Comprehensive SWMS for road profiler operations including stability controls, dust suppression systems, hearing protection requirements, and visibility management procedures

Road Profiler Machine Safe Work Method Statement

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Road profiler machine operation involves the use of heavy milling equipment to remove asphalt and concrete surfaces from roads, highways, car parks, and paved areas. These powerful machines use rotating drum assemblies with carbide-tipped cutting teeth to grind and remove surface layers to specified depths and profiles. This Safe Work Method Statement addresses the unique hazards associated with road profiler operations including machine tip-over on slopes and uneven surfaces, significant dust generation requiring respiratory protection, continuous noise exposure exceeding 85 decibels, and visibility limitations during operation. Road profiling is essential for surface preparation before resurfacing, correcting surface irregularities, removing failed pavement, and achieving required cross-fall and longitudinal grades. Operations typically occur in active traffic environments requiring comprehensive traffic management controls to protect workers and the public.

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Overview

What this SWMS covers

Road profiler machines, also known as cold planers or milling machines, are specialised heavy equipment designed to remove and recycle asphalt and concrete pavement surfaces. These machines feature a rotating cutting drum assembly equipped with hundreds of carbide-tipped cutting tools that grind pavement to specified depths ranging from 20mm to 300mm or more. The cutting process generates significant quantities of milled material that is collected by integrated conveyor systems and transferred directly to haul trucks for recycling or disposal. Road profilers are essential for highway maintenance, pavement rehabilitation, surface correction, and preparation for asphalt overlays. Machines vary in size from compact units suitable for footpaths and small areas to large highway-class profilers with cutting widths exceeding 4 metres. Modern profilers incorporate sophisticated control systems including laser or sonic sensors providing automated depth control and grade following capabilities. The milling process produces substantial dust, noise, and vibration requiring comprehensive environmental and worker protection controls. Operations typically occur in active traffic environments necessitating detailed traffic management planning to separate workers and equipment from passing vehicles. Road profiler operators require specialised training and certification to safely operate these complex machines while managing multiple simultaneous tasks including steering, depth control, material discharge, and coordination with support vehicles. The work environment presents numerous hazards including machine instability on slopes, dust inhalation, excessive noise exposure, visibility limitations, and interaction with traffic and support equipment. This SWMS provides comprehensive guidance for managing hazards throughout road profiling operations from pre-start inspection through project completion and site restoration.

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Why this SWMS matters

Road profiler operations present significant occupational health and safety risks requiring stringent controls to prevent serious injury and illness. Machine rollover represents one of the most severe hazards with potential for operator fatality and significant property damage. Profilers have high centres of gravity and can become unstable when operating on slopes, uneven surfaces, or near unprotected edges. Australian statistics indicate multiple serious incidents involving profiler rollover have occurred during road maintenance operations. Dust generation during milling operations poses significant respiratory health risks with exposure to crystalline silica dust known to cause silicosis, chronic obstructive pulmonary disease, and lung cancer. Safe Work Australia identifies respirable crystalline silica as a priority health hazard in construction and road maintenance activities. Noise exposure from profiler operations regularly exceeds 85 decibels requiring implementation of hearing protection and operational controls to prevent noise-induced hearing loss. Long-term exposure without adequate protection causes permanent hearing damage affecting thousands of construction workers annually. Road profiling occurs predominately in live traffic environments creating substantial risk of vehicle strikes affecting workers, equipment, and the travelling public. Traffic management failures contribute to multiple fatalities each year on Australian road worksites. The Work Health and Safety Act 2011 requires elimination of risks so far as reasonably practicable with systematic risk management following the hierarchy of control. Inadequate safety measures can result in serious legal consequences including prosecution of companies and individuals under workplace health and safety legislation. Beyond legal requirements, organisations have moral obligations to protect workers from preventable injuries and occupational diseases. Implementing comprehensive safety controls demonstrates organisational commitment to worker welfare, enhances industry reputation, and contributes to positive safety culture. This SWMS provides practical, implementable controls based on engineering principles, manufacturer recommendations, industry standards, and regulatory requirements specific to Australian road profiling operations.

Reinforce licensing, insurance, and regulator expectations for Road Profiler Machine Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

High

Road profilers have elevated centres of gravity due to the weight of cutting drums, conveyors, and operating compartments positioned above the chassis. When operating on cross-slopes, longitudinal grades, or uneven pavement surfaces, profilers can become unstable and tip sideways or backwards. Tipping is exacerbated when turning on slopes, operating near pavement edges or drop-offs, or when cutting drums are lowered on one side creating asymmetric loading. Soft ground conditions or pavement edge collapse can cause one side of the machine to drop suddenly resulting in rapid rollover. Operators have been seriously injured or killed when machines tip and operator compartments contact the ground or are struck by other equipment.

Consequence: Operator fatality or serious injury from crushing, impact, or ejection from machine. Significant equipment damage and project disruption. Potential damage to surrounding infrastructure and vehicles.

