In February 2021, maintenance personnel at an exploration camp were carrying out maintenance to a reverse circulation drill rig and had attached a rod handler to the upright mast.
The rod handler, which is a hydraulically activated mechanism that consists of a grabbing implement and pivoting ‘elbows’, was lifted into place and fitted to the vertically orientated mast by means of a bolted mounting bracket, with the pivot/rotation point of the rod handler arm located at the bottom.
Maintenance personnel then installed a break out assembly – a gripping mechanism used to secure rods when coupling or uncoupling – to the drill rig and commenced reattaching hydraulic hoses.
During the task, a driller's assistant, who was instructed to reconnect hydraulic hoses, had placed himself between the rod handler and break out assembly.
The rod handler arm unexpectedly rotated down crushing the assistant’s head between the loweringrod handler arm and the breakout assembly.
The driller’s assistant sustained serious injuries.
Direct causes
- The driller's assistant was in the line of fire when the rod handler arm swung down causing crushing injuries.
Contributory causes
- The unsecured rod handler was installed in the vertical position due to the mast being upright.
- The original equipment manufacturer (OEM) procedure for attaching the rod handler required the mast to be positioned horizontally prior to mounting.