Mobile Concrete Crusher Safe Work Method Statement

Operating a mobile concrete crusher in Australia requires specific high-risk work licenses and training depending on the crusher type and capacity. For tracked mobile crushers that self-propel on tracks and weigh over 5 tonnes, operators require a Dozer license (specifically for tracked equipment) issued by the relevant state or territory WorkSafe authority. For wheeled mobile crushers or crushers mounted on wheeled trailers, different licensing may apply depending on whether the crusher self-propels or requires separate towing vehicle. All crusher operators should complete manufacturer-specific training in the operation, maintenance, and safety systems of the specific crusher model being used. This training typically covers crusher start-up and shutdown procedures, feeding rate and material size requirements, adjustment of crusher settings for different product specifications, blockage recognition and clearing procedures following isolation requirements, routine maintenance including wear part inspection and lubrication, emergency stop activation and emergency procedures, and dust and noise control system operation. In addition to crusher-specific training, all operators must hold a current Construction Induction Card (White Card) mandatory for all construction site workers. For workers feeding the crusher using excavators or loaders, the appropriate Excavator license or Loader license is required. Site supervisors should hold relevant qualifications in construction management or plant operations and have demonstrated experience with crushing operations and safety management systems. Before allowing any person to operate a crusher, verify they have completed appropriate training and hold current licenses for the specific equipment being used. Maintain copies of operator licenses and training certificates on-site available for inspection by regulators. Provide site-specific induction covering the particular crushing operation, site hazards, emergency procedures, and communication protocols. Document all training and inductions in site records. Never allow untrained or unlicensed persons to operate crushers regardless of claimed experience - licensing requirements exist because crushing operations present extreme hazards requiring demonstrated competency.

Controlling respirable crystalline silica dust during concrete crushing requires implementing the hierarchy of control starting with engineering controls before relying on respiratory protection. The primary and most effective control is comprehensive water suppression using multiple spray points throughout the crushing process. Install water spray nozzles at the crusher feed hopper wetting concrete before it enters the crushing chamber, internal water injection into the crushing chamber if the crusher model supports this feature (wetting material during the actual crushing process), water sprays along the discharge conveyor wetting crushed aggregate immediately after crushing, and water spray at stockpile discharge points suppressing dust when crushed material drops onto stockpiles. The water suppression system must provide adequate flow rate - typically minimum 200 litres per minute at 3-5 bar pressure. Material should be visibly wet throughout the crushing process with water creating surface sheen on crushed aggregate. Adjust water flow rates to maintain effective dust suppression without creating excessive slurry or flooding - too little water is ineffective, too much water creates handling problems and site flooding. Increase water application during hot dry windy weather when dust generation peaks. Monitor water system continuously during crushing operations; stop crushing immediately if water system fails or supply is interrupted. In addition to water suppression, implement administrative controls including positioning crusher to account for prevailing wind direction - locating crushing operations upwind of other site activities and downwind of sensitive receptors where possible, limiting crushing operations during very windy conditions (wind speeds exceeding 40km/h) when dust dispersion is difficult to control, and conducting atmospheric monitoring for respirable crystalline silica to verify exposure levels remain below workplace exposure standard of 0.05 mg/m³. Engage qualified occupational hygienist to conduct personal atmospheric monitoring during representative crushing operations, positioning sampling pumps in breathing zones of crusher operator, ground crew feeding crusher, and any other workers regularly near crushing operations. If monitoring shows exposures approaching or exceeding 50% of the workplace exposure standard despite maximum feasible water suppression, implement additional controls including mandatory respiratory protection using minimum P2 respirators (preferably P3 respirators if exposures high), reduction of individual worker exposure time through job rotation, or upgrading crusher to model with enclosed cabin providing operator protection. For respiratory protection, provide P2 or P3 particulate respirators (AS/NZS 1716) to all workers in dusty areas, conduct fit testing for all respirator users to verify adequate facial seal, train workers in correct donning, fit checking, cleaning, and storage of respirators, prohibit wearing respirators over beards or long facial hair that prevent seal, and replace respirators when breathing resistance increases or when visibly contaminated. Establish hygiene facilities including hand washing stations and designated eating areas away from dusty work zones. Remember that respiratory protection is the least effective control and should supplement rather than replace engineering controls - prioritise maximising water suppression effectiveness over relying on respirators alone.

