prioritising worker engagement and consultation, organisations can ensure a smoother transition to collaborative robotics and safeguard employee wellbeing.
TAKING ACTION ON LUNG HEALTH AMIDST STRONGER SILICA REGULATIONS
Amy Steed
Despite stronger crystalline silica protections taking effect from 1 September 2024, a new survey has found that more action is needed on workplace lung health.
Lung Foundation Australia recently released results from a survey of over 500 workers, in an effort to gain insight into current awareness and attitudes towards silicosis. Industries where participants worked included at-risk fields such as construction, mining/ quarrying, manufacturing and tunnelling.
Key survey findings
• 78% of participants were aware of silica dust and the risk of silicosis, but only 23% were worried about developing the lung condition.
• 36% were aware of the symptoms of silicosis, with awareness rising to 73% amongst those who knew someone with the disease.
• 34% of respondents understood that silicosis is incurable, with older Australians showing a higher level of knowledge.
• 49% of respondents thought about their lung health when engaging in activities that could have a negative impact, such as working in environments with dust exposure.
• Only 23% were aware that silicosis can be asymptomatic.
• Only 8% had discussed silicosis or lung health with their GP or medical practitioner; however, this increased to 45% amongst those that personally knew someone with silicosis.
• Respondents who knew someone with silicosis were more aware of which materials contain silica dust than those who were only aware of silicosis.
Lung Foundation Australia CEO Mark Brooke said the survey results emphasise the need for ongoing awareness around silicosis, as well as highlighting the importance of education in encouraging workers to be more proactive about their lung health.
“While the recent ban on engineered stone marks a significant step forward in protecting workers from silica dust, there’s still more work to be done. There is an ongoing need for awareness, better education and a cultural shift in how we address workplace lung health,” Brooke said.
Stronger regulation of crystalline silica substances
As of 1 September 2024, changes to work health and safety regulations mean that per-
sons conducting a business or undertaking (PCBUs) must comply with additional obligations to keep workers safe.
According to Safe Work Australia, the workplace exposure standard (WES) for respirable crystalline silica (RCS) is 0.05 mg/m3 (eight-hour time-weighted average). The WES must not be exceeded.
The recent legislative amendments also provide stronger regulation of work with all materials containing at least 1% crystalline silica and require:
• controlled processing of all crystalline silica substances;
• assessing the risk of work involving processing of a crystalline silica substance; and
• additional duties for any processing of engineered stone that is assessed as high risk, including preparing a silica risk control plan. These changes may require PCBUs to implement control measures or make changes to workplace procedures so that the workplace exposure standard for RCS is not exceeded. This might include engineering controls (such as a combination of local exhaust ventilation or on-tool dust extraction and wet cutting methods), administrative controls and respiratory protective equipment.
Personal dust monitor warning system
Dustlight is a hand-held dust monitor designed to provide real-time monitoring of airborne particles in any environment where dust exposure is a concern. Built for durability and ease of use, Dustlight measures respirable dust, including PM1, PM2.5 and PM10 fractions, helping to ensure that workers know their surroundings and can take immediate action to protect their health.
A clear, intuitive display changes from green to yellow to red based on dust and fume concentration levels, alerting users to the need for protective measures. The display shows current dust or fume concentrations and averages over time, allowing users to monitor air quality trends throughout the workday. It syncs with the Dustlight app for easy access to historical data, detailed analysis and personalised settings adjustments.
Users can wear it with a range of attachments for belts, straps and clothing patches, keeping the Dustlight within reach, ready to use and, most importantly, close to them to monitor the surrounding air.
It comes complete with a rechargeable lithium-ion battery offering up to 40 hours of monitoring in eco-mode, making it suitable for long shifts and extended use in the field.
Techware Pty Ltd www.maxisafe.com.au
Emergency-equipped tool vest
Dual AI camera
The FLIR TrafiBot Dual AI Camera is a multispectral camera system that enhances safety for drivers.
This closed-circuit traffic camera is designed to improve safety in tunnels and on bridges where drivers are most at risk for hitting unseen objects or being trapped by fast-growing vehicle fires.
The TrafiBot Dual AI offers a fast thermal core, a reliable 14-bit early fire detection for road tunnels, robust artificial intelligence for detection performance, and good traffic data collection along interurban roadways, without sacrificing imaging resolution or data loss due to bandwidth restrictions.
It utilises three FLIR AI models simultaneously, developed and trained from millions of FLIR-captured images collected across the world. One model identifies and classifies fallen objects while the other two classify vehicles on thermal and visual streams, including unusual objects such as e-scooters and vulnerable road users like pedestrians and bicyclists.
As vehicles enter its field of view, the camera anticipates vehicle speed and trajectory, even if tracked objects become obscured by other objects. TrafiBot Dual AI can also detect sudden lane changes and wrong-way drivers, providing critical data to traffic managers to better manage safety incidents while reducing false alarms.
Analysing the 14-bit thermal information directly on the camera side gives the camera algorithm 64 times more information, which enhances fire detection, speed and reliability while reducing the potential for false alarms.
