Worker’s crushed hand leads to $295k safety overhaul following charges

A masonry products manufacturer has entered into an enforceable undertaking to improve workplace health and safety after a worker suffered a severe hand injury, leading to multiple charges against the company.

National Masonry has committed to spending $295,000 to improve workplace health and safety after a worker suffered a severe hand injury in a forklift accident that resulted in a partial amputation.

In late September, the Sunshine Magistrates Court heard that the masonry products manufacturer had entered into an enforceable undertaking while facing four charges relating to failing to ensure a safe workplace.

Under the terms of the undertaking, the company faces the possibility of WorkSafe reinstating the charges if it breaches or withdraws from the agreement.

According to WorkSafe, the incident occurred in August 2023 at the company’s factory and storage yard in Deer Park, where a worker’s forklift tipped over after a truck moved forward unexpectedly, striking the forklift’s tynes and causing it to topple.

The worker’s left hand became trapped in the forklift’s frame rails and was partially amputated when it hit the ground.

While re-attachment surgery has restored some movement, WorkSafe has stated that a full recovery remains “not expected”.

Investigations by WorkSafe uncovered that “a number of near misses” had occurred at the site prior to the accident, including “several instances of unidentified pedestrians almost coming into contact with vehicles moving in the yard”.

Through such revelations, WorkSafe alleged that National Masonry had failed to reduce the risk of “powered mobile plant overturning or colliding with other powered mobile plant and pedestrians”.

The workplace health and safety regulators also alleged that the company failed to implement exclusion zones for forklifts during loading, did not provide adequate training for forklift operators and truck drivers, and did not ensure that pedestrians used designated walkways.

Under the $295,000 enforceable undertaking, WorkSafe has reported that National Masonry has agreed to:

• Hire an engineering designer to develop and test mast detection and payload monitoring systems that can be retrofitted to forklifts to prevent accidents.

• Analyse and validate the prototypes across various scenarios, providing evidence of training for workers.

• Produce an educational video series for industry associations highlighting gaps in current forklift safety systems, lessons from the project, and the new prototype solutions.

• Donate $15,000 to the Australian Institute of Health & Safety’s “Body of Knowledge” program.

Sam Jenkin, WorkSafe chief health and safety officer, stressed that forklift incidents are far from rare, with many injuries occurring in situations that could be prevented through proper safety measures, including effective training and robust safety systems.

“In 2024–25, forklifts were a factor in almost 160 workplace injuries, and yet there are many cost-effective safety systems that can be implemented to reduce or eliminate the risk of these incidents,” Jenkin said.

“This case is an example of how safe systems and adequate training can make a significant difference, and we’re confident the improvements to come out of this terrible incident will help prevent further harm at this workplace and others in the industry.”