When a crusher blockage or jam occurs, following proper isolation procedures before attempting to clear the blockage is absolutely critical to prevent fatal injuries. Never attempt to clear blockages while the crusher is running or in standby mode - most crusher fatalities occur during blockage clearing when workers access crushing chambers without proper isolation. The correct blockage clearing procedure is: First, immediately stop feeding material to the crusher - signal the excavator or loader operator to stop and move equipment clear of the crusher. Second, stop the crusher mechanism using the normal shutdown control at the operator station. Third, stop the crusher engine completely and remove the ignition key from the operator station. Fourth, apply your personal safety lock to the isolation point (typically a lockable isolation switch or the ignition key removal point) - this lock prevents any person from restarting the crusher while you are clearing the blockage. Fifth, display a 'Danger - Equipment Isolated - Do Not Operate' lock-out tag at the operator controls including your name, date, and reason for isolation. Sixth, wait a minimum of 5 minutes after shutting down the crusher engine before approaching or accessing the crushing chamber - this waiting period allows all rotating components to coast to a complete stop. Heavy crusher rotors, jaws, and conveyor systems can continue rotating for several minutes after power is removed. Seventh, visually verify that all crusher components are stationary before reaching into or accessing the crushing chamber. Eighth, use long-handled tools including pry bars, hooks, chains, or poles to dislodge jammed material rather than reaching into the crusher with your hands - maintain maximum distance from the crushing zone. If the blockage is accessible from the feed hopper opening, hook the jammed material and pull upward to extract it. If the blockage is deep within the crushing chamber and cannot be reached with hand tools, you may need to remove crusher access panels or jaw plates following the manufacturer's procedures for safe access to internal components. Ninth, maintain the two-person rule during all blockage clearing - minimum two workers must be present with one person performing the blockage clearing work and the second person monitoring the work, holding the isolation key, and ready to summon help if the first worker becomes injured. The second person must never enter the crusher - their role is to maintain isolation and provide emergency assistance. Tenth, following blockage clearance, remove all tools from the crusher and verify all personnel are clear of the equipment before removing your personal lock. Conduct a pre-start inspection verifying no damage occurred from the blockage before restarting the crusher. Finally, investigate the cause of the blockage to prevent recurrence - common causes include feeding oversize material exceeding crusher feed opening dimensions, feeding excessive quantities of steel reinforcement that cannot pass through the crusher, feeding unsuitable materials including timber, plastic, or contaminated concrete, or incorrect crusher settings creating insufficient gap for material to pass through. Address the root cause through improved material screening, better operator training in feeding practices, or adjusting crusher settings. Document all blockages in the crusher log including cause, time required to clear, and corrective actions taken - recurring blockages indicate systemic problems requiring process changes rather than continued clearing of individual incidents.

Mobile concrete crushing operations generate extreme noise levels requiring comprehensive controls to protect workers and comply with environmental regulations particularly when crushing near residential areas, schools, hospitals, or other noise-sensitive receptors. Worker protection requirements under WHS legislation mandate implementation of noise control measures when noise levels exceed 85dB(A) as a time-weighted average over an 8-hour work period. Concrete crushers typically generate 95-110dB(A) at the crusher location requiring hearing protection and exposure time limits for all workers. For workers, provide and mandate use of Class 4 or Class 5 hearing protection (AS/NZS 1270) providing minimum 25dB noise reduction for all personnel within 20 metres of operating crusher. Fit operator cabins with acoustic insulation if not already fitted, reducing internal noise levels by minimum 15dB. Rotate workers between high-noise crushing operations and quieter duties limiting individual exposure time. Conduct noise monitoring using sound level meters establishing actual exposure levels for crusher operators and ground crew. Arrange baseline audiometric hearing tests for all workers with regular crusher exposure; repeat annually to detect early hearing loss indicating inadequate protection. For environmental noise control protecting neighbours and complying with local council regulations, first determine the applicable noise limits by consulting the local council's environmental protection policies or development consent conditions - limits vary by jurisdiction but commonly range from 45-55dB(A) at residential boundaries during daytime hours with lower limits during evening and weekend periods. Conduct baseline noise monitoring measuring noise levels at the nearest sensitive receptors (residences, schools, etc.) to establish actual noise impacts from your crushing operations. If monitoring shows noise exceeds council limits, implement additional controls including installing acoustic barriers or temporary noise walls around the crusher creating a barrier between crusher and noise-sensitive receptors - barriers must be solid construction (plywood, acoustic blankets, or purpose-built noise walls) and positioned close to either the noise source or the receiver for maximum effectiveness. Orient the crusher discharge conveyor away from sensitive receptors where possible as conveyor discharge creates significant impact noise. Select quieter crushing technologies where feasible - jaw crushers generally produce lower noise levels than impact crushers due to different crushing mechanisms. Limit crushing operating hours to standard construction hours permitted by local council (typically 7am to 6pm weekdays, restricted Saturday hours such as 8am to 1pm, and no Sundays or public holidays) - some councils allow extended hours for major projects but require specific approval. Implement truck movement controls including limiting truck numbers during early morning or late afternoon periods when ambient noise lower and community sensitivity higher. Conduct pre-project community consultation with nearby residents and businesses advising of crushing operations, expected duration, timing of works, and providing contact details for noise complaints. Respond to noise complaints immediately by verifying actual noise levels, implementing additional suppression measures if levels exceed limits, and maintaining communication with complainants about actions taken. For major crushing operations or particularly noise-sensitive locations, councils may require a detailed Noise and Vibration Management Plan approved before crushing permit is granted. This plan specifies noise limits at various receptor locations, real-time noise monitoring with data logging, specific control measures for different crushing phases, complaint response procedures and timeframes, and regular reporting to council on noise compliance. Some councils require continuous noise monitoring for major projects with real-time data available to council officers. Keep detailed records of all noise monitoring, complaints received and actions taken, and modifications made to crushing operations for noise control - these records demonstrate due diligence if enforcement action or complaints escalate.