FLIR Systems Australia Pty Ltd www.flir.com.au
Twiceme Technology has collaborated with Diamondback to introduce the Diamondback 701 tool vest. The hi-vis vest is designed to enhance the overall wellbeing of tradespeople and help them to work confidently and securely in any environment. The vest is engineered to offer good support, tool storage and high visibility. Crafted from military-grade 1000 denier Nylon mesh, it has 3M reflective strips and heat-sealed loops for securing accessories. Its fully modular design allows users to customise pouch and tool attachments on the torso and waist, allowing comfort and functionality on the job.
Twiceme’s Help The Helpers (HTH) technology, seamlessly integrated into the vest, offers comprehensive protection before and after an incident. Utilising NFC technology accessible via any smartphone, bystanders can access vital medical information uploaded by the wearer, alert emergency contacts, and relay the exact location to first responders swiftly and efficiently. Twiceme Technology www.twiceme.com
TOP TIPS TO
BOOST EMPLOYEE MENTAL WELLBEING
Workers in Australia are experiencing rates of stress, anxiety and burnout that are concerning, according to reports.
Safe Work Australia’s 2024 report on psychological health and safety found that mental health conditions accounted for 9% of all serious workers compensation claims and 7% of all work-related injuries and illnesses in 2020–21 — a 36.9% increase in claims since 2016–17.
Hazel Stewart, MD of Innovate Learn, said that there is growing evidence to suggest that employees who are happy at work are more productive and better for the bottom line — and that the mental wellbeing of employees needs to be an ongoing priority.
“Current workplace health and safety regulations obligate employers to implement the necessary measures to manage the mental wellbeing of employees and ensure that workers feel safe and happy at work. Companies that fail to meet this obligation may be prosecuted or fined,” Stewart said.
The rise in mental health concerns
Various reports and surveys have highlighted the increase in mental health conditions of workers:
• A Committee for Economic Development Australia (CEDA) report found that mental health claims are expected to at least double by 2030.
• The Australian Financial Review reported that workers took an average of 76 days off work for each compensation claim linked to a mental health condition in 2023, and the average payout for psychological injuries was almost three times larger than the average payout for physical injuries between 2019 and 2023, at $42,335.
• The TELUS Health Mental Health Index released in January this year revealed that the mental health of workers in Australia has declined to levels in line with lows documented during the COVID pandemic. 35% of workers were found to have a high mental health risk, with anxiety, isolation and work productivity continuing to be major mental health concerns.
With this in mind, Stewart has six practical steps that companies can take to improve the mental wellbeing of employees.
1. Invest in adequate staffing
The best way to prevent employees feeling over-worked, under pressure or stressed, is to ensure there are enough hands on deck to share the load. “The employment of additional staff may seem costly, but the costs associated with the declines in productivity, increased employee turnover and absenteeism, as well as workers compensation claims, that result when staff feel overworked, can be crippling,” Stewart said.
IT’S A GOOD IDEA TO INVEST IN MENTAL HEALTH TRAINING FOR MANAGERS, SO THEY ARE EMPOWERED TO SUPPORT THE POSITIVE MENTAL HEALTH OF WORKERS.
2. Invest in an Employee Assistance Program (EAP)
There are a variety of programs available, offering counselling services, stress management or legal support (or a mix).
3. Give employees greater control and more flexibility
Studies have shown that when workers don’t have autonomy in their work, they’re more likely to experience stress. “Empowering workers with the resources, skills and support they need to really take ownership of their jobs and make decisions about their work, is a powerful way to improve engagement and job satisfaction,” Stewart said. “This approach works best when the work environment is also flexible. If you haven’t already done so, consider adopting a hybrid work model or introducing more flexible working hours and work venues.”
4. Create a culture of wellness
Workplaces that champion long hours with no time for rest, exercise and hobbies, or time spent with loved ones, are problematic — as are workplaces that do not remove the stigmas around mental wellbeing and performance. “It’s important that all workers — from management level down to the new intern — feel that their wellbeing is valued by the company, just as much as productivity and sales targets. It’s also essential that workers feel they can discuss their mental health with their managers, and seek out support, without negative consequences,” Stewart said.
5. Provide personalised support
Tap into the needs of each employee — personal and professional — to identify where they need support, and how the business can meet this need. Some employees may be caring for an ailing parent or young children, and would benefit from a more flexible work schedule, for example. Others may be neurodivergent, requiring additional job support from their mentors. “Noting the recent cost of living increases, many workers are facing growing financial stress. It’s important to support employees by assuring them of their job security and financial security through regular check-ins to discuss their role in the business, their future career plan and how they can make the most of career growth opportunities,” Stewart noted.
6. Turn managers into mental health champions
It’s widely understood that managers have a great impact on employees’ experience of work. This is why it’s a good idea to invest in mental health training for managers, so they are empowered to support the positive mental health of workers and drive engagement with company mental health programs.
RESPIRATORY PROTECTION FOR WELDERS:
IS IT EFFECTIVE ENOUGH?
There are not enough measures in place to protect welders from hazardous fumes at work, according to research from the University of Sydney.
Researchers from the Curtin School of Population Health and the University of Sydney said that at least 46,000 Australian welders are exposed to high levels of dangerous, potentially cancer-causing fumes. They surveyed 634 workers and employers involved in welding in Australia and asked participants about work tasks, their working environment and safety measures implemented in their workplace.
What were the key findings?
