LTI: Foot trapped between pipes

What happened

During pipe handling operations a rigger positioned himself at the pipe’s bottom layer gap. A pipe from the upper layer rolled down into the space on the bottom layer, trapping the riggers left foot resulting in a Lost Time Injury (LTI). 

What went wrong? The worker walked towards the pipe stack. The pipe on the top layer was still connected to the gantry crane. He stepped forward into the gap on the bottom layer. At the same time, the pipe stack shifted, trapping his ankle, causing an LTI. The sequence of events is illustrated here:      

   What was the cause?

• This was a repetitive task which had been ongoing for two months (loading and unloading 2000 pipejoints during this period);
• There were sufficient team members on site, but the other riggers were involved in another task elsewhere. The crew person involved decided to continue the task on his own to get the job done;
• Temporary wedges were available during the pipe handling operations. The pipe stacking area, however, was not set up with permanent wedges or spacers to ensure the pipes could not roll;
• A stacking plan and a risk assessment were available, but neither were being followed at the time;
• Inspections and audits had failed to verify controls and preventive measures;
• Human factors – risk perception and competency of personnel involved in operations.

Members may wish to refer to

• Serious injury during pipestalk rolling operation (2006)
• Lost time injury (LTI) during lifting operations – backloading tubular cargo (2015)
• Injury caused by shifting load of pipes (2016)
• LTI: Leg Fractured While Loading Tubulars (2020)