In the workshop, a section/flange of an armoured pipe [compound material of normal steel (outside) and of wear-resistant steel (inside), with a diameter of 150 mm] needed to be cut.

In the first phase of the operation the pipe section was placed on a roller stand, one employee cut all the way around the pipe (from above, the upper 180 °). The operator only cut the layer of normal steel, assuming that the wear-resistant steel inside still had sufficient contact with the flange.

For the final cut, the plan was to rotate the pipe (including the flange) by 180°. However, the connection between the normal steel and the inner wear-resistant steel was defective, a full compound of the two layers was compromised. As a result of this, the flange unexpectedly detached before the pipe could be rotated, and fell onto the finger of the second employee assisting with the task.

This resulted in a fracture of the first limb of the ring finger of the second colleague.

KEY FINDINGS

• The risk assessment was up to date.
• Although an on-site safety check (Take 5) was carried out, it failed to take into consideration the risk of the materials not bonding properly any longer and, consequently, the flange falling unexpectedly.
• The joint/compound in the armoured material was faulty.
• They had failed to secure the section/flange to prevent it from falling.
• They had been wearing normal gloves (without protectors).

LESSONS LEARNT

• When planning the work, take measures to secure the part to be cut.
• Carry out a full Take 5 assessment with consideration of all possible risks.
• Do not put yourself into the line of fire.
• Make use of the available safer gloves with protectors.

NOTE

Take 5 is a safety checklist is a quick 5-minute personal risk assessment that workers complete before starting any task to identify immediate hazards and set safety controls. It follows a simple 5-step procedure: Stop, Look, Identify, Assess, Control.