Comprehensive SWMS for Remote-Operated Compaction Equipment in Trenches and Excavations

Remote Control Trench Roller Safe Work Method Statement

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Remote control trench rollers are specialised compaction machines designed for compacting backfill materials in trenches, pipe bedding zones, and excavations where space constraints prevent conventional roller access. These compact machines, typically weighing between 200kg and 1,200kg, are operated via wireless remote control systems allowing operators to stand outside the trench while controlling machine movements. This SWMS addresses the unique safety requirements for remote control trench roller operations including radio control system management, confined space considerations, operator positioning protocols, and coordination with ground personnel in accordance with Australian WHS legislation for remote-operated machinery.

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Overview

What this SWMS covers

Remote control trench rollers represent a specialised category of compaction equipment developed specifically for confined space applications where conventional rollers cannot safely or practically operate. These machines compact backfill materials in trenches for underground service installation, pipe bedding zones surrounding water, sewer, and drainage infrastructure, excavations for building foundations, and confined areas where space restrictions prevent access by larger equipment. Machine weights typically range from 200kg for narrow trench applications up to 1,200kg for wider trenches and heavier compaction requirements, with drum widths varying from 400mm to 1,200mm depending on trench width. The defining characteristic of these machines is their remote control operation system. Rather than featuring an operator's position on the machine itself, operators control all functions via handheld wireless remote control units communicating with receivers mounted on the roller. The remote control typically includes forward/reverse travel controls, vibration activation for compaction, and emergency stop functionality. This remote operation capability addresses the fundamental safety issue of placing operators in confined trenches with operating machinery—by enabling operators to stand at trench level or on the excavation edge while the machine works below, the remote system eliminates operator exposure to trench collapse hazards, poor ventilation, and being trapped in the trench with the machine. Remote control trench rollers generally employ either radio frequency (RF) or infrared (IR) control systems. RF systems provide the advantage of not requiring line-of-sight between operator and machine, allowing operation even when the machine is temporarily obscured by trench configuration or materials. IR systems require clear line-of-sight but offer immunity to radio frequency interference that could affect machine control in areas with high RF noise. Modern machines increasingly feature safety interlocks including dead-man switches requiring constant operator input to maintain operation—releasing control triggers causes immediate machine shutdown preventing runaway scenarios if operators drop the remote or lose control. Typical trench roller applications include compacting bedding sand beneath pipes before pipe installation, compacting sidefill materials alongside pipe barrels after installation, and compacting final backfill materials in layers as trenches are progressively filled. The compaction process requires multiple passes over the same area with machines travelling forward and backward along trench lengths. Operators must coordinate with excavator operators who are placing fill materials, with ground personnel who may be working in or near trenches, and with other trades including plumbers and electricians who install services that will be buried. The confined nature of trench environments creates complex interaction hazards requiring clear communication protocols and exclusion zone management despite the remote operation reducing some risks.

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Why this SWMS matters

The development of remote control trench rollers directly addressed a persistent safety hazard in civil construction—the need for compaction equipment operators to work inside trenches alongside operating machinery while exposed to trench collapse risks. Before remote control technology became widespread, operators of conventional walk-behind compactors and small rollers worked within excavations, creating dual exposure to both machinery hazards and excavation collapse risks. Multiple fatalities occurred where operators were struck by machinery in confined trenches or where trench collapse buried operators who were operating equipment at trench bottom level. Remote control systems eliminate this combined exposure by positioning operators outside the excavation. Despite the safety advantages of remote operation, significant hazards remain. Loss of control scenarios where radio interference disrupts communication between remote and machine can cause unexpected machine movements or failure to respond to control inputs. Operators positioned at trench edges face fall risks if they step too close to unsupported edges while focused on controlling the machine below. The confined space nature of trench work creates ongoing hazards for any personnel who must enter trenches to adjust materials, reposition the machine, or conduct maintenance. Vibration exposure affects operators who must stand on the ground surface above operating machines transmitting vibration through soil layers, though this exposure is substantially lower than riding on conventional equipment. From a regulatory perspective, remote control trench roller operations intersect with multiple WHS requirements. Confined space regulations apply to trench work even when operators remain outside the excavation—any personnel entering trenches require confined space entry permits, atmospheric testing, emergency extraction equipment, and trained standby personnel. Machinery operation regulations require documented operator competency, pre-start inspection procedures, and maintenance records. The Work Health and Safety Act's requirements for managing risks so far as reasonably practicable apply to both the machinery operation hazards and the excavation environment hazards that remain despite remote operation. Case law has established that while remote control systems represent a significant risk reduction compared to operator-aboard equipment, they do not eliminate all reasonably foreseeable risks. Courts expect PCBUs to implement supplementary controls including operator positioning protocols preventing falls into excavations, radio control system testing and interference management, emergency stop testing verification, and coordination with excavation support systems ensuring trench stability. The failure to maintain trenches in stable condition or to prevent unauthorised entry to unsupported excavations represents a breach of duty regardless of whether remote control equipment is used. Practically, comprehensive SWMS for remote control trench roller operations provides operators with clear protocols for positioning themselves safely relative to excavation edges, testing radio control systems before each operational period, coordinating with excavator operators and ground personnel, and responding to control failures or emergency situations. The SWMS must integrate with the site's excavation and trenching SWMS, confined space management plans, and traffic management systems to address the full spectrum of interaction hazards present in these operations.