High

The milling process generates enormous quantities of airborne dust containing respirable crystalline silica from asphalt aggregate and concrete. Cutting teeth pulverise pavement material into fine particles that become airborne and can remain suspended for extended periods. Without adequate suppression, dust clouds can reduce visibility to zero and expose workers to silica concentrations far exceeding workplace exposure standards. Crystalline silica particles smaller than 10 microns penetrate deep into lung tissue causing irreversible damage. Even short-term exposure to high concentrations presents serious health risks. Operators inside machine cabins are exposed if cab pressurisation or filtration systems fail. Ground workers directing operations or managing traffic are exposed to dust drifting downwind from active milling.

Consequence: Acute respiratory distress and long-term development of silicosis, chronic obstructive pulmonary disease, or lung cancer. Silicosis can develop after months of exposure and may continue progressing even after exposure ceases. Reduced visibility can contribute to traffic or equipment incidents.

Medium

Road profilers generate continuous high-intensity noise from cutting drum operation, hydraulic systems, and diesel engines. Noise levels at operator position typically exceed 85 decibels even inside enclosed cabs, while ground workers near the machine are exposed to levels exceeding 100 decibels. Prolonged exposure causes permanent noise-induced hearing loss through damage to delicate hair cells in the inner ear. Damage is cumulative and irreversible. Communication difficulties in high-noise environments increase risk of miscommunication contributing to coordination failures between profiler operators, traffic controllers, and truck drivers. Excessive noise causes fatigue, stress, and reduced concentration affecting worker performance and safety awareness.

Consequence: Permanent hearing loss affecting quality of life and employment opportunities. Tinnitus causing persistent ringing or buzzing. Communication difficulties contributing to safety incidents. Reduced situational awareness from hearing protection use.

Medium

Road profiler operators have restricted visibility due to machine configuration with large cutting assemblies and conveyors obscuring views to the sides and rear. Dust generation further reduces visibility even with water suppression operating optimally. Working in active traffic environments requires operators to monitor road users, support vehicles, ground workers, and machine performance simultaneously while maintaining travel path and depth control. Limited visibility increases risk of striking ground workers, colliding with support vehicles, or failing to detect approaching traffic. Reversing operations are particularly hazardous with operators unable to see behind machines clearly. Night operations compound visibility issues despite lighting systems.

Consequence: Workers struck by machines during reversing or turning operations causing serious injuries or fatalities. Collisions with support vehicles or infrastructure causing equipment damage and injuries. Failure to detect approaching traffic resulting in vehicle strikes.

High

Road profiling operations occur predominantly on active roads, highways, and streets with traffic passing the work zone. Despite traffic management measures, vehicles regularly encroach into work areas due to driver inattention, excessive speed, or failure to observe signage. Profiler operators focused on machine operation may not detect approaching vehicles until collision is imminent. Ground workers including traffic controllers, spotters, and support vehicle operators are particularly vulnerable to vehicle strikes. High-speed road environments significantly increase severity of vehicle strikes. Night operations and reduced visibility conditions further increase strike risk despite additional warning measures.

Consequence: Worker fatalities or serious injuries from high-speed vehicle impacts. Damage to profiler equipment and support vehicles. Traffic incidents involving multiple vehicles. Long-term psychological trauma for workers and drivers involved in serious incidents.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Conduct comprehensive ground condition assessment and machine inspection before commencing operations to identify and eliminate hazards at the planning stage. Engineering surveys establish safe operating parameters including maximum slopes, edge clearances, and ground bearing capacity requirements. This eliminates rollover risks by ensuring operations only proceed where ground conditions support machine stability.

Implementation

1. Survey work area identifying cross-slopes, longitudinal grades, pavement edge conditions, and drop-offs 2. Test ground bearing capacity at pavement edges and on soft shoulders using proof rolling or penetrometer 3. Determine maximum safe operating slope based on machine specifications - typically 15-20% cross-slope maximum 4. Identify areas requiring ground improvement, edge protection, or operational restrictions before profiler mobilisation 5. Review machine stability specifications with operator including centre of gravity, maximum operating slopes, and stability limits 6. Plan milling patterns to minimise operations on cross-slopes and near unprotected edges 7. Inspect profiler mechanical systems including hydraulics, steering, brakes, and cutting drum assemblies 8. Test all safety systems including ROPS integrity, seatbelt function, and emergency stops before commencing operations

Implement integrated water suppression systems that physically prevent dust generation at the cutting interface. Engineering controls inject water directly at cutting teeth and material discharge points preventing dust from becoming airborne. Modern profilers incorporate sophisticated spray bar systems with multiple nozzles providing complete coverage across cutting width.

Implementation

1. Verify profiler water suppression system is operational with adequate flow rate - typically 100-200 litres per minute minimum 2. Inspect all spray nozzles before operation ensuring none are blocked or damaged 3. Fill water tank to capacity before commencing milling - monitor level continuously during operations 4. Position spray bars to direct water at cutting drum leading edge and material discharge points 5. Adjust water flow rate based on material type, cutting depth, and observed dust generation 6. Supplement machine water system with water truck providing additional dust suppression downwind of operations 7. Install cab pressurisation and HEPA filtration systems maintaining positive pressure inside operator compartment 8. Monitor cab air pressure and filter condition replacing filters according to manufacturer schedule 9. Stop operations if water system fails until repairs are completed - do not mill dry

Profiler operator compartments engineered with sound insulation materials and sealed construction reduce noise exposure inside cab to below 85 decibels eliminating hearing damage risk for operators. Engineering control separates operator from noise source and reduces exposure through physical barriers and absorption materials.