Survey data suggested that the majority (91%) of welders are exposed to ‘welding fume’, a mixture of very fine particles and gases produced when a metal is heated above its boiling point. Welding fume is a known to be carcinogenic to humans.
According to the researchers, such exposure makes it highly likely that other carcinogenic metals are also present in the workplace. Most commonly, more than three-quarters of working environments involving welding are exposed to hexavalent chromium, a common contaminant that arises during welding, while almost half are exposed to stainless steel and nickel.
Study co-author Professor Tim Driscoll from the University of Sydney said the exposure risk was exacerbated by the conditions in which most welders worked. Two-thirds of respondents said they welded in restricted spaces, while nearly half said they worked in confined spaces. Most (86.3%) also reported leaning over the welding area while working, often putting their breathing zone directly above the fume source.
“Despite this, only 19% of study participants said their workplace had some form of mechanical ventilation, such as a welding booth or exhaust hoods,” Driscoll said.
What are the risks?
Study lead Dr Renee Carey from Curtin University — who was previously involved in a landmark study outlining the dangers of working with engineered stone — said this new research showed many welders in Australia could be at risk of developing serious health problems.
“Given that many Australian workplaces are apparently without effective ventilation, it is even more concerning that nearly two-thirds of workers in non-ventilated areas reported they do not use an airsupplied welding helmet,” she said.
“Data shows at least 60,000 people are employed as welders; however, the number of people who complete welding tasks as part of their job would be far higher.
“Welding fume exposure has been associated with various adverse health effects, including cancer, respiratory disease, neurological disorders and reproductive effects.”
Public Health Association Chief Executive Terry Slevin said the study revealed serious health risks which must be reduced.
“We have seen strong action to reduce the health problems linked to asbestos and silica; this is another example where Australia’s health and safety legislation must be put to work to protect our tens of thousands of welders,” Slevin said.
“This study demands every professional welder in Australia be supplied with upgraded protective equipment to make their work as safe as humanly possible.
“We have the technology — now we need to ensure it is mandatory to use it in our workplaces.”
Occupational exposure to welding fume in Australia: An online survey was published in the Australian and New Zealand Journal of Public Health.
Industrial hydration formula
Maxisafe has added Aqualyte to its range of workplace safety solutions. Aqualyte is specifically formulated for industrial environments where workers are at higher risk of dehydration. With its low-sugar, rapid-absorption formula, the product helps maintain hydration levels and replenish essential electrolytes to combat fatigue and improve workplace performance.
From mining and construction to manufacturing, the product helps workers stay hydrated and productive, even in challenging conditions. The hypotonic solution offers a balanced electrolyte concentration that assists with fast, effective hydration. In addition, an all-natural delicious flavour encourages frequent consumption, promoting better hydration throughout the day.
Techware Pty Ltd www.maxisafe.com.au
Heavy-duty hand cleaner
Solvol is a heavy-duty hand cleaning soap that blends a powerful cleaner with a gentle, natural moisturiser.
In its updated formula, the product combines natural essential oils with fine pumice granules to create a soap that’s tough on dirt but gentle on hands. The formula effectively removes stubborn substances like dirt, grease, oil, paint, ink and solvents, all while leaving hands clean, soft and moisturised.
The soap is suitable for those working in trades, gardening or any other industry that involves dirtying the hands.
The soap bar is also free from GMOs, parabens, sodium lauryl sulfate (SLS), phthalates and microplastics, making it a cleaner choice for the environment. Solvol solvol.com.au
Radar sensor for collision avoidance and positioning
The OndoSense reach WA is a compact radar sensor for collision avoidance, vehicle detection and object positioning.
With its wide detection range, the OndoSense reach WA (Wide Angle) is particularly suited for detecting obstacles such as vehicles, people or objects — as well as for positioning robots and machines.
It detects static and moving objects even at close range from 0.1 m and can be easily integrated even in confined spaces, thanks to its very small design. With up to four adjustable sensor zones, the OndoSense reach WA is suitable for flexible monitoring of security areas or collision avoidance of mobile robots or other vehicles.
The radar sensor is able to detect objects of any nature, even outdoors or in difficult environments with dirt, smoke, steam, rain or poor lighting conditions.
The OndoSense reach WA is suitable for collision avoidance, vehicle detection, object positioning and limit level control in transport and logistics, mining, shipping, mechanical and plant engineering, and agriculture.
OndoSense ondosense.com/en
Safety system
Rockwell Automation has announced the launch of Logix SIS, a safety instrumented system (SIS) designed to address the evolving needs of modern industrial environments.
Rockwell says the Logix SIS provides a modern and integrated safety solution, offering both SIL 2 and SIL 3 certifications for process and hybrid safety. Logix SIS provides all components of a safety instrumented system including the process logicsolver and I/O. The system is engineered to provide high availability leveraging the latest 1756 controller, FLEX 5000 I/O platform and Studio 5000 Logix Designer application for an integrated user experience.
The Logix SIS solution aims to deliver comprehensive safety across a wide range of industrial applications with high availability for continuous operation of critical processes. Implementation is streamlined by leveraging familiar hardware and software, reducing engineering time to maximise efficiency through simplified design and configuration. The system can also be upgraded without requiring planned downtime, and is available through Rockwell Automation distribution channels worldwide.
