Safety Alert

What Happened

A process operator collapsed from heat exhaustion while conducting a routine inspection of the SAG mill discharge area. The ambient temperature was 44 degrees Celsius. The operator had been working for 3 hours without a scheduled heat rest break and had consumed less than 500mL of water during that period. Co-workers administered first aid and the operator was transported to the site medical facility. Full recovery was made.

Why It Matters

Heat stress is a serious and preventable hazard in Western Australian mining operations. Heat exhaustion can rapidly progress to heat stroke, which can cause organ failure and death. The body can lose up to 1.5 litres of sweat per hour in extreme heat — inadequate fluid replacement leads to rapid dehydration and impaired thermoregulation.

Immediate Actions Required

1. 1Heat stress management plan to be reviewed — mandatory rest breaks at 1-hour intervals when temperature exceeds 40 degrees Celsius
2. 2Cool water stations to be installed at all remote process plant inspection locations
3. 3Supervisors to actively monitor crew hydration and rest compliance during extreme heat events
4. 4Deploy portable shade structures at outdoor inspection locations in the Processing Plant
5. 5Issue personal hydration monitoring cards to all outdoor workers

Key Learning

Heat stress is preventable but unforgettable. In 44-degree heat, your body needs at least 1 litre of water per hour. Rest breaks are not optional — they are a medical necessity. Look out for your mates: if someone looks red-faced, confused, or stops sweating — that is a medical emergency. Act immediately.

Discussion Points for Toolbox Talk

• •How much water do you typically drink during a shift in hot conditions? Is it enough?
• •What are the early warning signs of heat exhaustion that you should look for in yourself and your workmates?
• •Do you know the correct first aid response for heat stroke? What is the critical difference between heat exhaustion and heat stroke?