Implementation

1. Operate only profilers equipped with fully enclosed operator cabs meeting manufacturer noise specifications 2. Maintain cab door seals, window seals, and floor penetrations in good condition preventing noise infiltration 3. Keep cab doors and windows closed during milling operations maximising noise reduction 4. Inspect and maintain cab sound insulation materials replacing damaged acoustic panels 5. Monitor in-cab noise levels using dosimeter or sound level meter verifying exposure remains below 85dB(A) 6. Service air conditioning systems ensuring operators can work comfortably with cab closed 7. Report any increase in cab noise levels immediately for investigation and repair 8. Install communication systems allowing operator to communicate without opening cab or removing hearing protection

Install electronic aids including reversing cameras, proximity detection sensors, and radar systems providing operators with enhanced visibility around machines. Engineering controls overcome human visual limitations using technology to detect workers, vehicles, and obstacles in blind spots.

Implementation

1. Fit profilers with reversing cameras providing rear visibility displayed on in-cab monitors 2. Install side-mounted cameras covering blind spots along machine sides and conveyor areas 3. Implement proximity detection systems using radar or ultrasonic sensors alerting operators to nearby personnel 4. Configure audible and visual alarms activating when objects detected within programmed zones 5. Test camera and detection systems daily before operations verifying clear images and system functionality 6. Clean camera lenses and sensors regularly preventing dust accumulation degrading performance 7. Train operators in camera and detection system use including understanding alarm meanings and appropriate responses 8. Ensure detection systems supplement rather than replace direct communication with ground workers

Develop and implement comprehensive traffic management plan separating road profiling operations from active traffic using signs, barriers, and traffic control. Administrative control establishes procedures and work methods minimising vehicle strike risk through systematic traffic management.

Implementation

1. Engage qualified traffic management designer to develop site-specific traffic guidance scheme 2. Obtain traffic management approvals from road authority before commencing work 3. Install traffic management in accordance with approved plan including advance warning signs, speed restrictions, and lane closures 4. Use physical barriers including water-filled barriers or concrete blocks separating work zone from traffic where practical 5. Position traffic controllers at approach and departure points with clear lines of sight to oncoming traffic 6. Implement reduced speed zones through work areas - typically 40km/h in active work zones 7. Ensure all workers wear high-visibility clothing compliant with AS/NZS 4602.1 Class D or N 8. Install vehicle conspicuity markings on profiler and support vehicles including flashing lights and retro-reflective tape 9. Brief all workers on traffic management arrangements, vehicle access routes, and emergency procedures 10. Monitor traffic management effectiveness throughout operations adjusting measures if traffic intrusions occur

Provide comprehensive personal protective equipment protecting workers from residual dust, noise, and impact hazards during road profiling operations. PPE represents final control layer when engineering and administrative controls cannot eliminate all hazards.

Implementation

1. Issue P2 or P3 rated disposable respirators or reusable half-face respirators to all ground workers exposed to milling dust 2. Fit-test respiratory protection for workers ensuring proper seal and protection factor 3. Provide Class 4 or 5 earmuffs or foam earplugs rated SLC80 ≥25dB for ground workers near operating profilers 4. Ensure operators wear hearing protection if in-cab noise levels exceed 85dB(A) 5. Supply impact-resistant safety glasses or goggles to all personnel protecting from dust and debris 6. Issue high-visibility clothing including day/night vests, shirts, and trousers with reflective tape 7. Provide steel-capped safety boots with slip-resistant soles suitable for working on asphalt surfaces 8. Train all workers in correct PPE selection, donning, adjustment, and maintenance procedures 9. Implement respiratory protection program including fit testing, training, and medical assessments 10. Replace disposable respirators and filters according to manufacturer specifications - typically daily for high dust environments

Download complete control procedures

Personal protective equipment

Requirement: Mandatory for ground workers exposed to milling dust including traffic controllers, spotters, and support personnel

When: Required whenever within 50 metres of active milling operations or when visible dust is present in the work area

Requirement: Mandatory for all ground workers within 20 metres of operating profiler and operators if in-cab noise exceeds 85dB(A)

When: Required continuously during milling operations and when working near support equipment including haul trucks and water trucks

Requirement: Mandatory for all workers in road environment including machine operators when outside cabs

When: Required at all times when within or near traffic management zones, essential during all milling operations regardless of lighting conditions

Requirement: Mandatory eye protection for all personnel on site including machine operators and visitors

When: Required at all times when on work site particularly during active milling operations when dust and debris are generated

Requirement: Mandatory safety footwear for all workers on road profiling sites

When: Required continuously when on work site or within traffic management zones, essential near operating equipment and material handling areas