Rockwell Automation Australia www.rockwellautomation.com/en-au.html
Group lock box
The lightweight Master Lock S3570 group lock box is an efficient, multipurpose solution for smaller teams. The S3570 can be wall mounted and is also highly portable. Its compact design holds up to six padlocks internally for protected storage and can be locked out with up to eight padlocks or hasps externally.
The top-hinged transparent polycarbonate window allows for easy key viewing and there are two external hooks to hold folded permit paperwork, or hang tags and extra items. When group lockout is required in various areas throughout a facility, the S3570 provides flexibility regarding where it is placed and how it can be used. Permanently mounting brackets in areas where group lockout may take place allows the lock box to be fixed in place or quickly and easily moved from one bracket to another within the facility as needed. Optimal operating temperature is -40 to 65°C.
The product comes with a limited lifetime warranty. Mayo Hardware Australia www.mayohardware.com.au
Boosting safety for traffic control workers
A traffic control company has deployed a fleet of eye-catching vehicles to boost visibility and safety for its workers on the roads.
Stop Slow Traffic Control provides a range of traffic control services, including designing traffic plans, onsite traffic management, risk management and traffic equipment hire for the Illawarra area in Sydney. The team operates everywhere from roadworks to construction sites, public events, and even the occasional film shoot. Its fleet comprises 14 brightly designed Isuzu trucks (each with its own special name). Models include the Ready-to-Work Traypack, seven NNR 45-150 Crew Cab Traypacks, four NLR 45-150 Traypacks, two NLR 200 Traypacks and one FTR 900 Medium Rigid Traffic Mounted Attenuator that helps safely direct traffic and drop off equipment and crew.
Director Lisa Murphy said the reliability and visibility of the Isuzu truck fleet deployed by Stop Slow Traffic Control has enabled the business to continue aiming for even higher safety standards.
“Most other traffic control companies have plain white vehicles with a logo — there’s nothing that’s really eye-catching or that makes them stand out,” she said.
“People actually notice our vehicles, which is a critical safety requirement, plus the team have so much pride in the trucks that they are always presented clean even after working in all types of weather and site conditions.
“But we are not all for show here at Stop Slow; we work towards being the best and the most reliable traffic control company in the Illawarra, which at the end of the day is what we’re all about.”
With many different locations, conditions and operational requirements, Stop Slow Traffic Control has designated a role for each of its Isuzu vehicles.
“Queeny is one of our advanced warning vehicles, so it’s a smaller truck that sits on the road shoulder prior to the worksite with a variety of warnings on its message board,” Murphy said.
“The Queeny idea came about when I just had a baby and my husband organised for our latest NLR truck to be done in a pink theme as a surprise for me.
“Di Signs assisted with the design process and wrapped the truck in a glitter pink vinyl with a crown consisting of my initials, because my staff are always calling me ‘The Queen.’”
For Stop Slow, the Traypack’s factory-fitted reversing camera is a key safety feature. The camera can operate in low light conditions and, importantly, includes a microphone, which means the driver can hear instructions from the team working outside the vehicle while keeping an eye on what’s happening behind.
“My crew love driving the Isuzu trucks; they appreciate the quality level of comfort and safety,” Murphy said.
“The trucks themselves are all maintained using Isuzu genuine parts, which ensures we have little downtime and can continue to meet the needs of our customers. Our demand is set to increase with a greater emphasis on workplace safety, where more traffic management services will be required.”
Queeny: an NLR 45-150 Traypack.
The Stop Slow Traffic Control fleet.
CASE STUDY
Nanofibre uniform protects against chemical hazards
A next-generation uniform prototype has successfully been developed by CSIRO researchers for Australian soldiers.
The innovative material is a fabric that is designed to protect troops from chemical and biological threats. It does this by filtering out harmful particles while remaining lightweight and breathable, keeping the wearer comfortable in extreme temperatures.
CSIRO Manufacturing Research Unit Director Dr Marcus Zipper said this textile innovation was the result of collaboration with industry and research partners, including DMTC.
“Our nanofibre technology, pioneered by CSIRO scientists, has the potential to significantly improve the level of protection soldiers’ uniforms provide and can also be used for non-military applications, including protecting emergency responders and hazmat crews,” Zipper said.
“CSIRO research and development in materials science looks to improve how a particular material functions — we work across a broad range of advanced materials including metals, composites, polymers, adsorbents and nanofibres.”
CSIRO project lead Dr Yen Truong said the key to the prototype’s success lies in its innovative nanofibre technology, developed by CSIRO scientists.
“We harnessed the unique properties of nanofibres to create a lightweight fabric that effectively filters out harmful particles while remaining highly breathable,” Truong said.
“In rigorous testing, the prototype surpassed all performance targets for air filtration, air permeability, thermal comfort and chemical protection.
“This means it effectively filters pollutants from the air, allows for breathability, maintains comfortable temperatures even in extreme conditions, and offers superior protection from hazardous chemicals.”
The initial phase of this project was funded by the Department of Defence. The successful nanofibre suit prototype was coordinated by DMTC Limited.
Safety glove
The Graphex Beyond+ safety glove enhances impact protection by combining dexterity, comfort and safety in a single, cutting-edge design. Engineered with a low-profile impact protection, the 21-gauge liner is suitable for industries where precision and safety cannot be compromised.