Mobile concrete crushers require comprehensive maintenance and inspection programs to ensure safe operation, prevent breakdowns, and maintain crushing efficiency. Maintenance schedules divide into daily pre-start inspections, periodic servicing, and major overhauls with specific timeframes for each activity. Daily pre-start inspections conducted before each crushing shift include visual inspection of crusher structure for cracks, damage, loose bolts, or deformed components that could indicate structural failure developing, checking all guards are in place and secure including feed hopper screens, crusher chamber guards, conveyor covers, and drive mechanism enclosures, testing all safety interlock switches by opening each guard and verifying crusher will not start, testing emergency stop buttons at all locations verifying immediate shutdown when activated, inspecting hydraulic system for leaks at hoses, cylinders, and connections; checking hydraulic fluid level, inspecting conveyor belt for tears, cuts, excessive wear, or tracking problems; verifying belt runs centrally on rollers, checking all conveyor rollers and idlers rotate freely without seized bearings or excessive noise, examining crusher wear parts including jaw plates (measure thickness if gauges available), impact bars and hammer tips, or cone wearing surfaces; document wear levels, testing water suppression system activating all spray zones and verifying adequate flow and spray patterns, checking control systems including start/stop functions, crusher adjustment mechanisms, and instrumentation, and inspecting fuel and oil levels; refuelling as needed for planned crushing duration. Document daily inspections in crusher logbook recording date, operator name, inspection findings, and any defects requiring attention. Do not operate crusher if safety-critical defects identified including missing or damaged guards, non-functional emergency stops or interlocks, excessive wear parts requiring replacement, hydraulic leaks indicating seal failure, or damaged conveyor belt at risk of failure. Weekly maintenance during ongoing crushing operations includes detailed cleaning of crusher removing accumulated concrete dust and debris from all components to allow thorough inspection, greasing all lubrication points following manufacturer lubrication chart (may require daily greasing for heavily used pivots), checking torque on all major bolts particularly jaw mounting bolts, impact bar retaining bolts, or structural connection bolts, cleaning water spray nozzles removing blockages and verifying spray patterns, inspecting electrical connections for looseness, corrosion, or damage, checking battery condition and connections, and documenting crusher operating hours for service scheduling. Monthly or hours-based servicing (typically every 100-200 operating hours depending on manufacturer specifications) includes changing hydraulic oil and filters, changing engine oil and filters following engine manufacturer service intervals, inspecting and adjusting conveyor belt tension to specifications, replacing conveyor idler bearings showing wear or roughness, inspecting crusher jaw bearing condition checking for roughness, excessive play, or noise, measuring crusher wear parts and planning replacement when approaching wear limits (typically replace jaw plates when worn to 70% of original thickness), inspecting and adjusting crusher drive belts for correct tension, and conducting detailed structural inspection using dye penetrant or magnetic particle testing on critical welds and high-stress areas. Major component replacement intervals vary by usage intensity but typically include replacing jaw plates every 500-2000 crushing hours depending on concrete hardness and wear rates, replacing impact bars or hammer tips every 200-1000 hours depending on crusher type and impact intensity, replacing conveyor belts every 2000-5000 hours or when damage exceeds repairable levels, replacing hydraulic hoses every 2-3 years regardless of condition due to aging degradation, and rebuilding or replacing crusher jaw bearings, impact shaft bearings, or cone bearings every 3000-5000 hours. Maintain comprehensive maintenance records documenting all inspections, servicing, component replacements, and repairs including dates, work performed, parts replaced with part numbers, and technician name. These records enable predictive maintenance identifying components reaching end of service life before failure occurs, provide evidence of proper maintenance if regulatory investigation occurs, support warranty claims if component failures occur within warranty periods, and demonstrate due diligence in asset management if crushing efficiency declines. Engage manufacturer-trained technicians for complex maintenance including bearing replacement, structural repairs, or hydraulic system overhauls - field repairs by unqualified personnel can compromise safety systems or create new hazards. Keep adequate spare parts inventory including common wear parts (jaw plates, impact bars), consumables (filters, lubricants), and critical components (hydraulic hoses, conveyor belt) enabling rapid repair if failures occur minimising crushing downtime.