The task ahead
A series of targeted upgrades had been rolled out across 36 of Dubbo Regional Council’s (DRC) pump stations, strengthening safety standards and creating a more secure environment for employees.
Safe access specialist Mass Products was engaged by DRC to work alongside staff to conduct an audit of 33 sewerage pump stations and three raw water pump stations.
The detailed audit helped the council identify, prioritise and allocate a budget for legacy maintenance and structural issues at the sites.
The audit found key access issues included dated infrastructure designs that contributed to manual handling risks and potential falls into voids, as well as structural issues.
Across all sites, common problems included heavy covers, a lack of safety grates or permanent handrails surrounding openings, missing restraining systems and access systems that could not be safely operated by one person.
Simplifying access
Mechanical coordinator Dennis Murphy said the wet well at Bunglegumbie sewerage pump station was a prime example of dated infrastructure designs before the upgrades.
“To extract a single pump, we had to remove 17 lid sections and the central beam,” he said. “We even had to lay down on our bellies to reach into the well and undo bolts to get the beam out. The whole well was fully open and we’d just be tethered to a side handrail.”
“It’s dangerous when workers accept that sort of situation as normal – but it is pretty much across the water industry.”
Murphy said the enhancements undertaken since the audit have made the sites much safer.
“Getting a pump out of a wet well now doesn’t take 17 processes; we lift one hinged lid and it has a safety grate protecting us. If there’s no exposed opening it’s impossible to fall in,” Murphy said.
Worker safety prioritised
Mass Products CEO, Paul Harazim, said his company was appointed to design, manufacture and install a standardised system of safe access covers, grates, rails, bollards and lids. Many of these items are ergonomic and lightweight. The program took about 12 months to complete.
“It’s now virtually impossible for council workers to fall into pits and wells. Using a standardised approach makes compliance with workplace health and safety legislation and Australian Standards clear. You don’t need different controls for 33 pump stations; you really only need one,” Harazim said.
“Maintenance is less of a chore. Mass Products estimates that a standardised safe access approach can result in a 50 per cent time saving and a 90 per cent cost saving for routine maintenance. For a regional council water business, that could be hundreds of thousands of dollars saved each year”.
Dubbo Regional Council manager operations water supply and sewerage Bec Eade, said the comprehensive enhancements across facilities has changed the work environment for her team.
“There have been no safety incidents at council pump stations since we completed the safe access program.”
For more information, visit www.massproducts.com.au
This article appears in the March/April 2026 edition of Utility. Subscribe HERE.