Also involved in supporting the project are Bruck Textiles, Defence Science and Technology Group, and RMIT University.
With DMTC Limited, Truong and team are seeking funding to progress to the next stage of development, which is expected to involve field testing with Australian Defence Force personnel and further refinement of scaled manufacturing processes with industrial partners.
Crafted by subatomic engineering, the Beyond+ glove is produced from a carbon-based, paper-thin 21-gauge Cut Level F liner to help it fit like a second skin, as well as provide protection against cut and laceration risks. It is suitable for mechanics and manufacturers handling intricate parts and accessories that are sharp or pose a crush risk. With a combination of features, the Beyond+ removes the necessity to carry multiple gloves for intricate tasks and impact protection.
Graphex stands on a solid certification foundation, ensured by the reputable BSI Group, with independent and regular third-party audits. It offers the precision of mechanical score claims and good performance in the industry.
Private Brands Pty Ltd www.privatebrands.com.au
Welding and grinding helmets
Kemppi Zeta Fresh Air welding and grinding helmets are lightweight helmets that come with a respirator for breathing protection, while also offering eye and face protection.
The helmets are equipped with a respirator for TH3-level breathing protection. The synergy between the helmet and certified respirator stops 99.8% of harmful fumes, gases and particles to help keep the user safe, according to the company. The helmets also deliver comprehensive face protection. Both the grinding and welding helmets are certified to AS/NZS 1716:2012. Plus, the auto-darkening welding filter (ADF) delivers increased eye protection.
The helmets’ lightweight design delivers enhanced comfort and reduces neck fatigue. In addition, the narrow shape of the helmets makes it easier to move around onsite or in the workshop. Each model in the Fresh Air range is specifically designed for one-hand use. Buttons and controls are easy to reach and operate with one hand.
The Zeta Fresh Air W201x helmet features integrated LED lights. These built-in automatic work lights increase safety while providing the user with enhanced visibility. The lights are powered by the blowing unit and they automatically turn off or on based on the ambient light. Alternatively, they can be controlled manually by hand.
Kemppi Australia Pty Ltd www.kemppi.com
INTELLIGENT ROBOTIC WORK CLOTHES THAT ADAPT IN THE HEAT
With the intensification of global warming, it is becoming more important to keep workers thermally comfortable.
To assist with enhancing worker safety during hot weather, a team of researchers from the School of Fashion and Textiles at The Hong Kong Polytechnic University (PolyU) has developed thermally insulated and breathable soft robotic clothing that can automatically adapt to changing temperatures.
The importance of keeping cool
Maintaining a constant body temperature is one of the most critical requirements for living and working. High-temperature environments elevate energy consumption, leading to increased heat stress and thus exacerbating chronic conditions such as cardiovascular disease, diabetes, mental health issues and asthma, while also increasing the risk of infectious disease transmission. According to the World Health Organization, there were approximately 489,000 heat-related deaths annually between 2000 and 2019, with 45% occurring in Asia and 36% in Europe.
Thermal protective clothing is therefore essential to safeguard individuals in extreme high-temperature environments, such as firefighters who need to be present at fires scenes and construction workers who work outdoors for extended periods. However, traditional gear has been limited by statically fixed thermal resistance, which can lead to overheating and discomfort in moderate conditions, while its heat insulation may not offer sufficient protection in extreme fire events and other high-temperature environments.
“Wearing heavy firefighting gear can feel extremely stifling. When firefighters exit a
fire scene and remove their gear, they are sometimes draining nearly a pound of sweat from their boots. This has motivated me to develop a novel suit capable of adapting to various environmental temperatures while maintaining excellent breathability,” said lead researcher Dr Dahua Shou.
“Our soft robotic clothing can seamlessly adapt to different seasons and climates, multiple working and living conditions, and transitions between indoor and outdoor environments to help users experience constant thermal comfort under intense heat.”
So how does the clothing work?
The research was inspired by biomimicry in nature — such as the adaptive thermal regulation mechanism in pigeons, which is mainly based on structural changes. For instance, pigeons use their feathers to trap a layer of air surrounding their skin to reduce heat loss to the environment. When the temperature drops, they fluff up their feathers to trap a significant amount of still air, thereby increasing thermal resistance and retaining warmth.
The protective clothing developed by the team uses a soft robotic textile for dynamic adaptive thermal management. Soft actuators, designed like a human network-patterned exoskeleton and encapsulating a non-toxic, non-flammable, low-boiling-point fluid, were strategically embedded within the clothing. This thermo-stimulated system turns the fluid from a liquid into a gas when the ambient temperature rises, causing expansion of soft actuators and thickening the textile matrix, thereby enhancing the gap of still air and doubling the thermal resistance from 0.23 to 0.48 Km2/W. The protective clothing can also keep the inner surface temperatures at least 10°C cooler than
conventional heat-resistant clothing, even when the outer surface reaches 120°C.
This unique soft robotic textile, made by thermoplastic polyurethane, is soft, resilient and durable. Notably, it is far more skin-friendly and conformable than temperature-responsive clothing embedded with shape-memory alloys and is adjustable for a wide range of protective clothing. According to the researchers, the soft actuators have exhibited no signs of leakage after undergoing rigorous standard washing tests. The porous, spaced knitting structure of the material can also significantly reduce convective heat transfer while maintaining high moisture breathability. Not relying on thermoelectric chips or circulatory liquid cooling systems for cooling or heat conduction, the lightweight, soft robotic clothing can effectively regulate temperature itself without any energy consumption.