Reinforce licensing, insurance, and regulator expectations for Remote Control Trench Roller 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

Loss of Radio Control and Runaway Machine Scenarios

High

Radio frequency interference from power tools, site radios, mobile communications, or electrical installations can disrupt communication between handheld remote controls and machine receivers. When control signals are interrupted, machines may fail to respond to operator inputs, may execute the last command repeatedly creating unintended movement, or in older systems without failsafe controls, may continue operating without ability to stop. Operators attempting to regain control may move closer to trench edges or even enter trenches to reach manual stop controls. Flat batteries in remote control units can cause sudden loss of control during operation. Physical damage to remote control units from being dropped or exposed to weather can cause intermittent functionality creating unpredictable machine responses.

Consequence: Machine continues operating without control potentially striking workers or damaging underground services. Operators entering trenches to manually stop machines expose themselves to trench collapse and being struck by uncontrolled machinery. Property damage from machines running into trench walls or installed infrastructure.

Operator Falls into Trenches While Operating Remote Control

High

Operators focused on controlling machines via handheld remotes while watching the roller work in trenches below may not maintain awareness of their position relative to excavation edges. Walking backwards while operating the remote to maintain visual contact with the machine can result in operators stepping off unsupported trench edges. Excavation edges can fail unexpectedly under operator weight particularly after rain or vibration from compaction operations. Operators may position themselves too close to edges to maintain visual contact with machines in deep or narrow trenches. Poor lighting conditions during early morning or late afternoon can obscure edge positions.

Consequence: Fatal injuries from falls into trenches resulting in impact trauma and potential burial if fall triggers edge collapse. Fractures, head injuries, and spinal damage even from non-fatal falls into trenches. Secondary risk of being struck by operating machinery if operator falls into trench where machine is working.

Confined Space Hazards During Machine Repositioning or Maintenance

High

While remote operation eliminates routine operator presence in trenches, personnel must still enter excavations to reposition machines that become stuck, conduct on-site maintenance or repairs, change vibration settings not accessible via remote, or resolve operational problems. Trenches deeper than 1.5 metres are classified as confined spaces with associated hazards including oxygen deficiency, accumulation of toxic gases from underground sources or decomposing materials, flooding from groundwater or rain, trench collapse burying workers, and difficulty extracting injured personnel. These hazards persist despite remote control operation and create risk for anyone entering trenches even briefly.

Consequence: Fatal asphyxiation from oxygen deficiency or toxic gas exposure in poorly ventilated trenches. Burial and suffocation from trench collapse. Drowning if trenches flood while workers are inside. Difficulty rescuing injured workers from confined spaces requiring specialised extraction equipment.

Vibration Transmission Through Ground to Operators

Medium

Operating trench rollers produce significant vibration transmitted through compacted materials and soil layers to the ground surface where operators stand. While vibration exposure is substantially reduced compared to riding on conventional compaction equipment, operators standing directly above or adjacent to operating rollers for extended periods still receive whole-body vibration through their feet and legs. The vibration frequency and amplitude vary with machine size, ground conditions, and compaction settings. Operators working full shifts on multiple trench locations accumulate exposure that can approach threshold limits requiring controls.

Consequence: Cumulative exposure contributing to lower back pain, joint damage in ankles and knees, and circulatory effects in legs and feet. While substantially lower risk than conventional compaction equipment, extended exposure without controls can still cause health effects over career duration.

Trench Edge Collapse Near Operating Equipment

High

Vibration from operating trench rollers can destabilise trench walls particularly in cohesionless soils, saturated ground conditions, or trenches near maximum depth without support systems. The continuous vibration over extended compaction periods can trigger collapse of previously stable edges. Trench boxes or support systems may not extend to full trench length leaving sections of unsupported excavation where machines must operate. Operators positioned near edges when collapse occurs can be swept into trenches. Ground personnel working ahead of or behind the roller positioning pipes or materials face burial risk if vibration triggers collapse.

