Leg injury when struck by rebounding hammer

The incident occurred when the crew member was using the hammer to remove a stainless steel securing pin on the brake band drum of a tugger winch. The crew member was using the hammer and other equipment to remove a stainless steel securing pin, which was positioned at knee height on the brake band drum.

The pin was moving both ways a little, but required more lubrication. Spray lubricant was applied and was working through the pin mounts. 

The crew member was striking the pin out using the hammer; one blow missed the pin, rebounded back and struck his right lower leg, causing a small cut and bruising above the ankle.

• A Toolbox Talk and Operational Risk assessments had taken place before starting work.
  
  
• All correct PPE was being worn at the time of the incident occurring.

• The crew member was in the line of fire – his leg was so positioned as to be hit when the hammer rebounded.
  
  
• The arc / swing of the hammer onto the pin required precision to avoid striking to the side, which resulted in uncontrolled rebound of the hammer in an undesired direction.

• Immediate causes
  
  
  • The crew member hit the pin in such as way as to cause the hammer to rebound in an uncontrolled direction.
    
    
  • The crew member's leg was in the way. 
    
    
• Root causes
  
  
  • Inadequate continuous risk assessment
    
    
    • The crew member did not identify the potential hammer miss-hit and rebound direction of the hammer during the activity.
      
      
    • The risk assessment did not identify the required body position to ensure it was not in the line of fire.

• STOP Work Authority
  
  
  • No “Stop Work” and review the activity was undertaken during the tasks to evaluate the controls being implemented and the possible requirement to improve (by the individual or others).