Mechanic crushed under prime mover

Possible control measures to prevent similar incidents

Persons conducting a business or undertaking (PCBU) are required to manage the risks associated with vehicle repair and recovery at the roadside, including immobilised vehicles. Working on, under or around trucks and trailers can lead to severe crush injuries if you don't securely immobilise them. Make sure your workers are using suitable controls to immobilise vehicles before work commences. Effective controls are often made up of a combination of controls. Some examples are below.

Park brake warning systems

Installing a park brake warning system to alert drivers when the park brake has not been applied:

• Park brake warning systems are a good way to remind drivers to apply the park brake before they get out, wherever they are.
• Before making any modifications to your vehicle, the competent person conducting any changes should consult with the manufacturer of the vehicle first.
• Ensure that any modifications are compliant with the relevant Australian Design Rules (ADRs) and design of the vehicle.

Safe system of work

Implementation of a safe system of work to manage the potential risks associated with inspection, repair and recovery of vehicles at the roadside or other locations (including immobilisation) should be done by the PCBU in consultation with workers.

The safe system of work needs to include documented risk assessments to control the risks when working on, near or under vehicles at offsite locations. This may include:

• Before leaving a vehicle ensure it is stationary and out of gear with the park brake applied. In the case of prime movers and semi-trailers ensure the park brake for the prime mover and trailer is applied. Do not rely on the trailer brake alone to prevent the vehicle moving.
• Remove the ignition key while working on the vehicle, preferably with the person working under the vehicle keeping the key.
• Work in a controlled environment where possible and restrict access to the immediate work area. Create an exclusion zone around the vehicle (ensuring it’s clearly marked and enforced).
• Consider chocking wheels on both sides of the vehicle using serviceable purpose-built chocks, especially on sloping ground.
• Using a flat even surface that can bear the general load of the vehicle and the point load of any equipment such as jacks/lifting equipment.
• Develop and use safe work procedures that describe the vehicle repair and recovery tasks that identify the hazards and document how the task is to be performed to minimise the risks in line with the manufacturer's recommendations
• You then need to ensure workers are instructed, trained and supervised in these procedures. This can also include, but is not limited to, ensuring drivers and other workers know what actions they are required to take in the event of a vehicle breakdown. For example:
  • pull the vehicle off the road where possible
  • turn on vehicle’s hazard lights
  • apply (or set) the vehicle’s park brake
  • mark the area with portable warning triangles (or similar)
  • use (or set) wheels chocks, use of stands, jacks, or other suitable systems for immobilising vehicles
  • a lock and tag out process to effectively immobilise vehicles.

• Wearing suitable personal protective equipment such as high visibility clothing and steel cap boots.
• When wheels are removed, never get under a vehicle that is supported by a jack – always make sure load rated vehicle stands of adequate capacity are correctly placed under designated support points on the vehicle.

Depending on the circumstances, you must also follow any applicable road rules.

The control measures you put in place should be reviewed regularly to ensure they are effective.