Requirement: Required for workers exposed to overhead hazards including those near material transfer points and conveyor systems

When: Mandatory when working near conveyor discharge area, beneath elevated components, or as specified by site safety plan

Requirement: Required for outdoor work during daylight hours to prevent ultraviolet radiation exposure

When: Essential during all outdoor work activities between 10am and 3pm or when UV index exceeds 3, particularly important during summer months

Inspections & checks

Before work starts

✓Review traffic management plan and verify approved traffic guidance scheme is current and appropriate for work to be conducted
✓Walk work area identifying ground conditions, slopes, edge stability, underground services, and overhead powerlines
✓Inspect road profiler conducting systematic pre-start check including fluid levels, hydraulic hoses, cutting drum teeth, conveyor operation, and water system
✓Test water suppression system filling tank and verifying spray coverage across cutting width with adequate flow at all nozzles
✓Verify operator high-risk work license is current and operator has completed site induction and task-specific training
✓Inspect all traffic management devices including signs, cones, barriers, and flashing lights ensuring equipment is clean and serviceable
✓Test communication systems including two-way radios between profiler operator, traffic controllers, and truck drivers
✓Conduct weather check for rain, high winds, or poor visibility that may affect operations or require additional controls
✓Brief all workers on daily work plan, specific hazards, traffic management arrangements, emergency procedures, and communication protocols
✓Verify emergency equipment including first aid kit, fire extinguisher, spill kit, and emergency contact numbers are accessible
✓Check haul trucks and support vehicles are roadworthy with current registration and operated by appropriately licensed drivers
✓Confirm all workers have required PPE including respiratory protection fit-tested and in serviceable condition

During work

✓Monitor ground conditions continuously watching for soft areas, pavement edge degradation, or changes in slope that may affect stability
✓Observe water suppression system operation ensuring adequate dust control maintained throughout milling operations
✓Check dust generation and visibility conditions - increase water flow or cease operations if excessive dust present
✓Monitor traffic management effectiveness watching for vehicles speeding, weaving, or encroaching into work zone
✓Verify communication between profiler operator, traffic controllers, and support vehicle drivers remains clear and effective
✓Observe worker positions ensuring ground personnel remain outside machine exclusion zones and dust exposure areas
✓Check PPE compliance ensuring respiratory protection, hearing protection, and high-visibility clothing worn correctly
✓Monitor haul truck positioning during material loading maintaining safe separation from profiler during loading operations
✓Watch for signs of machine mechanical issues including unusual noises, hydraulic leaks, or control problems requiring investigation
✓Inspect cutting drum teeth periodically for wear or damage replacing damaged teeth before continuing operations
✓Monitor worker fatigue levels particularly during extended shifts implementing rotation or additional breaks as needed
✓Verify exclusion zones remain enforced around machine travel path and material discharge conveyor area

After work

✓Inspect milled surface for specification compliance including depth uniformity, surface texture, and damage to existing structures
✓Check pavement edges for stability and damage repairing any edge degradation before opening to traffic
✓Clean profiler removing accumulated material from cutting chamber, conveyor, and chassis preventing buildup affecting machine operation
✓Inspect cutting drum teeth documenting wear and noting any damaged teeth requiring replacement
✓Check machine for damage from operations including hydraulic hose wear, conveyor alignment, and chassis cracking
✓Document fuel consumption, operating hours, water usage, and maintenance requirements in machine logbook
✓Remove milled material stockpiles and debris from roadway leaving clean surface ready for subsequent operations
✓Remove or adjust traffic management as appropriate for stage completion ensuring area is safe for intended traffic use
✓Conduct debrief with crew discussing safety observations, production rates, issues encountered, and improvements for subsequent shifts
✓Complete daily inspection checklist and incident reports documenting any near-misses, hazards identified, or equipment issues
✓Secure work site if leaving overnight ensuring adequate signing and barriers protect public from hazards
✓Review next day work plan considering weather forecast, material availability, and equipment requirements

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Pre-Start Inspection and Traffic Management Setup

Begin each work shift with systematic pre-start inspection of road profiler verifying all systems are operational and safe for use. Walk around machine checking for fluid leaks, damaged hoses, loose components, and general condition. Check engine oil level, hydraulic fluid level, coolant level, and fuel level topping up as required. Inspect cutting drum assembly verifying teeth are sharp and securely fastened - replace any missing or damaged teeth before operation. Count teeth and document number remaining as teeth wear indicator. Test cutting drum rotation ensuring smooth operation without binding or unusual noise. Inspect conveyor system including drive chains, belt tracking, and discharge chute alignment. Verify conveyor rotates freely and material discharge path is clear. Test water suppression system filling tank and operating spray bars. Check all spray nozzles for blockages ensuring even water distribution across cutting width. Adjust nozzles if required to optimise coverage. Inspect machine undercarriage including tracks or wheels, checking for damage, wear, and proper tension. Verify steering and braking systems operate correctly through full range of motion. Test all machine controls including drum raise/lower, travel forward/reverse, steering, and emergency stops. Ensure controls respond correctly without delay or binding. Check safety devices including ROPS structure for damage, seatbelt for function, and fire suppression system for charge pressure. Test reversing alarms and beacons. Review operator manual for specific pre-start checklist items required by manufacturer. Meanwhile, traffic management crew installs traffic control according to approved plan. Position advance warning signs at specified distances - typically 500m, 250m, 90m, and 30m from work zone. Install regulatory signs including speed restrictions and lane closure warnings. Position delineation devices including traffic cones or barriers defining taper and work zone extent. Install temporary barriers providing physical separation between work area and traffic where specified in plan. Traffic controllers position themselves at work zone approaches with clear visibility of oncoming traffic and means of communication with profiler operator. Conduct final walk-through of traffic management verifying all elements installed correctly, sight lines are adequate, and work zone provides safe working space for profiler and support vehicles.