Consequence: Fatal burial if workers are in trench when vibration triggers wall collapse. Crushing injuries from partial burial. Damage to installed services if collapse occurs after service installation. Machine burial requiring costly recovery operations and work delays.

Coordination Failures with Excavator Operators Placing Fill

Medium

Trench compaction work requires close coordination with excavator operators who place backfill materials into trenches. The trench roller operator must work in areas where excavators are simultaneously swinging loaded buckets overhead, dumping materials, and manoeuvring near trench edges. If communication protocols are unclear or not followed, excavator buckets can strike trench roller operators positioned at trench edges, or can dump loads onto operating rollers causing damage or burying the equipment. Both operators are focused on their respective tasks and may not maintain awareness of the other's position and movements.

Consequence: Trench roller operators struck by excavator booms or falling materials causing serious impact injuries. Buried equipment requiring recovery operations. Damage to remote control systems if excavator loads impact the roller causing loss of control.

Manual Handling During Machine Transport and Positioning

Medium

While remote control trench rollers are compact, they still weigh between 200kg and 1,200kg requiring mechanical lifting equipment for transport onto and off trucks. However, smaller units are sometimes manually manhandled by multiple workers to position at trench edges or move short distances between work areas. This manual handling creates back strain, crush injuries if machines tip or roll, and finger pinch injuries when guiding machines into position. Machines being lowered into trenches via excavator lifting chains or slings create struck-by hazards if rigging fails or loads swing during placement.

Consequence: Back injuries and musculoskeletal strain from attempting to manually move heavy equipment. Crush injuries to feet and hands if machines tip during manual positioning. Struck by falling equipment if lifting rigging fails during placement into trenches.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Dead-Man Switch and Failsafe Control Systems

Engineering Control

Implement remote control systems featuring dead-man switch functionality requiring constant operator pressure on control triggers to maintain machine operation. Releasing the control trigger causes immediate machine shutdown preventing runaway scenarios. Verify failsafe programming causes machines to stop all movement and vibration if radio signal is lost rather than continuing previous command. Test emergency stop buttons on remote controls daily to confirm they immediately halt all machine functions from any distance within operating range. Only operate machines with verified failsafe control systems—withdraw older equipment lacking these safety features from service.

Implementation

1. Verify all remote control trench rollers are fitted with dead-man switch controls requiring constant trigger pressure to operate 2. Test dead-man functionality daily: start machine via remote, release all control triggers, verify machine immediately stops 3. Test radio signal loss failsafe: start machine, move to maximum operating distance, switch remote control off, verify machine stops within 2 seconds 4. Test emergency stop button functionality by pressing E-stop during machine operation and confirming immediate shutdown of all functions 5. Replace any remote control units with damaged or worn trigger mechanisms that do not reliably activate dead-man functions 6. Train operators that dead-man systems only work if hands remain on controls—never prop triggers or bypass dead-man switches 7. Maintain documentation showing daily testing of safety systems and any defects identified requiring maintenance 8. Withdraw machines from service if any safety system testing fails; repair before permitting return to operation

Operator Positioning Protocols and Edge Setback Requirements

Administrative Control

Establish mandatory minimum setback distances from trench edges that operators must maintain while controlling remote machines. Typical setback is 1.5 to 2 metres from unsupported edges, adjusted based on trench depth, soil conditions, and whether edges are supported. Mark setback lines using spray paint, marker posts, or barrier tape creating visual reference for operators. Designate specific operator zones outside excavations where visibility is adequate and ground is stable. Prohibit operators from moving backwards while operating remotes—operators must periodically glance behind to verify their position remains safe.

Implementation

1. Assess trench configuration and soil conditions to determine appropriate setback distance from edges 2. Mark operator setback lines parallel to trench edges using high-visibility spray paint at 1-2 metre intervals 3. Place marker posts with flagging tape at 5-metre intervals along trench length showing operator safe zones 4. Instruct operators to position themselves between setback line and site vehicle traffic areas maintaining awareness of threats from both directions 5. If visual contact with machine requires closer approach to edge, stop machine operation and reposition to location with adequate visibility 6. Never operate machines while walking—stop walking, establish stable footing outside setback zone, then operate controls 7. Assign second worker as observer to monitor operator positioning and alert if operators approach edge setback limits 8. Conduct supervisor observations ensuring operators maintain setback compliance throughout shift

Radio Control System Testing and Interference Management

Administrative Control

Implement daily pre-start testing of radio control systems verifying full control responsiveness, emergency stop effectiveness, and failsafe activation. Identify and manage sources of radio frequency interference on site including relocating site radios or power tool charging stations away from trench work areas. Maintain spare remote control units and charged batteries immediately available on site. Establish protocols requiring immediate work stoppage if any control anomalies or delayed responses are observed during operation.

