Fatal incident involving fall from tilt tray truck

Possible control measures to prevent similar incidents

Persons Conducting a Business or Undertaking (PCBU) must control the risks associated with plant, including the risk of people falling from trucks associated with tilt tray towing operations.

PCBUs should conduct a risk assessment of work practices, develop appropriate safe work systems, conduct appropriate training and ensure the system is enforced at the workplace.

The person with management or control of plant at a workplace must:

• Determine whether or not the proposed use of the plant increases the risk to health and safety, by ensuring the risk is assessed by a competent person.
• Take all reasonable steps to ensure all safety features, warning devices, guarding, operational controls and emergency stops are used in accordance with the instructions and information provided.

PCBUs also have a duty to ensure the health and safety of other people who may be put at risk from work carried out by the business or undertaking, for example involving members of the public in tow truck operations.

A safe system of work should be implemented to manage the risks associated with tilt tray truck operations.

This should include, but is not limited to, the following:

• The plant selected for the work is:
  • Suitable for the task for example, the truck or trailer’s tray is long enough to transport the vehicle and the vehicle’s mass is within the capacity of the winch and truck.
  • Fitted with appropriate safety features.
  • Maintained in a safe condition, including all safety features are correctly adjusted and operating correctly.
• Ensuring the plant (including the winch system) is inspected, maintained and repaired according to the manufacturer’s recommendations and specifications. The manufacturer's instructions must be included in a safe work procedure on how inspection and maintenance should be carried out.
• Attachment hardware (such as chains, shackles, binders and tie down straps) and the different rigging configurations used for vehicle recovery should be specified by a competent person. All attachment hardware should be load rated by the manufacturer and comply with the relevant Australian Standard for the intended task.
• Ensuring the stall capacity of the winch is less than the minimum breaking capacity of all connectors such as shackles, cables and slings for the rigging configuration in use.
• Ensuring tow points on the vehicle to be retrieved are adequate and have not been damaged.
• A regular inspection program should be implemented for both the recovery winches and any attachment hardware including engaging a competent person to carry out inspections of all critical components as prescribed by the manufacturer. This includes but is not limited to the inspection of the winch, winch cable, chains and tie- down points.
• Implementing exclusion zones to prevent unnecessary people from entering the area. The size of the exclusion zone should be based on a written risk assessment and clearly marked.
• Ensuring the tilt tray operator has received adequate information, training and instruction to use the plant and its equipment. PCBU’s should assess and verify the operator’s knowledge and competence to operate the plant before they commence work. In some circumstances, the operator may also need to hold the appropriate licence(s).
• Information, training and instruction should include, but not limited to:
  • Ensuring the loading and unloading of a vehicle is undertaken according to the manufacturer's instructions.
  • Ensuring the truck is on firm level ground with no side slope.
  • Ensuring the vehicle is in line with the tray and the wheels are straight to stop the vehicle falling off the side of the tray (where practicable).
• Ensuring the vehicle is firmly secured on the tray in accordance with the NHVR Load Restraint Guide (PDF, 46.38MB) and transported in compliance with Department of Transport and Main Roads requirements.
• Minimising the time needed for a worker to stand on a truck tray, especially close to the edge of the tray.

Any remaining risk must be minimised with suitable personal protective equipment (PPE). Examples of appropriate PPE include eye protection, hard hats, steel cap boots, and high visibility vests.

Administrative control measures and PPE rely on human behaviour and supervision. If used on their own, they are not as effective in minimising risks. The control measures you put in place should be reviewed regularly to make sure they work as planned.