Safe Work Procedures for Water Cart and Dust Suppression Operations

Water Cart Safe Work Method Statement

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Water carts are specialised trucks equipped with large water tanks (typically 10,000-30,000 litres) and spray systems used for dust suppression on construction sites, mining operations, roadways, and earthworks. These vehicles operate continuously throughout shifts travelling over unprepared haul roads, rough terrain, and sloped access areas while dispensing water through rear and side-mounted spray bars. The combination of heavy water loads, elevated center of gravity, variable terrain conditions, and spray operations creates distinct safety challenges. This Safe Work Method Statement addresses the specific hazards of water cart operations including vehicle rollover on slopes due to high center of gravity when fully loaded, water spray hazards if high-pressure systems employed, visibility hazards during water delivery obscuring surrounding traffic and pedestrians, and electrocution hazards when operating spray booms near overhead power lines.

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Overview

What this SWMS covers

Water carts have become essential equipment on construction and mining sites where dust control is required for worker health, environmental compliance, and community relations. Modern water carts range from small 10,000-litre truck-mounted units suitable for construction sites, to massive 30,000+ litre articulated tankers servicing mining haul roads. The water tank elevates the vehicle's center of gravity substantially when full - a 20,000-litre load weighs 20 tonnes positioned 2-3 metres above ground level creating significant rollover risk on slopes or during sharp turns. This top-heavy configuration makes water carts particularly susceptible to stability loss compared to similar-weight vehicles with lower load centers. The spray system configuration varies by application and site requirements. Basic systems employ gravity-fed rear spray bars with manual control valves dispensing water as vehicle travels forward. More sophisticated systems include hydraulically-controlled spray booms extending up to 10 metres width with adjustable nozzle patterns, pump-pressurised systems delivering water at controlled rates independent of vehicle speed, and front-mounted spray bars for forward visibility during reversing operations. Some mining water carts feature automated spray controls maintaining consistent application rates regardless of speed variations. The spray pattern and water pressure must be carefully managed to achieve effective dust suppression without creating excessive mud, water pooling, or spray drift affecting visibility. Operators typically work alone conducting continuous water delivery operations throughout extended shifts (often 10-12 hours) travelling repeatedly over designated routes. The work involves constant steering inputs to maintain vehicle position on rough unprepared surfaces, monitoring water level gauges to coordinate refill timing, adjusting spray patterns for changing conditions, and maintaining awareness of surrounding traffic and pedestrians despite limited visibility through water spray. The monotonous nature of repetitive route following creates fatigue and reduced alertness, while the rough terrain generates sustained whole-body vibration exposure. Radio communication with site supervisors and water supply operators coordinates refill logistics preventing extended idle periods. Water sourcing and refill operations vary by site. Construction sites typically use municipal water supplies requiring connection to hydrants or storage tanks. Mining operations often extract water from on-site dams, bores, or recycled process water requiring dedicated fill stations. The refill process involves positioning water cart at fill point, connecting hoses or positioning fill nozzles into tank openings, monitoring fill progress to prevent overflow, and disconnecting supply before departing. Some sites employ pressurised filling systems requiring specific connection procedures and pressure management. Others use gravity filling from elevated tanks requiring precise positioning. Understanding site-specific fill procedures and water quality (recycled water may contain dissolved minerals affecting spray nozzle performance) is essential for efficient operations.

