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Component Mixing: The practice of mixing and matching scaffold components without an engineer- ing report, adhering to the Australian standards con- tributes to instability and potential accidents. These compliance and safety issues in scaffolding are not to be taken lightly. Adherence to Australian standards is paramount for ensuring worker safety and the success of the vessel construction project. Immediate corrective actions are essential to rectify these concerns and uphold the high safety and qual- ity standards required in the shipbuilding industry.
This inspection uncovered massive issues with the scaffold work done by Scaff-west which was well below minimum industry requirements with work- ers being forced to use incomplete scaffold that was dangerous. The subsequent four-day shutdown of the scaf- folding highlights the severity of the situation. By allowing these substandard contractors to operate below Australian standards, Luerssen is jeopardis- ing worker safety on the project. Scaffolding is a critical component of shipbuilding construction, and its compliance with Australian standards are essential for worker safety and proj- ect integrity. However, recent observations have revealed several issues that demand immediate at- tention.
This is not the first safety incident Luerssen has been involved in at Henderson.
Challenges and Safety Concerns Plague Luerssen Offshore Patrol Vessel Project The Luerssen Offshore Patrol Vessel project in Hen- derson, Western Australia, is facing critical challeng- es that have and will cause significant project delays and cost blowouts. The most serious are the choice of substandard subcontractors and a consistent history of minor and major safety incidents which have cre- ated a toxic environment that raises concerns about the project itself. The construction of offshore patrol vessels is a mas- sive endeavor that necessitates strict adherence to safety standards and efficient project management. However, the Luerssen project in Henderson is fraught with substantial delays and alarming safety issues. The foremost concern with the Luerssen project is the compromised safety conditions on-site. Safety is a non-negotiable aspect of any project, and it is ev- ident that these standards are nowhere near being met . The mismanagement of subcontractors by Lu- erssen has resulted in ineffective oversight and coor- dination, further exacerbating safety concerns. There is a culture of non-reporting of safety incidents and coverups where possible with senior safety managers refusing to acknowledge the problems that are right in front of them.
A previous incident highlighted issues related to electrical standards, power distribution boards, and lighting. There have been four serious crane inci- dents over the last few months, including a dropped load when rotating a 30-tonne block section and a fender incident. Shadbolt and Luerssen’s tried to force the rigging crew to attempt to lift two engines into a vessel without a safe working load assessment on the lifting points, raising serious concerns about the company’s safety culture. This was compounded when management threatened the rigging team to accept unsafe conditions or face redundancy which is deeply troubling. There have been 2 separate crane hook block dropping incidents with the second one going through scaffold encapsulation and the walk- way for painters – both were near fatalities but for dumb luck. Combine all these incidents with Luerssen basic mis- understanding around high-risk work licenses and the need for them and it’s easy to see why things are so catastrophically wrong. Luerssen’s have had workers performing high risk work without the re- quired high-risk licenses. They even thought that performing dogging work didn’t need the HRWL li- cense and workers could perform dogging work off another dogmen’s’ license. The management assertion that if the current team doesn’t comply and overlook safety incidents and concerns, they’ll resort to Vulcan, an external com- pany, for rigging operations without independent engineer reports or a lift plan is a glaring indication of Luerssen’s alarming disregard for safety and stra- tegic planning. The incident in the other workshop further emphasizes the pervasive safety issues that put workers at risk.
Engagement of Substandard Subcontractors and Safety Concerns One of the primary factors contributing to safety is- sues and project delays is Luerssen’s choice of sub- standard subcontractors. The use of these contrac- tors, who do not uphold the basic required safety standards, is evident from their shoddy treatment of their workers - including substandard wages, in- ferior working conditions, substandard Safe Work Method Statements (SWMS), and Job Hazard Anal- yses (JHA). The MUA was left with no choice but to raise safety concerns directly with the Defense Department in Canberra. As a result, we were invited onto site for a site inspection on the 24th of October where we highlighted a host of safety concerns including scaf- folding, electrical leads and tagging, and air quality.
Compliance and Safety Challenges with the Scaffold Missing Bracing and Faulty Boards: Scaffolding often suffers from missing bracing and the use of faulty boards, compromising the structural integri- ty and posing significant safety risks. Inadequate Access and Egress: Inadequate access and egress points create hazards for workers trying to navigate scaffolding safely. Emergency Stretcher Access: The absence of proper emergency stretcher access routes raises concerns about timely response in critical situa- tions.
It’s no wonder that all lifts were completely suspend- ed in the workshop for over 2 weeks.
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