Safety considerations

Never operate profiler if pre-start inspection identifies defects affecting safety - repair defects before use. Ensure traffic management is fully installed and verified by traffic management supervisor before profiler enters work zone. All personnel installing traffic management must wear high-visibility clothing and use traffic controllers to protect while working in live traffic.

Machine Setup and Water System Activation

Position profiler at milling commencement point identified in work plan. Approach work area slowly under traffic controller direction maintaining separation from traffic flow. Position machine on stable ground away from soft edges or unstable areas. Verify ground conditions are suitable before lowering cutting drum - test suspect areas by driving over slowly and observing for deflection or settlement. Activate water suppression system bringing pump up to operating pressure. Monitor pressure gauge ensuring system achieves specified pressure - typically 50-100 psi. Open spray bar valves sequentially observing flow at each nozzle. Adjust individual nozzle controls to optimise coverage ensuring entire cutting width receives adequate water. Ideal spray pattern produces fine mist completely covering cutting drum and material discharge. Pay particular attention to drum leading edge where cutting occurs and dust is generated. Verify water tank level is adequate for planned milling duration - typical consumption is 100-200 litres per minute. Coordinate with water truck operator to ensure tank refilling capability during extended operations. Position water truck to provide supplementary dust suppression downwind of profiler without interfering with haul truck access. Adjust cab ventilation and filtration system ensuring positive pressure is maintained inside operator compartment. Check cabin door and window seals are intact preventing dust infiltration. Close all cab openings during milling operations. Lower cutting drum to initial depth setting using depth control system. Most profilers offer either manual depth control or automated systems using sonic or laser grade sensors. When using automated systems, program target depth and grade parameters. Verify grade sensors are functioning correctly and reference points are established. When using manual control, set depth indicators to specified cut depth for first pass - typically 40-75mm depending on material and project requirements. Position machine perpendicular to milling direction with cutting drum centred on desired path. Engage cutting drum rotation bringing drum speed up to operating rpm - typically 80-120 rpm depending on machine model. Allow drum to stabilise at operating speed before commencing forward travel. Verify all systems are operating correctly including cutting drum rotation, water flow, conveyor operation, and controls responsiveness. Communicate with ground crew confirming readiness to commence milling and verifying haul truck is positioned for material loading.

Safety considerations

Ensure all ground personnel are clear of machine travel path and outside exclusion zones before activating cutting drum. Verify adequate water flow before lowering drum to surface - never mill dry as this generates excessive dust. Check ground stability before positioning machine near edges or on slopes - relocate if ground appears unstable. Maintain continuous communication with spotters and traffic controllers throughout setup process.

Milling Operations and Material Removal

Commence forward travel engaging transmission at appropriate speed for conditions. Typical milling speeds range from 5-30 metres per minute depending on material hardness, cutting depth, machine capacity, and desired surface finish. Harder materials and deeper cuts require slower travel speeds to prevent overloading cutting drum and motor. Monitor engine rpm and hydraulic pressures continuously adjusting travel speed to maintain systems within operating range. Lower cutting drum to operating depth once forward motion is established. Depth control may be manual requiring operator to monitor depth indicators and adjust as needed, or automated systems may maintain programmed depth automatically. When using automated grade control, monitor system operation ensuring grade sensors track reference properly and drum responds correctly to elevation changes. Maintain consistent travel speed throughout milling pass avoiding sudden acceleration or deceleration that disrupts cut uniformity. Steer machine to maintain alignment with intended path using painted guidelines or automated steering systems. On wider roads, maintain straight travel path using edge guides or string lines. Overlap previous milling pass by 50-100mm ensuring complete surface removal without ridges between passes. Monitor cutting drum performance observing material removal rate and surface finish being produced. Adjust travel speed if drum appears to be labouring or surface finish is unsatisfactory. Ideal milling operation produces consistent texture without gouging or ridging. Observe material discharge to conveyor checking flow is consistent without bridging or spillage. Material should discharge from cutting chamber promptly without accumulating in drum housing. If material flow appears sluggish, reduce travel speed or increase drum speed to improve discharge. Maintain water suppression ensuring dust generation remains minimal. Adjust water flow rate if dust becomes visible either increasing flow or slowing travel speed. Monitor water tank level arranging refilling before tank depletes completely. Coordinate with haul truck operators positioning trucks at conveyor discharge without interfering with profiler operation. Maintain minimum 1 metre separation between profiler and truck during loading process. Observe traffic management and passing traffic continuously watching for vehicles encroaching into work zone or traffic controller signals indicating issues. Be prepared to stop operations immediately if unsafe traffic conditions develop. Check machine systems regularly including temperatures, pressures, and unusual noises indicating mechanical issues developing. Stop operations promptly to investigate any abnormalities before damage occurs.