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Why this SWMS matters

Vehicle rollover constitutes the most severe hazard in water cart operations due to the elevated center of gravity created by full water tanks positioned high on truck chassis. When fully loaded, a 20,000-litre water cart has its center of gravity 2-3 metres above ground level, substantially higher than comparable-weight vehicles carrying lower-density materials. This top-heavy configuration dramatically reduces the critical rollover angle - the slope angle at which vehicle tips over. While conventional trucks might safely negotiate 15-20 degree slopes, water carts can rollover at angles as low as 10-12 degrees depending on load distribution and turn radius. Operators have been killed when water carts rolled on slopes that appeared manageable, or during sharp turns on level ground when centrifugal force exceeded stability limits. The dynamic nature of water loads exacerbates rollover risk through liquid surge effects. Unlike solid loads that remain static, water sloshes within tanks during acceleration, braking, and cornering. When water cart initiates a turn, the water mass continues moving in original direction creating lateral force pushing vehicle toward rollover. Similarly, sudden braking causes water to surge forward potentially lifting rear wheels and compromising steering control. Emergency maneuvers to avoid obstacles trigger violent water movement potentially causing rollover even on level surfaces. Baffles within water tanks reduce but do not eliminate surge effects, and partially-filled tanks (50-70% capacity) exhibit worse surge behaviour than completely full tanks where water movement is restricted. Visibility impairment during water delivery operations creates collision hazards with other vehicles, mobile plant, and pedestrians. The water spray creates mist obscuring the operator's rear and side vision through mirrors and reducing visibility for following traffic. In dusty conditions, the combination of water spray and dust creates dense clouds completely obscuring following vehicles from operator's view. Workers walking near operating water carts become invisible to operators until dangerously close. Reversing operations present particular hazards as rear spray creates total obscurement of reversing path. Multiple incidents have occurred where water cart operators reversed into workers, light vehicles, or equipment invisible through spray and dust clouds. Electrocution hazards arise when water cart spray booms or fill hoses contact or approach overhead power lines. Many construction and civil work sites have overhead electrical infrastructure with conductors at varying heights. Operators focused on spray patterns, refill operations, or navigating rough terrain may fail to recognise power line proximity. Water spray creating conductive path from power lines to vehicle can energise entire truck electrocuting operator and any person in contact with vehicle. Even without direct contact, electrical arcing can occur if spray or fill hoses approach within minimum safe distances. The distances required depend on voltage - 11kV distribution lines require 3-metre clearance, higher voltage transmission lines require 6+ metres. Workers have been electrocuted when raised spray booms or fill hoses contacted overhead power lines during site movements or refill operations. From a regulatory perspective, water cart operations involve heavy vehicle operation requiring appropriate licensing, compliance with road rules when operating on public roads, and implementation of traffic management when operating in construction zones. The dust suppression objective, while beneficial for environmental and health outcomes, does not exempt operators from fundamental safety obligations including maintaining vehicle stability, ensuring visibility, and avoiding electrical hazards. Following rollover incidents, investigations have examined whether operators were trained in stability awareness, whether site speed limits were appropriate for terrain and vehicle configuration, and whether supervision adequately monitored operator compliance with safe practices. Duty holders must demonstrate that water cart operations were planned considering terrain hazards, that operators possessed necessary competencies, and that adequate controls were implemented and monitored.

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Hazard identification

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

Risk register

Vehicle Rollover on Slopes Due to High Center of Gravity

High

Water carts carrying 15,000-25,000 litres of water have elevated centers of gravity 2-3 metres above ground level making them highly susceptible to rollover on slopes, during sharp turns, or when travelling across side-slopes. The critical rollover angle (slope at which vehicle tips) reduces to 10-12 degrees for fully loaded water carts compared to 15-20+ degrees for conventional trucks. Lateral slopes (travelling across slope) create particularly hazardous conditions as the elevated load shifts weight toward downhill side. Sharp turns at speed generate centrifugal forces exceeding stability limits even on level surfaces. Liquid surge within tanks during braking, acceleration, or cornering creates dynamic forces pushing vehicle toward rollover. Soft ground conditions reducing traction on uphill wheels exacerbate rollover susceptibility. Operators unfamiliar with loaded vehicle handling characteristics may apply steering or braking inputs that trigger rollover. Partially filled tanks (50-70% capacity) exhibit worse surge behaviour than full or nearly empty tanks.

Visibility Hazards from Water Spray Obscuring Surroundings

High

Water spray from rear and side spray bars creates mist and combines with dust forming dense clouds that obscure operator's visibility of surrounding traffic, mobile plant, and pedestrians. Rear spray completely obscures following vehicles and workers in reversing path when viewed through mirrors. Side spray reduces visibility through side windows and mirrors preventing recognition of approaching vehicles or workers. The visibility impairment increases in dusty conditions where water spray and dust create impenetrable clouds. Following traffic cannot see through spray cloud and may not recognise water cart's speed or intended movements. Pedestrians and workers on foot become invisible to operators until dangerously close. Night operations compound visibility issues as lighting inadequate to penetrate spray and dust. Operators accustomed to spray obscurement may become complacent about checking mirrors and monitoring surroundings. Reversing operations present extreme hazards as rear visibility completely obscured.

Electrocution from Contact with Overhead Power Lines

High

Overhead electrical conductors present electrocution hazards when water cart spray booms raised for transport, when fill hoses held vertically during refilling operations, or when water spray creates conductive path approaching power lines. Construction and civil sites frequently have overhead power distribution lines at 11kV-66kV with conductors positioned 4-8 metres above ground. Operators focused on spray patterns or refill operations may not recognise power line proximity. Spray booms raised to transport position or fill hoses held upward can contact conductors electrocuting operator and ground workers touching vehicle. Even without direct contact, electrical arcing occurs if metallic boom or water streams approach within minimum safe distances (3 metres for 11kV, 6+ metres for higher voltages). The electricity travels through vehicle chassis energising entire truck creating touch potential hazards for anyone contacting vehicle while it contacts power lines. Water containing dissolved minerals creates better conductor than pure water amplifying current flow and arcing distance.

