DOS-AW-201641-SAS-1620093 Downstream Oil Sands – Shell Albian Sands October 2016

Shovels – Worker’s Foot Gets Pinned under a Shovel Trackpad Actual Track Pads

Target audience for this alert

 Heavy Equipment Technicians
 Maintenance Personnel

What happened
On April 20, 2016, at the Muskeg River Mine Shovel #01 Maintenance Pad, Simulation
a set of two new trackpads were delivered and staged on the maintenance
pad.

On April 21, 2016, at approximately 09:30 am, the trackpads had to be

separated to make two single pads available prior to installation on Shovel
#01. Two employees (one loader operator, one spotter) were attempting to lift
the trackpad closest to the loader. The spotter was positioned beside the other
trackpad (see image). The spotter initiated hand signals to the loader operator attempting to guide the forks under
the trackpad. Both trackpads shifted, resulting in the spotter's right foot being pinned under the rear trackpad.

The trackpad was lifted with a sling to free the spotter’s steel toe boot. The worker was transported to Northern
Lights Regional Hospital for assessment.

Why it happened
 The worker’s attention was focused on the advancement of the loader and alignment of the forks.
 The worker had their foot in the line of fire and did not recognize the potential movement of the outer trackpad as
a pinch point.
 When the loader forks were being lined up to re-position/separate the pads, the trackpads shifted and the outer
trackpad contacted the spotter’s right foot on the top of the steel toe boot.
 The worker felt that the risk was low enough to position themselves in this way.
Lessons learned
 It's important to be mindful of new potential pinch points / line of fire hazards while working around equipment
and machinery.
 Always review and follow the appropriate maintenance procedures.
 In this situation, risk assessments were not completed or adequately updated to reflect the change of job scope.
 Taking shortcuts to get the job done increases risk potential and can lead to injuries. It's important to PAUSE and
ask questions if something doesn’t feel right.

Recommendations
 Update procedure “495HF- Tracks - Split, Unwrap/Wrap, Remove/Install Track Pads/Install Track” to include a
warning (in applicable steps); all personnel in the area must stay out of the line of fire while the loader is pulling.
 If you are unsure of the proper procedure, it’s important to ask a fellow worker or Team Leader for assistance.

Further information
Jason Weller, Shovel Manager, can be contacted for more incident details or more information regarding the
recommendations. FIM Incident ID: 1620093