Safety considerations

Never allow ground workers in front of or beside operating profiler - maintain minimum 5 metre exclusion zone around machine. Watch for soft ground or pavement edges that may collapse under machine weight causing tip-over. Reduce speed on cross-slopes and when turning to maintain stability. Stop operations immediately if water system fails or excessive dust is generated. Monitor traffic continuously prepared to stop if vehicle enters work zone unsafely.

Edge Work and Detail Milling

Exercise increased caution when milling near pavement edges, kerbs, manholes, and other structures requiring precision work. Reduce travel speed when working near edges allowing better control and reducing tip-over risk if edge fails. Maintain minimum 500mm separation between machine tracks and unprotected pavement edges wherever possible. On narrow roads where full machine width must be used, verify edge stability before proceeding. If edge appears unstable or soft material is visible, place temporary edge support using timber mats or steel plates. For kerb lines, position cutting drum edge within 50-100mm of kerb face without striking kerb with drum. Damaged kerbs can cause sudden drum deflection and potential machine control loss. Watch for raised manholes, valve boxes, and drainage grates within milling path. Raise cutting drum before reaching these structures and mill around them manually using smaller equipment. Never attempt to mill over raised structures as drum teeth will impact metal causing tooth damage and potentially breaking loose material creating projectiles. When milling must extend to structures, use jack hammers or small handheld profilers to remove material close to metalwork. For edge milling along centre lines or lane lines, use profiler edge guides or operator sight references maintaining straight cutting line. Inconsistent edge alignment creates poor appearance and may affect subsequent paving operations. Position ground workers outside machine travel path and dust generation zones during detail work. Spotter personnel should position themselves where they have clear view of edge conditions, oncoming traffic, and ability to communicate with operator. Use hand signals or radio communication to guide operator along complex edge alignments. Workers should never position themselves between machine and kerbs or barriers where they could be crushed if machine moves unexpectedly. When working near overhead structures including bridges, signs, or powerlines, verify adequate clearance for conveyor and beacon heights. Typical profiler heights with conveyor elevated range from 3.5-4.5 metres. Stop operations and assess if clearance appears marginal. For work near powerlines, verify clearances meet regulatory minimums and notify power authority as required. Maintain heightened awareness during detail work as focus on precision may reduce attention to surrounding hazards.

Safety considerations

Reduce speed near edges and maintain heightened awareness of stability risks. Never position ground workers between operating machine and kerbs, walls, or barriers. Verify overhead clearances before raising conveyor or travelling beneath structures. Increase spotter communication during precision edge work. Stop operations if edge stability is questionable until edge support is installed.

Material Loading and Conveyor Management

Coordinate material loading operations carefully managing interaction between profiler conveyor discharge and haul trucks positioned to receive milled material. Communication between profiler operator and truck drivers is critical for safe loading operations. Establish clear signals or radio protocols for truck positioning, loading start/stop, and truck departure. Haul truck approaches profiler from behind positioning centreline of truck beneath conveyor discharge chute. Truck must approach slowly at walking pace guided by spotter if operator visibility is limited. Truck stops in position maintaining minimum 1 metre separation from profiler rear. Separation gap prevents accidental contact if profiler stops suddenly or truck misjudges distance. Conveyor discharge height should be set to deposit material into truck body centre minimising spillage and preventing buildup in truck front or rear. Adjust conveyor discharge angle using hydraulic controls to direct material flow. Monitor material loading watching for truck body filling uniformly. Material should spread throughout truck body without excessive accumulation in one area causing overloading or unstable loads. If material distribution is poor, stop profiler travel and reposition truck or adjust conveyor angle before continuing. Signal truck driver when truck is approaching capacity using agreed signals or radio communication. Typical signal is when material reaches top of truck side walls indicating truck is full. Truck driver remains in vehicle throughout loading process ready to move if emergency requires. Driver must not exit truck cab while positioned under conveyor as falling material could cause injury. Profiler operator slows or stops forward travel as truck approaches capacity allowing truck to depart and replacement truck to position. Some operations use two-truck shuttle system where second truck positions as first truck reaches capacity providing continuous milling. Spacing between trucks must be adequate preventing second truck entering loading position before first truck clears. Monitor conveyor operation throughout loading checking belt tracking remains centred and material flow is consistent. Belt misalignment can cause material spillage or belt damage requiring operational stop for correction. Keep conveyor idlers and rollers clear of material buildup that can affect belt tracking. Watch for material bridging in conveyor feed preventing smooth flow. Bridging may indicate material moisture content is too high or conveyor angle needs adjustment.