Struck by Other Mobile Plant in Congested Work Areas

High

Water carts operate in active construction and mining environments with multiple mobile plant including excavators, dozers, graders, and haul trucks operating simultaneously. The water cart's slower operating speed (typically 15-25 km/h during spraying) compared to other traffic creates overtaking situations where faster vehicles approach from behind. The rear spray creates visibility obscurement for following drivers who may not recognise water cart's presence until closing distance becomes unsafe. Water cart operators focused on maintaining spray coverage may not monitor mirrors adequately recognising approaching traffic. Congested intersection areas where multiple vehicles converge create collision risks as operators from different directions fail to see each other through dust and spray. Reversing excavators and dozers may not recognise water cart proximity due to limited visibility from operator positions. Communication gaps between mobile plant operators prevent coordination of movements.

Whole-Body Vibration from Rough Terrain Operation

Medium

Water cart operators experience sustained whole-body vibration throughout extended shifts (10-12 hours) travelling over rough unprepared haul roads, rutted construction access tracks, and uneven earthwork areas. The vibration sources include engine and transmission systems, wheel and suspension impacts from surface irregularities, and resonance from water movement in tanks. The vibration magnitude increases when operating empty (lighter vehicle weight reduces suspension dampening) or partially full (water surge creates oscillations). Operators seated in truck cabins absorb vibration through spine and buttocks. The rough terrain requires constant steering corrections preventing operators adopting comfortable postures and increasing muscle tension. Repeated gear shifting in manual transmission vehicles creates additional vibration and awkward postures. Cumulative exposure over months and years of operation creates chronic health effects.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Slope Limitation and Speed Management

Administrative

Establish and enforce maximum slope and speed limits for water cart operations preventing rollover from stability loss

Implementation

1. Prohibit water cart operations on slopes exceeding 10-degree maximum gradient when fully loaded 2. Reduce slope limit to 8 degrees when operating across slopes (lateral slope) due to increased rollover risk 3. Mark hazardous slope areas using signage and ground markings warning water cart operators 4. Implement maximum speed limit of 25 km/h on level prepared surfaces during normal operations 5. Reduce speed to 15 km/h maximum on rough or sloped terrain, enforce through supervisory monitoring 6. Prohibit sharp turns at speed, require gradual turning movements reducing lateral load transfer 7. Avoid sudden braking that triggers water surge, maintain gradual speed reductions where possible 8. Establish designated water cart routes avoiding steep slopes and sharp corners where feasible 9. Install slope indicators in water cart cabins enabling operators to monitor terrain angles 10. Brief operators daily on terrain hazards and required speed reductions for specific site areas

Mandatory Seatbelt Use and Rollover Protection

Engineering

Rollover protective structures and compulsory seatbelt use protecting operators if rollover occurs despite prevention efforts

Implementation

1. Ensure all water carts fitted with ROPS (rollover protective structures) meeting AS 1636 standards for vehicle weight 2. Verify ROPS structural integrity annually checking for cracks, deformation, or corrosion reducing protection 3. Install compliant three-point seatbelts meeting AS/NZS 1754 providing secure restraint during rollover 4. Enforce mandatory seatbelt use through supervisory monitoring and disciplinary procedures for non-compliance 5. Install seatbelt warning alarms activating if vehicle moved with seatbelt unfastened 6. Conduct regular seatbelt inspections checking webbing condition, buckle function, and anchorage security 7. Replace damaged or worn seatbelts immediately maintaining protection effectiveness 8. Train operators on seatbelt adjustment achieving proper fit across hips and shoulder 9. Prohibit seatbelt modifications or alterations including comfort clips that reduce restraint effectiveness 10. Include seatbelt compliance in daily pre-start inspections with operators signing acknowledgment of requirement

Spotter Assignment for All Reversing Operations

Administrative

Dedicated spotter personnel guiding all water cart reversing movements eliminating blind spot hazards

Implementation

1. Prohibit water cart reversing without trained spotter present and actively guiding movement 2. Assign qualified personnel as spotters trained in standard hand signals and communication protocols 3. Position spotter where visible to driver throughout reverse movement maintaining clear sight lines 4. Establish communication protocol: driver announces 'reversing' via radio, spotter acknowledges and takes position 5. Use standard hand signals for directing reverse movements, prohibit non-standard or ambiguous signals 6. Equip spotters with high-visibility vests and STOP/GO signs providing clear direction indicators 7. Implement immediate stop procedure if spotter loses sight of driver or hazard appears in reverse path 8. Install reversing cameras on water carts supplementing but not replacing spotter requirement 9. Fit audible reversing alarms operating automatically when reverse gear engaged warning nearby workers 10. Brief water cart operators and spotters daily on communication procedures and designated spotter personnel