What’s next?
Moving forward, Shou said the innovation could have a wide range of potential applications — from activewear to winter jackets, healthcare apparel, outdoor gear and sustainable textilebased insulation for construction and buildings — contributing to energy-saving efforts. Supported by the Innovation and Technology Commission and the Hong Kong Research Institute of Textiles and Apparel, Shou and his team have also extended the thermo-adaptive concept to develop inflatable, breathable jackets and warm clothing. This soft robotic clothing is suitable for low-temperature environments or sudden temperature drops to aid those who are stranded in the wilderness to maintain normal body temperature.
The findings have been published in the international interdisciplinary journal Advanced Science
A team led by Dr Dahua Shou, Limin Endowed Young Scholar in Advanced Textiles Technologies and Associate Professor at the School of Fashion and Textiles at PolyU, has developed first-of-itskind soft robotic clothing that can automatically adapt to changing ambient temperatures, thereby ensuring working safety in hot environments.
Heat detectors for hazardous areas
The E2S Warning Signals H1 range of heat detectors are designed for hazardous areas. They are globally approved to UL, cUL, IECEx and ATEX standards and offer explosion-proof, flameproof, increased safety and intrinsically safe protection.
The H1 range contains Ex db flameproof, Ex db eb increased safety and Ex ia intrinsically safe variants approved for use in Zone 0, 1, 2, 21, 22 and Class I/II Division 1 and Division 2. They are UL521 and CAN/ULC-S530 approved and SIL2 compliant to IEC61508 (2010).
The E2S termination enclosures are combined with heat detector elements as a complete approved assembly to create a fully certified solution for heat detection in hazardous areas. Primarily used for signalling overheat or fire conditions, the H1 range provides the initial heat sensing in automatic fire and gas detection and suppression systems.
Incorporating industry standard Detect-A-Fire (D-A-F) rate compensated heat detector elements that feature stainless steel housings and hermetically sealed contacts the H1 range is available in a wide range of operating temperatures. All versions feature IP66/67, Type 4/4X/13/3R sealing for the harshest of environments and an optional protective guard for the element. Selected variants can be specified with an LED to indicate an alarm condition and a wide range of addressable modules can be factory installed.
Mechtric Pty Ltd www.mechtric.com.au
Portable area monitor
The Blackline EXO 8 portable area monitor boosts gas detection and early hazard identification for organisations and first responders. It is a direct-to-cloud area monitor that is capable of detecting up to eight gases as well as gamma radiation.
Suitable for large industrial organisations in the oil and gas, petrochemical, mining, water and wastewater sectors — alongside fire-hazmat and homeland security associations — EXO 8 helps teams rapidly respond to incidents involving hazardous substances and improves the safety of workers, first responders, the public and the environment during these events.
Real-time connectivity provides situational awareness that can be shared among all responders. Automated analytics provide insights into incidents after the event, enabling teams to understand what happened and take proactive measures to improve safety.
EXO 8 offers a gas expansion module with the ability to add up to four additional sensors for a total of eight gases; an integrated gamma radiation sensor with a range that is three times the distance of competitors, according to the company, and that operates continuously without cycling on or off; and higher resolution full-colour dual display with a live readings screen for real-time gas and gamma levels and dashboard screen to quickly see alarms and device status.
Blackline Safety
www.blacklines.com
Powered floor cranes
Pack King powered floor cranes offer safety and efficiency for users. The cranes have been designed so that operators can be free of overhead cranes and forklifts when lifting and moving heavy objects.
The cranes are always on hand with no licence required. Users can simply drive the crane to the site, hook up the heavy item in the crate and power lift it out. They can then take it to the bench, repair and place it back into the open-topped crate.
For users needing to lift and rotate a steel drum and decant the contents into a hopper, the Pack King drum rotator fits right into the end of the crane jib. Users can simply rotate the drum using the chain.
Pack King
www.packking.com.au
Portable buildings
Modulate portable building solutions offer flexibility and durability for demanding industries. These safely portable Australian-made container-based buildings — including stackable and double-width 4.5 m-wide types — are being introduced across Australia.
The robust cyclone-rated structures, configured from standard 20 ft, 30 ft and 40 ft (approximately 6 m, 9 m and 12 m) respond to expanding demand for comfortable, functional and comprehensively fitted out buildings that can be readily moved from site to site as production and construction demands change in fast-moving market sectors.
These buildings can be engineered to cost-effectively meet the repeat-use needs of sectors such as mining, energy, infrastructure, construction, government projects, defence, and water and power utilities.
The buildings offer a larger range of dimensions, including both standard width 2.4 m container structures and variations out to 4.5 m wide. They can be used to accommodate the needs of facilities such as site offices, accommodation, catering facilities, engineering workshops, maintenance facilities, safety and medical facilities, testing facilities, chemical stores, and electrical, switchboard, automation and process control centres.
Wider-than-standard floor plans offer 25–87% more space, depending on length, comfort and functionality, and to account for the special insulation needs of both plant and of people who must work in widely varying climates ranging from alpine to tropical.
