Background
Mines safety inspectors have identified serious safety issues related to the performance and management of on-site structural welding. Structural welds include welds associated with lifting lugs, safety devices and safety protection systems, which are often only loaded during critical safety events.
Failure of structural welds can lead to catastrophic structural collapse and expose workers to the risk of serious or fatal injury.
Regulation 6.4(2) of the Mines Safety and Inspection Regulations 1995 (MSIR) requires site welding to be undertaken to Australian Standards (AS) unless a higher standard is available.
The AS/NZS 1554 set covers the requirements of welding, with AS/NZS 1554.1 section 1.7.2 stating that a weld shall:
- be made in accordance with a qualified welding procedure
- be carried out by a welder suitably qualified to carry out such a procedure
- be carried out under the supervision of a welding supervisor
- comply with the appropriate requirements of this Standard.
Summary of hazard
Welds that are not carried out to the required standard expose workers to the risk of serious or fatal injury if the weld fails at a safety critical time, such as:
- collapsing plant or sections of plant
- lifted loads falling from height
- falling from heights if the handrail or safety attachment point fails
- uncontrolled movement of plant if welded connections fail.
Contributory factors
- Weld requirements not specified by a competent person.
- Welds not made in accordance with qualified welding procedures.
- Welds not carried out by suitably qualified welders.
- Welds not carried out under the supervision of a qualified welding supervisor.
- Welds not inspected by a qualified welding inspector.