Overhead Power Line Identification and Clearance

Elimination

Systematic identification and marking of overhead power lines with mandatory clearance distances eliminating electrocution hazards

Implementation

1. Conduct pre-work site inspection identifying all overhead power lines noting voltage, height, and position 2. Contact electricity distributor confirming voltage and obtaining safe approach distances for identified lines 3. Mark power line locations using high-visibility bunting or signs at site entry points warning of overhead hazards 4. Establish exclusion zones beneath power lines prohibiting water cart operation unless lines de-energised 5. Implement minimum 6-metre horizontal and vertical clearance from all overhead conductors regardless of voltage 6. Lower spray booms to transport position before site entry if overhead power lines present anywhere on site 7. Prohibit raising fill hoses vertically during refill operations near overhead lines, use ground-level fill points 8. Install height indicators on water cart cabins enabling operators to monitor maximum vehicle height 9. Coordinate with electrical authority for temporary de-energisation or line relocation if work required near lines 10. Train operators in electrical hazard recognition, safe approach distances, and emergency response if contact occurs

Mobile Plant Communication and Traffic Management

Administrative

Radio communication protocols and designated routes separating water carts from other mobile plant traffic

Implementation

1. Equip all water carts with two-way radios tuned to site-wide mobile plant frequency 2. Require water cart operators announce position and intended movements every 15 minutes during operations 3. Establish communication protocol for congested areas: operators call when approaching intersections awaiting confirmation path clear 4. Designate specific water cart routes separate from main haul roads and heavy plant traffic where feasible 5. Install high-visibility rotating beacons on water cart cabin roofs operating continuously during operations 6. Fit amber strobe lights at vehicle rear supplementing brake lights improving visibility through spray 7. Paint water carts in high-visibility colours (yellow, orange) with reflective striping improving recognition 8. Implement site speed limits with differential speeds for different vehicle types managing relative speed differences 9. Schedule water cart operations during lower traffic periods if possible reducing mobile plant conflicts 10. Conduct daily coordination meetings with all mobile plant operators reviewing planned movements and potential conflicts

Water Cart Operator Competency and Licensing

Administrative

Training and assessment ensuring operators possess skills for safe water cart operation on variable terrain

Implementation

1. Verify operators hold appropriate heavy vehicle driving licence (HR or MR) for water cart configuration 2. Provide water cart-specific training covering vehicle dynamics, rollover prevention, and spray system operation 3. Conduct practical competency assessment demonstrating ability to control vehicle on slopes and rough terrain 4. Train operators in liquid load management understanding surge effects and techniques for minimising dynamic forces 5. Provide site familiarisation training identifying hazardous terrain, slope areas, and overhead power line locations 6. Ensure operators understand spray system controls including emergency spray shutdown and pattern adjustment 7. Train in reversing procedures including spotter communication protocols and interpretation of hand signals 8. Provide electrical safety awareness training covering power line recognition and safe clearance distances 9. Implement supervised operating period for new operators working under experienced operator guidance before solo operation 10. Conduct annual refresher training reviewing incidents from industry and reinforcing critical safety practices

Vibration Exposure Reduction Measures

Engineering

Equipment specifications and operational practices reducing whole-body vibration exposure for operators

Implementation

1. Specify air-ride suspension seats with adjustable dampening in all water carts providing vibration isolation 2. Adjust seat settings to operator weight per manufacturer guidance optimising suspension performance 3. Maintain vehicle suspension systems replacing worn shock absorbers and springs that increase vibration transmission 4. Implement maximum shift duration of 10 hours for water cart operators limiting cumulative vibration exposure 5. Grade and maintain haul roads removing major potholes, corrugations, and obstacles reducing vibration sources 6. Fill water tanks to 90-95% capacity where possible as full tanks reduce water surge and associated oscillations 7. Reduce operating speeds on roughest terrain sections minimising impact severity and vibration magnitude 8. Rotate operators between water cart duties and other roles if multiple qualified operators available 9. Monitor and document operator complaints of vibration discomfort or back pain investigating and implementing additional controls 10. Consider upgrading older water carts lacking modern suspension systems if vibration monitoring indicates excessive exposure

Pre-Operational Vehicle Inspection

Administrative

Daily inspection of water cart systems identifying defects before commencing operations