Quality doors, windows, insulation, air conditioning, electrical, flooring and roof features are standard, while structures can be custom-engineered to provide wider access, greater window and service counter openings (such as for service areas), and security.
Modulate Group www.modulategroup.au/
CASE STUDY
Emergency services workers who respond to incidents on high-speed roads have a higher fatality rate and serious injury rate when compared to other workers.
In fact, SafeWork Australia data reveals that the fatality rate of emergency services personnel is 2.1 per 100,000 workers, compared with the national rate of 1.5.
Meanwhile, the serious injury claim rate is four times higher, and the prevalence of post-traumatic stress disorder in first responder populations is estimated to be six to seven times that of the wider community.
To combat this problem, Professor Sharon Newnam, Head of the QUT School of Psychology and Counselling in the Faculty of Health, created the ‘Safety in the Grey Zone’ program while at Monash University.
Newnam has now published a review of a trial of the program conducted with participants from six Victorian incident response agencies — ‘Safety in the Grey Zone’: Evaluation of a training program to improve the safety of incident responders on high-speed roads — in the Journal of Safety Research
The program differentiates between competencies like skills required to manage safety in high-risk traffic environments, which are role-specific and process-driven tasks, and capability, including skills in collaboration, engagement and teamwork requiring personal, interpersonal and cognitive ability.
Representatives from a Victorian Government transport agency, the police service, ambulance service, rural fire brigade, a private transport agency and a state emergency service took
part in online sessions using real-life scenarios, including a multi-car fatality and a breakdown, to help them understand the impact of their actions on their own and others’ safety practices. Most participants had at least 10 years’ experience in their roles.
The majority of trial participants reported that they encountered an average of three secondary incidents each month at the scenes of the incidents to which they respond, and had acquired substantial exposure and experience in managing safety on high-speed roads.
“High-speed roads are complex and dynamic environments long recognised as posing a significant safety risk for workers, largely due to factors such as fast-moving vehicles, traffic volume, attitudes of motorists (unsafe driving behaviours), roadworks,
existing crashes and back-of-queue incidents,” Newnam said.
“Safety in the Grey Zone was created to optimise the skills of incident responders in communicating and coordinating safety practices at the scene of an incident on a high-speed road.
“The concept of the grey zone originated during a stakeholder focus group discussion where it was mentioned that ‘things are never black and white during an incident on a highspeed road’.
“The roles and responsibilities of workers within each agency are important to consider in understanding the management of safety. In Victoria, each emergency service, such as ambulance services and fire brigades, is allocated distinct responsibilities, but there are instances where certain responsibilities
are shared depending on the availability of resources.”
Implementation of the program was conducted in collaboration with the Holmesglen TAFE, Eastlink and Visual Learning Design, with funding from the Victorian Department of Education and Training, Workforce Training Innovation Fund.
“Participants reported positively on their experience and satisfaction with the Safety in the Grey Zone program, especially in relation to it helping them think outside the square on how other agencies view a scene,” Newnam said.
“Feedback included how the training highlighted the need for inter-agency collaboration, the value of debriefing and having the confidence to approach other agencies to get an understanding of scene safety issues.
“We also found that the greater the number of attendees at a training session, along with representation of a variety of agencies, the greater the engagement of participants.
“Our findings provide recommendations to consider in the program’s future rollout in Victoria and Australia-wide, as well as suggestions for future evaluations to assess the program’s effectiveness in improving the safety of incident responders operating on high-speed roads.
“Also, while most participants had many years of experience this is not always an advantage because they are not hearing about the challenges faced by people newer to the job. Further implementation of the program should take that into account.”
Hazard detection sensors
TROAX Active Safety systems utilise advanced sensors, real-time monitoring, and automated responses for proactive hazard detection. These solutions promote safer interactions between pedestrians and vehicular traffic such as forklifts, thereby minimising the risk of accidents.
The product line is designed to elevate workplace safety standards by preventing accidents before they happen, safeguarding employees and assets.
Pedestrian Safety Systems include pedestrian alerts and crossing guards, while Forklift Safety Systems offer collision avoidance, roof radars, low-speed areas and blind spot detection. Meanwhile, Access & Traffic Control provides traffic control and pedestrian crossings.
The Active Safety range can be tailored to meet the specific needs of any industrial environment in various sectors including manufacturing, warehousing and logistics.
Troax Safety Systems Pty Ltd www.troax.com
Uncrewed military ground vehicle
The BAE Systems Australia autonomous tactical light armour system (ATLAS) collaborative combat variant (CCV) is an uncrewed ground vehicle (UGV) that gives military commanders an added tactical option while keeping soldiers out of harm’s way.
ATLAS CCV is a cost-effective, modular, 8 x 8 UGV that has been designed and built with autonomous technology. It incorporates existing, proven technologies to provide a capability that is mission configurable and upgradable, so that it continues to evolve to counter new and emerging technologies and threats.
The autonomy system at the core of the ATLAS CCV will ‘drive’ the vehicle, avoid obstacles, route plan, and make tactical decisions. It is designed to give soldiers the advantage on the modern battlefield.
ATLAS CCV is armed with a lightweight, automated medium-calibre turret system called ‘VANTAGE ATS’, designed for use on uncrewed platforms. The turret is designed with a ‘human in-the-loop’ targeting system.
