A lump of hardened concrete had built up on the mixer support structure of a concrete plant.

During the loading of a mixer truck the lump became loose, falling to the ground. The lump fell and landed inside an exclusion zone, however as the lump struck the ground, it broke into several large pieces, with some travelling outside the exclusion zone. Moments before the lump fell a driver had been standing outside the exclusion zone, adjacent to where the lump fell. Although the lump would not have hit him directly, there was potential for the broken pieces to have struck him on the back of the legs.

Image 1 - Driver standing outside exclusion zone washing his truck down

Image 2 - Build up fell the other side of the cross bracing, breaking into large parts and narrowly misses the driver

• Review cleaning regimes to minimize the buildup of material and the risk of lumps being dislodged and falling.
• Areas where there is a risk of material falling to be designated exclusion zones with barriers and warning signs displayed.
• Where access is required controls in place to protect against falling material.