Implementation

1. Conduct documented pre-start inspection checking all safety-critical systems before operations each shift 2. Check seatbelt condition and function confirming webbing undamaged and buckle operates correctly 3. Test reversing cameras and alarms verifying functionality before reversing operations commence 4. Inspect spray system components checking for leaks, damaged nozzles, or blocked spray bars 5. Verify water level gauge functional providing accurate indication of tank contents and fill level 6. Check tyre pressures and condition identifying unusual wear patterns or damage requiring replacement 7. Test service brakes and park brake confirming adequate stopping power for loaded vehicle weight 8. Inspect ROPS structure for damage, cracks, or modifications compromising protection effectiveness 9. Verify radio communication functional and tuned to correct site frequency 10. Document inspection completion in vehicle log, tag out vehicle if safety-critical defects identified until repairs completed

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Personal protective equipment

Requirement: Class D day/night vest or coveralls with reflective tape meeting retroreflectivity standards

When: Required when exiting water cart cabin, during refill operations, or working near other mobile plant

Requirement: Steel toe cap work boots with slip-resistant soles, ankle support for uneven ground surfaces

When: Mandatory at all times including when operating water cart and during ground-based activities

Requirement: Type 1 hard hat providing impact and penetration protection when working outside cabin

When: Required when exiting cabin for refill operations, equipment adjustment, or working near other plant

Requirement: Class 3 or higher earmuffs or fitted earplugs if cabin noise exceeds 85dB(A)

When: Required during extended operation periods if noise monitoring indicates hearing protection necessary

Requirement: Wide-brim hat, long-sleeved shirt, long pants, SPF 50+ sunscreen for UV protection

When: Required during all outdoor activities, particularly during refill operations and site movements

Requirement: Impact-resistant safety glasses with side shields or goggles when working outside cabin

When: Required during refill operations where pressurised water or spray could contact eyes

Inspections & checks

Before work starts

  • ✓Verify operator holds appropriate heavy vehicle licence (HR or MR) for water cart configuration
  • ✓Complete documented pre-start inspection checking seatbelt, brakes, lights, spray system, and ROPS condition
  • ✓Test reversing camera and audible reversing alarm confirming both systems functional
  • ✓Check water tank level gauge operational providing accurate indication of current water volume
  • ✓Verify radio communication functional and tuned to correct site frequency for mobile plant coordination
  • ✓Review daily site briefing identifying terrain hazards, overhead power line locations, and operational constraints
  • ✓Confirm spotter personnel assigned and present if any reversing operations anticipated during shift
  • ✓Check weather forecast for high wind warnings requiring operational modifications or suspension

During work

  • ✓Monitor vehicle stability continuously adjusting speed for terrain conditions and slope angles encountered
  • ✓Observe spray pattern effectiveness adjusting nozzles as required achieving adequate dust suppression without excessive water use
  • ✓Check water tank level regularly coordinating refill timing to prevent extended idle periods
  • ✓Verify radio communications functioning maintaining coordination with other mobile plant operators
  • ✓Monitor visibility conditions through spray and dust adjusting spray intensity if visibility becomes unsafe
  • ✓Watch for overhead power lines when operating in new areas or near site boundaries
  • ✓Ensure spotter positioned correctly and visible throughout all reversing movements
  • ✓Check tyre pressures during mid-shift break if operating on rough terrain that may cause deflation

After work

  • ✓Empty remaining water from tank if parking overnight on sloped ground reducing rollover risk
  • ✓Park water cart on level ground applying park brake firmly and placing transmission in park
  • ✓Position spray controls to closed position preventing unintended operation during non-operational periods
  • ✓Check spray system for damage sustained during operations documenting issues requiring repair
  • ✓Inspect tyres for cuts, damage, or unusual wear patterns that developed during shift
  • ✓Document hours operated, water volume dispensed, and any incidents or near misses in vehicle log
  • ✓Report all equipment defects, terrain hazards identified, or safety concerns to supervisor
  • ✓Clean cabin removing mud and debris tracked in during operations maintaining operator comfort and visibility

Step-by-step work procedure

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

Field ready
1

Pre-Operational Planning and Site Assessment

Review daily work plan identifying areas requiring dust suppression and designated water cart routes. Examine site map noting slope areas, overhead power lines, and confined work zones requiring special precautions. Contact site supervisor confirming planned activities by other mobile plant coordinating operations to avoid conflicts. Check water supply availability and fill point locations ensuring adequate water accessible throughout shift. Review weather forecast particularly wind conditions affecting spray drift and dust generation rates. Identify location of medical facilities and emergency assembly points in case of incidents requiring evacuation or medical response. Verify spotter personnel assigned for shift and confirm they have completed spotter training. Collect required PPE including high-visibility vest, hard hat, and safety glasses. Obtain radio for mobile plant communication channel ensuring charged battery and correct frequency setting. Brief on any new hazards identified since previous shift including terrain changes, new excavations, or temporary power line installations.