ATLAS CCV is easily transportable, designed to fit into a standard 20-ft ISO container or 20-ft ISO flat rack. It will also deliver a logistics multiplier effect for companion crewed platforms, effectively extending the combat endurance of vehicles currently in service.
BAE Systems www.baesystems.com
Intelligent toilets
Instant Products Group intelligent toilets are equipped with monitoring technology that allows for real-time, remote monitoring of the waste being generated. Toilet spills and overflows in portable ablution blocks are a health and safety issue on worksites. By minimising the risk of an overflow incident, site sanitation is improved, adding to overall worker wellbeing. Where previously toilet waste was monitored through a basic float system that simply triggered a warning light when full, this updated technology enables real-time monitoring that maps usage and waste generated — designed to accurately forecast how long it will take until the tanks are full. It can also send text and email alerts when the tanks reach pre-set levels, which users can customise, avoiding the potential of any spill or overflow. This allows for improved planning and overall general health and safety standards onsite.
Instant Products Group instantproducts.com.au
CASE STUDY
Immersive VR training to keep forestry workers safe
A newly developed immersive VR training tool could enable forestry workers to be trained in a risk-free environment.
The ‘Mills Skills VR’ tool uses virtual reality across a range of scenarios, immersing users in a 3D environment that simulates all aspects of forestry practices, while training them in a risk-free setting.
The tool was developed by the University of South Australia with the support of the Green Triangle Forest Industry Hub, and is also expected to save the industry millions of dollars in the long term.
Lead researcher and immersive technology expert Dr Andrew Cunningham and developer Jack Fraser have spent the past year working on the VR tool to support training in South Australia’s forestry mills, and hope to roll it out nationally.
“For the untrained, the forest industry is inherently risky, especially in the mills because it involves large, heavy machinery,” Cunningham said. “It is also a fast-moving and busy environment, so if we can train workers to recognise the hazards and equip them with the skills before they step into the mill, it’s better for everyone.”
A significant benefit is that the trainees can use the VR tool anywhere in Australia with a virtual reality headset, saving time and costs in flying them halfway across the country.
Workforce Development Manager at the Green Triangle Forest Industry Hub Josh Praolini said the VR training model could reshape how training is delivered to forest industry workers in Australia.
“At the moment, we rely on access to trainers and machinery that is an essential part of the mill operations. By training new recruits on these machines, you slow or halt production, and expose them to potential risks,” Praolini said.
“This virtual reality tool allows us to safely introduce recruits to multiple scenarios they could encounter in the mill, as well as offering updated training to existing workers without impacting day-to-day operations of the mill.”
Cunningham is confident the industry’s willingness to embrace new technology will also make it an appealing career choice for high school and university students.
“The forest industry currently supports around 80,000 direct jobs in Australia, but we still need a lot more workers. Virtual reality can take people into a mill and a plantation, showcasing what is involved and the opportunities that lie ahead for a progressive and satisfying career.”
The next step is to adapt the training tool to other industries where safety is important, including building and manufacturing.
THE RIGHT TO DISCONNECT: WHAT EMPLOYERS NEED TO KNOW
Under new legislation that came into effect in August 2024, employees now have the “right to disconnect” from their workplace after hours.
So what does this means for employers?
According to employment expert and Managing Director of Employee Matters Natasha Hawker, every business in Australia with 15 or more staff is at risk for failing to meet their right to disconnect obligations.
“Ignorance is no excuse — employers must take action to comply now,” Hawker said.
What is the right to disconnect?
Under the new industrial legislation, eligible employees have the right to disconnect with their employer outside of work hours, unless their refusal is unreasonable. It means an employee can refuse to monitor, read or respond to contact from an employer or a third party outside of working hours.
Penalties for non-compliance can reach up to $19,000 per breach for individuals and increase to $90,000 per breach for companies under the Closing Loopholes Bill, which covers the right to disconnect.
In a recent case, the NSW Personal Injury Commission ordered an employer to pay a return-to-work coordinator 10 months’ back pay plus ongoing compensation for harassment during the employee’s personal leave.
The employee’s supervisor repeatedly contacted them via calls and emails, and even suggested involving the police for a welfare check. These actions were deemed unnecessary and provocative, especially given the employee’s role in ensuring safe and
successful returns to work.
“Under the new right to disconnect laws, such a case could lead to fines,” Hawker said.
So what should employers be doing?
According to Hawker, Australian businesses should urgently seek expert HR advice to update their internal policies to cover the right to disconnect legislation. This includes training and guidance on what constitutes reasonable and unreasonable contact outside of work hours.
“Each business needs to determine what works best for their own circumstances, respecting employee rights while maintaining the desired flexibility for both parties,” she said.
“Implementing these changes offers an opportunity to improve workplace communication, attract and retain top talent, and enhance employee engagement by reducing potential psychological risks.
“These risks are known in the industry as ‘psychosocial hazards’. The alternative is non-compliance, the risk of hefty fines, low morale, decreased productivity, and poor employee retention.”
Top tips for employers:
• Educate yourself about the Closing Loopholes Bill.
• Understand your obligations as an employer.
• Use this opportunity to foster workplace communication.
• Seek expert advice to update and implement your internal policies.
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