Safety considerations

Never allow truck drivers to exit vehicles while positioned under conveyor discharge. Maintain minimum 1 metre separation between profiler and trucks during loading. Use spotter to guide trucks into position if operator visibility is limited. Stop milling operations if truck loading problems develop rather than attempting to resolve while travelling. Ensure clear communication between profiler operator and truck drivers using radio or hand signals.

Completion and Site Cleanup

As milling section nears completion, plan machine shutdown and site restoration procedures. When reaching end of milling section, raise cutting drum clear of pavement surface while maintaining forward travel. This prevents gouging or step formation at work completion point. Stop forward travel once drum is clear and disengage drum rotation. Allow drum to stop completely before repositioning machine. If additional milling passes are required, position profiler for next pass maintaining overlap with completed pass. Survey completed milling checking depth uniformity, surface texture, and specification compliance. Use straight edge or measuring devices verifying milled depth meets specification tolerances - typically ±10mm. Check surface for defects including gouges, ridges, or areas of inadequate milling requiring remediation. Document any defects and coordinate correction before proceeding. Inspect pavement edges for stability and damage. Damaged edges require repair before traffic is permitted on milled surface. Use cold patch asphalt or alternative materials to build up damaged edges providing stable support. Clean milled roadway removing loose material and debris. Use street sweeper or broom truck removing millings from surface. Accumulations of loose material create slipping hazards for vehicles and may dislodge causing windscreen damage. Ensure drainage structures including grates and pits are clear of millings and functioning correctly. For overnight work suspensions or project completion, ensure milled surface is safe for traffic. Sharp depth transitions between milled and unmilled areas require temporary ramping using asphalt or signage warning of rough surface. Some specifications prohibit leaving exposed milled surfaces overnight requiring temporary covering or paving. Clean profiler thoroughly removing accumulated material from cutting chamber, conveyor, and chassis. Buildup of material affects machine operation and can harden creating cleaning difficulty. Use high-pressure water or compressed air to clean cutting drum, conveyor components, and machine underside. Inspect machine for damage from operations including cutting tooth wear, hydraulic leaks, and mechanical issues. Document findings in machine service records and arrange repairs before next shift. Remove or modify traffic management appropriately for stage completion. If work is suspended overnight, leave warning signs and barriers protecting public from work zone hazards. If section is complete and ready for traffic, remove traffic management in reverse installation sequence maintaining worker protection throughout. Conduct crew debrief discussing safety performance, production rates, issues encountered, and improvements for subsequent operations. Document completion records including area milled, material removed, time taken, and specification compliance verification.

Safety considerations

Ensure milled surfaces are safe for traffic before removing traffic management including addressing sharp transitions, loose material, and damaged edges. Maintain traffic management protecting workers during cleanup operations. Clean profiler in safe location away from traffic where spilled material and water will not create hazards. Verify all site hazards are remediated or controlled before demobilising equipment.

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Frequently asked questions

What licenses are required to operate road profiler machines in Australia?

Road profiler operators must hold valid high-risk work licenses for the specific machine class being operated. In most jurisdictions, profilers are classified under RB (Reach Stacker) or RD (Slewing Mobile Crane) licenses depending on machine configuration and operational characteristics. Some jurisdictions may require specific profiler or milling machine endorsements. Additionally, operators require current driver's licenses appropriate for road travel if operating profilers on public roads. White card (Construction Induction Training) is mandatory for all construction site workers including profiler operators. Operators should complete manufacturer-specific training on the particular profiler model being operated as controls, systems, and operational characteristics vary significantly between makes and models. Regular refresher training and assessment of operator competency is recommended even for experienced operators. Verify licensing requirements with relevant state workplace health and safety authority as requirements vary between jurisdictions and are subject to change.

How can silica dust exposure be managed during road profiling operations?

Managing silica dust exposure requires implementation of multiple control measures following hierarchy of control. Primary control is water suppression using integrated spray bar systems injecting water at cutting teeth preventing dust generation. Profilers should deliver 100-200 litres per minute distributed across cutting width. Supplement machine water with water truck spraying area downwind of operations. Operator protection uses enclosed pressurised cab with HEPA filtration preventing dust infiltration. Ground workers require fitted respiratory protection minimum P2 rated for short duration exposure or P3 rated for extended exposure. Implement administrative controls including task rotation limiting individual exposure duration, scheduling work to avoid particularly dusty materials where possible, and positioning workers upwind of operations when practical. Monitor airborne silica concentrations using personal dust monitors or area sampling verifying exposure remains below workplace exposure limits - typically 0.05 mg/m³ for respirable crystalline silica. Implement health surveillance program including baseline and periodic respiratory function testing for workers with regular exposure. Never operate profilers without functioning water suppression - dry milling generates dust concentrations many times exposure limits causing acute and chronic health effects.

What should be done if profiler water suppression system fails during operations?