2

Vehicle Pre-Start Inspection

Conduct systematic pre-start inspection beginning with walk-around checking tyres for damage, under-inflation, or unusual wear. Inspect spray bars and nozzles for damage or blockages affecting spray pattern. Check for hydraulic leaks beneath vehicle and around spray control systems. Enter cabin checking seatbelt webbing condition and buckle function, adjust seat position for comfortable control reach and good visibility. Start engine monitoring gauges for normal operating ranges. Test service brakes applying firmly checking for adequate stopping response and verifying brake warning lights extinguished. Test park brake applying and releasing verifying positive engagement. Activate reversing camera system if fitted confirming clear display image. Test reversing alarm listening for audible tone clearly heard from 20 metres. Check spray system controls operating each valve confirming smooth operation and positive shutoff. Verify water level gauge indicating current tank volume. Test radio communication calling site supervisor confirming transmission clarity. Document inspection completion in vehicle logbook noting date, time, and operator name.

3

Safe Water Filling Procedures

Drive to designated water fill point positioning vehicle for easy fill hose connection. Apply park brake firmly before exiting cabin. Identify overhead power lines near fill point maintaining minimum 6-metre clearance from fill hose when held upward. Connect fill hose to tank inlet ensuring secure connection preventing disconnection under pressure. Signal fill operator ready to commence filling or activate fill pump if self-service system. Monitor tank fill level using gauge or sight glass preventing overflow that wastes water and creates slippery surfaces. Communicate with fill operator when tank approaching capacity coordinating shutdown before overflow. Shut off fill supply allowing pressure to release before disconnecting fill hose. Secure fill hose properly preventing trip hazards or damage during subsequent movements. Verify tank hatches secured preventing water spillage during travel. Check underneath vehicle for water leaks from tank or connections indicating required repairs. Note total water volume loaded in daily log for reconciliation with water usage tracking.

4

Commence Dust Suppression Operations

Drive to designated work area following approved water cart routes. Reduce speed to maximum 25 km/h on prepared surfaces or 15 km/h on rough terrain maintaining vehicle stability. Activate spray system using control valves adjusting nozzle patterns for area width and required coverage. Monitor spray effectiveness watching dust suppression achieved without excessive water creating mud or pooling. Adjust vehicle speed coordinating with spray rate achieving consistent water application. Watch water tank level gauge tracking consumption rate and calculating approximate time until refill required. Maintain awareness of surroundings monitoring for other mobile plant, workers on foot, and changing terrain conditions. Communicate position and movements via radio every 15 minutes enabling other operators to coordinate their activities. Reduce or cease spray when approaching workers or traffic preventing visibility obscurement. Adjust spray pattern for wind conditions preventing drift onto areas not requiring water or affecting operator visibility. Follow designated routes maintaining consistent coverage of high-traffic or high-dust-generation areas.

5

Navigate Slopes and Rough Terrain Safely

When approaching slopes, assess angle visually using cabin slope indicator if fitted. If slope appears to approach 10-degree limit, stop and assess whether alternative route available. If proceeding on slope, reduce speed to 10-15 km/h maximum preventing dynamic load transfer triggering rollover. Travel straight up or down slope avoiding diagonal paths that increase lateral rollover forces. When descending slopes, use engine braking in lower gear preventing need for sustained brake application that could fade brakes. Avoid sharp steering inputs on slopes as these generate lateral forces exceeding stability limits. When crossing side-slopes (travelling perpendicular to fall line), proceed at minimal safe speed maintaining constant heading without steering corrections if possible. If terrain requires turning on slope, make gradual wide-radius turns rather than sharp direction changes. Monitor vehicle behaviour continuously feeling for weight transfer indicating approaching rollover threshold. If vehicle feels unstable, immediately stop and assess whether safer path exists or whether operations should cease until terrain improved.

6

Coordinate with Other Mobile Plant

Maintain continuous awareness of other mobile plant through radio monitoring and visual observation. Announce position via radio when approaching intersections or congested areas requesting confirmation path is clear. Give way to larger, faster, or less maneuverable plant including loaded haul trucks and excavators with limited visibility. Use designated mobile plant routes where established staying in assigned lanes. When overtaken by faster traffic, reduce spray intensity temporarily improving following driver's visibility. If operating in areas with limited visibility due to terrain or structures, sound horn before entering blind areas warning other operators. Maintain safe following distances behind other vehicles allowing adequate stopping distance accounting for loaded vehicle weight. Do not position water cart between operating excavators and trucks during loading operations. Communicate with mobile plant operators if spray operations will affect their work coordinating timing. If radio communication with other plant lost due to equipment failure, suspend operations in congested areas until communication restored.

7

Execute Safe Reversing Procedures

When reversing becomes unavoidable, immediately contact assigned spotter via radio requesting guidance. Bring water cart to complete stop applying park brake. Observe spotter taking position at rear where visible in mirrors throughout reverse movement. Reduce or cease rear spray improving visibility for spotter and operator. Announce via radio 'commencing reverse' waiting for spotter acknowledgment confirming ready to guide. Release park brake and engage reverse gear sounding horn alerting nearby workers. Observe spotter continuously following hand signals for direction and speed. Proceed slowly at walking pace enabling rapid stopping if spotter signals halt. Activate reversing alarm ensuring audible warning provided to workers in reverse path. Stop immediately if spotter disappears from view or signals emergency stop. Do not continue reversing beyond distance spotter can clearly see and confirm clear path. When reverse complete, apply park brake before exiting reverse gear. Acknowledge spotter via radio confirming movement complete.

8

End-of-Shift Shutdown and Parking

Drive water cart to designated parking area on level ground away from traffic lanes and work areas. Position vehicle where overnight parking will not obstruct morning activities or emergency access. If parking on any gradient, position front wheels turned toward curb or uphill preventing rollover if brakes fail overnight. Apply park brake firmly and place transmission in park or lowest gear. If significant water remains in tank and vehicle parked on slope, consider emptying tank to reduce rollover risk overnight. Shut off spray system controls ensuring all valves fully closed. Shutdown engine following normal cooldown procedures per manufacturer guidance. Remove keys securing in designated location or taking with you per site procedures. Exit cabin taking radio, logbook, and personal items. Conduct post-operation inspection walking around vehicle checking for damage, leaks, or loose components developed during shift. Document hours operated, approximate water volume used, and any equipment defects in vehicle logbook. Report all incidents, near misses, or safety concerns observed during shift to supervisor for investigation and corrective action. Clean cabin if muddy or dusty maintaining good condition for next operator.

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Frequently asked questions

What licence do I need to operate a water cart in Australia?

Operating a water cart requires a heavy vehicle driving licence appropriate to vehicle configuration and weight. Most water carts fall into heavy rigid (HR) licence class covering vehicles exceeding 8 tonnes gross vehicle mass without trailer. Smaller water carts on medium rigid trucks may require only medium rigid (MR) licence. Check vehicle registration documents identifying actual gross vehicle mass and ensure your licence class covers that weight category. Beyond basic driving licence, many employers require completion of water cart operator training covering vehicle dynamics, rollover prevention, spray system operation, and site-specific hazards. If operating on public roads, comply with all heavy vehicle regulations including logbook requirements for fatigue management if shift durations exceed standard limits. Some mining operations require operators hold specific site-issued competencies demonstrating knowledge of site rules, communication protocols, and emergency procedures. Maintain current licence without restrictions or suspensions as employers verify licence status before allowing operation. If uncertain about licence requirements for specific water cart, contact licensing authority in your state providing vehicle details for clarification.

How can I prevent water cart rollover on slopes and rough terrain?

Preventing rollover requires understanding water cart stability limitations and operating within safe parameters. The elevated center of gravity when fully loaded reduces critical rollover angle to approximately 10-12 degrees depending on tank height and vehicle wheelbase. Limit operations to slopes not exceeding 10 degrees, which appears quite shallow - a 10-degree slope rises 1.8 metres over 10-metre horizontal distance. Use cabin-mounted slope indicators if available or obtain site survey identifying slope angles in work areas. Reduce speed to maximum 15 km/h on rough terrain and 10 km/h on slopes preventing dynamic load shifts. Travel straight up or down slopes rather than across slopes (traversing) which creates worst-case lateral loading. Avoid sharp turns particularly at speed as centrifugal forces can exceed stability limits even on level ground. Make gradual wide-radius turns instead. Use lower gears on steep descents preventing brake fade and maintaining control. Fill water tanks to 90-95% capacity where possible as full tanks reduce water surge compared to half-full tanks. Always wear seatbelt as rollover protection depends on operator remaining secured in protected cabin space. If terrain appears questionable, stop and assess rather than proceeding hoping vehicle will remain stable. Request site supervision to improve hazardous terrain through grading or establish alternative routes avoiding worst areas.

What should I do if visibility becomes too poor to operate safely during dust suppression?