If water suppression system fails during milling operations, stop work immediately raising cutting drum clear of surface and stopping forward travel. Do not attempt to continue milling without functioning water suppression as dust generation will quickly exceed safe exposure levels affecting operator, ground workers, and potentially surrounding properties and traffic. Assess water system failure determining cause - common issues include empty water tank, blocked spray nozzles, pump failure, or damaged water lines. For empty tanks, refill from water truck and resume operations after verifying spray pattern. For blocked nozzles, clear blockages using wire or compressed air ensuring all nozzles deliver adequate flow. For pump or line failures, conduct repairs before resuming operations. Some failures may require specialist mechanical repairs preventing same-day resumption. If repairs cannot be completed promptly, demobilise profiler and reschedule work for when equipment is operational. Never attempt makeshift repairs or continue operations relying solely on respiratory protection. Water suppression is primary control for dust hazards and must be functional before work proceeds. Document water system failures in machine maintenance records and investigate if failures occur frequently indicating systematic maintenance issues requiring attention.

How close to kerbs and drainage structures can road profilers safely operate?

Profilers can typically mill within 50-100mm of kerb faces and structures with experienced operators using machines with good visibility and control systems. However, final approach to structures should be slow and controlled watching for contact between drum teeth and concrete or metalwork. Contact with kerbs can deflect cutting drum suddenly potentially affecting machine control and causing tooth damage. For structures including manholes, valve boxes, and drainage grates, raise cutting drum before reaching structure and mill around obstacle using smaller equipment. Never mill over raised structures as drum teeth striking metal can break teeth loose creating projectile hazards and damaging structure covers. Some projects require milling closer to structures than profiler capabilities allow necessitating hand tool finishing or use of small walk-behind profilers for detail work. Edge stability is critical consideration when working near kerbs - verify ground beyond kerb is stable and will not collapse under machine weight. Soft ground, poor subgrade, or undermined areas near kerbs present tip-over risk. When working along kerb lines, position machine tracks to keep centre of gravity well away from edge - typically maintain 500mm minimum separation between track and edge. If close approach is necessary, reduce speed and maintain heightened awareness of stability. Brief operators on specific edge conditions and structures present in work area before commencing operations.

Can road profiling be conducted at night or in poor weather conditions?

Night profiling operations are common on busy roads where daytime lane closures would cause unacceptable traffic disruption. Night operations require additional controls including enhanced lighting, increased traffic management measures, and heightened awareness from all personnel. Profilers must have adequate lighting illuminating work area including forward travel path, cutting area, and conveyor discharge. Supplementary light towers may be required providing general illumination. All workers must wear high-visibility clothing rated for night use (Class D/N) with retro-reflective tape visible to approaching traffic. Traffic management must include additional warning devices including flashing lights, illuminated signs, and increased traffic controller vigilance. Operate at reduced speeds during night operations accounting for reduced visibility and driver awareness. Poor weather significantly affects profiling safety and operations. Heavy rain can destabilise pavements and subgrades creating tip-over risks and making precise depth control difficult. Water suppression becomes less effective in heavy rain as surface water prevents dust control assessment. Stop operations if rainfall becomes heavy or standing water accumulates affecting machine operation. High winds increase dust spread affecting surrounding areas despite water suppression and can affect machine stability particularly on cross-slopes. Extreme temperatures affect worker fatigue and equipment performance - implement additional breaks and monitor worker condition during very hot or cold weather. Lightning risk requires immediate work cessation and personnel withdrawal to safe locations. Always assess weather conditions before commencing work and monitor forecasts for deteriorating conditions requiring work cessation.

What emergency procedures should be established for road profiling operations?

Establish comprehensive emergency procedures covering potential incidents including machine rollover, worker injury, vehicle strike, and environmental emergencies. All workers must understand emergency procedures through pre-start briefings and site induction. For machine rollover, immediate response is to shut down engine if possible and assess operator condition. If operator is trapped or injured, call emergency services immediately (000) providing accurate location and incident details. Do not attempt to right overturned machine or extract operator without proper equipment and training as this may worsen injuries. Secure scene preventing additional personnel exposure. For worker injuries, provide first aid from trained personnel while summoning emergency services for serious injuries. Traffic controllers should divert traffic away from incident scene establishing safe working area for emergency responders. For vehicle strikes into work zone, assess for injuries providing first aid as required. Preserve scene for police investigation if serious incident. Review traffic management effectiveness and implement additional controls before resuming operations. For environmental incidents including fuel spills, contain spill using absorbent materials from spill kit preventing contamination spreading. Notify environmental authority if required by regulations - typically spills exceeding certain volumes or entering waterways require notification. Ensure emergency contact numbers are displayed prominently and all workers have means of communication. Conduct periodic emergency drills testing communication systems and response procedures. Document all incidents and near-misses investigating root causes and implementing corrective actions preventing recurrence.

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Key Controls

• Pre-start briefing covering hazards
• PPE: hard hats, eye protection, gloves
• Emergency plan communicated to crew

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Road Profiler Machine Safe Work Method Statement

What this SWMS covers

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Hazard identification

Control measures

Personal protective equipment

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Pre-Start Inspection and Traffic Management Setup

Machine Setup and Water System Activation

Milling Operations and Material Removal

Edge Work and Detail Milling

Material Loading and Conveyor Management

Completion and Site Cleanup

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