If visibility deteriorates to point where you cannot clearly see surrounding traffic, mobile plant, or pedestrians, immediately reduce spray intensity or cease spraying temporarily until visibility improves. The spray mist combines with dust creating dense clouds particularly in calm wind conditions. Reduce forward speed allowing spray to settle before continuing, and increase following distance from other vehicles if operating in convoy. If approaching areas with workers on foot or stationary equipment, shut off rear spray completely until passing clear of those areas then resume spray. For operations requiring continuous spray coverage but with poor visibility, request additional spotter personnel positioned to warn of approaching traffic or workers that may be invisible to you. Consider scheduling dust suppression during lower traffic periods such as lunch breaks or shift changes when fewer mobile plant and workers present. If windy conditions cause spray drift obscuring visibility in unintended directions, reposition spray bars or adjust nozzle angles directing spray downward rather than outward. For chronic poor visibility sites, discuss with supervision about alternative dust control methods including polymer soil stabilisers, covered haul roads, or speed restrictions for other traffic reducing dust generation. Never continue operating if you cannot maintain adequate awareness of surroundings - collision risks outweigh dust suppression benefits when visibility insufficient.

How close can I operate water cart near overhead power lines safely?

Maintain minimum 6-metre clearance from all overhead electrical conductors regardless of voltage. This distance applies to both horizontal approach (driving near poles) and vertical approach (spray booms or fill hoses). Power line voltages vary from 11kV distribution lines to 66kV+ transmission lines, but safe practice is assuming worst-case scenario and maintaining maximum clearance from all overhead lines. Before working on any new site, conduct site inspection identifying all overhead power lines and marking their locations. Contact electricity distributor if uncertain about line voltage or required clearances. If overhead lines present anywhere on site, lower spray booms to transport position before site entry and keep them lowered throughout operations. This prevents accidental boom contact if you misjudge clearance or become distracted. For refill operations near power lines, prohibit raising fill hoses vertically - instead use ground-level fill points or position water cart where fill hoses can be routed horizontally. Install height indicators on water cart showing maximum vehicle height with booms raised enabling quick assessment of clearance. If electrical work required near power lines closer than safe distances, arrange with electrical authority for temporary line de-energisation or physical line relocation. Never assume power lines are de-energised based on visual appearance - always verify with authority and implement lockout procedures. Remember that water spray can create conductive path if sprayed too close to power lines even without direct contact.

Why do I need a spotter when reversing if I have a reversing camera fitted?

Reversing cameras supplement but do not replace spotter requirement for water cart reversing operations. The camera provides limited field of view typically covering 120-180 degrees directly behind vehicle, while spotters can observe full 360-degree surroundings and warn of hazards approaching from sides or front that camera cannot see. Water spray from rear spray bar creates mist and dust coating camera lenses obscuring image particularly in dusty environments. Cameras may fail due to electrical faults, damaged cables, or water ingress into electronics without operator recognising loss of coverage. The camera screen in cabin can become sun-washed in bright conditions making image difficult to interpret. Most critically, rear water spray completely obscures reversing path creating visibility conditions where camera is essentially useless. The spotter provides direct visual confirmation that path is clear and can signal immediate stop if hazards appear. Spotters also communicate with workers in reversing path directing them to safe locations and coordinating timing of reverse with other site activities. Australian WHS regulations require effective controls for reversing hazards, and camera-only solutions have been found inadequate following serious incidents where workers were run over despite camera presence. Employers implementing camera-only reversing for water carts face prosecution risk if incidents occur. Always use qualified spotter for reversing movements regardless of technology fitted to vehicle.

How can I reduce whole-body vibration exposure during extended water cart shifts?

Reducing vibration exposure requires combination of equipment specification, seat maintenance, operational techniques, and work scheduling. Ensure water cart fitted with air-ride suspension seat providing vibration isolation - these seats use air bladders that absorb impacts and vibration. Adjust seat settings to match your body weight per manufacturer instructions as incorrect adjustment reduces isolation effectiveness. Maintain correct seated posture with back against seat back, feet flat on floor, and knees slightly bent avoiding perching forward or slouching which increases spinal loading. Take regular breaks from driving during shift - aim for 10-minute break every 2 hours allowing spine to decompress and reducing cumulative exposure. During breaks, walk around and perform gentle stretching exercises for lower back. Request site maintenance to grade haul roads removing major potholes, corrugations, and bumps that generate severe impacts. Reduce driving speed over roughest terrain sections as vibration magnitude increases with speed over given surface. Fill water tanks to maximum capacity where operational requirements permit as full tanks reduce water surge and associated low-frequency oscillations. Consider rotating between water cart duties and other ground-based activities if site has multiple qualified operators available. Report any back pain or discomfort promptly to supervisor enabling early intervention before chronic conditions develop. If vibration discomfort persists despite controls, request vibration monitoring assessment comparing exposure to regulatory action values and implementing additional controls if required.

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