Implementation

1. Conduct pre-start remote control testing minimum 30 minutes before commencing machine operation each day 2. Test all control functions: forward travel, reverse travel, vibration on/off, steering if applicable, and emergency stop 3. Test control response at minimum distance (2 metres) and maximum specified operating distance verifying equal responsiveness 4. Test signal penetration by operating machine inside trench and controlling from various positions above verifying consistent control 5. Identify RF interference sources on site: note locations of site radios, mobile phone towers, power tool storage, electrical switchrooms 6. Maintain 20-metre clearance between operating trench rollers and high-power radio frequency sources where feasible 7. If control response delays or intermittent functionality observed, stop operation immediately and investigate cause before proceeding 8. Maintain spare remote control unit with charged batteries in site vehicle for immediate replacement if primary control fails

Confined Space Entry Procedures for Machine Maintenance

Administrative Control

Classify all trenches exceeding 1.5 metres depth as confined spaces requiring formal entry procedures, atmospheric testing, and rescue arrangements even when normal compaction work is conducted remotely. When workers must enter trenches to reposition stuck machines, conduct maintenance, or resolve operational issues, implement full confined space protocols including atmosphere testing for oxygen levels and toxic gases, provision of extraction equipment, assignment of trained standby personnel, and time limits on entries. Never permit solo entry to trenches regardless of perceived urgency.

Implementation

1. Treat all trenches deeper than 1.5 metres as confined spaces requiring entry permits and gas testing before entry 2. Maintain calibrated gas detection equipment on site testing for oxygen levels (safe range 19.5-23.5%), carbon monoxide, hydrogen sulphide, and explosive atmospheres 3. Test trench atmosphere immediately before any entry taking readings at trench bottom where gases accumulate 4. If atmospheric testing reveals oxygen below 19.5% or presence of toxic gases, implement forced ventilation and re-test before permitting entry 5. Assign minimum two workers to any trench entry task: one enters while second remains at surface as standby person maintaining visual contact 6. Equip entering workers with harnesses connected to mechanical extraction systems or rope rescue equipment 7. Provide portable gas monitors to workers entering trenches with continuous monitoring and alarm functions 8. Establish 15-minute maximum for any trench entry requiring immediate exit if time limit is reached

Coordination Protocols with Excavator Operators

Administrative Control

Establish clear communication and coordination protocols between trench roller operators and excavator operators placing backfill materials. Implement sequential work patterns where excavators dump loads at designated locations, then withdraw to safe distance while trench rollers compact, alternating between placement and compaction phases. Use radio communication protocols requiring excavator operators to announce before swinging loads over areas where roller operators are positioned. Define exclusion zones where only one machine operates at any given time.

Implementation

1. Conduct pre-start coordination meeting between excavator operators and trench roller operators agreeing work sequence for the day 2. Establish sequential operation pattern: excavator places backfill load at designated trench section, withdraws to safe position, radio confirms clear for compaction 3. Trench roller operator radios confirmation before commencing compaction in section where material was placed 4. Require excavator operators to radio announcement before swinging loads: 'Excavator 2 swinging load over north section' allowing roller operators to clear area 5. Define 10-metre exclusion radius around operating excavators that trench roller operators must not enter during excavator work 6. Use traffic marshals or spotters to coordinate both operators' activities if work areas are congested or multiple machines operating simultaneously 7. Establish hand signal backup communication in case radio systems fail—agree signals for 'stop', 'proceed', 'move clear' at morning briefing 8. Conduct debrief at end of day discussing coordination issues encountered and improving protocols for following day

Mechanical Lifting for All Machine Transport and Positioning

Engineering Control

Eliminate manual handling of trench rollers by requiring mechanical lifting for all transport on and off trucks, placement into trenches, and repositioning between work areas. Use excavators with lifting chains or certified slings to lower machines into trenches and extract them at completion. Provide dedicated machine transport trailers with ramps or hydraulic tilt decks allowing machines to drive on and off without manual lifting. Only the smallest walk-behind units under 200kg may be manually positioned by teams of three workers using proper lifting techniques.

Implementation

1. Specify that all machines exceeding 200kg must be transported and positioned using mechanical lifting equipment only 2. Fit trench rollers with lifting points designed for excavator chain or sling attachment 3. Use excavators to lower machines into trenches at start of work and extract at completion rather than manual manhandling 4. Provide machine transport trailer with loading ramps allowing remote-controlled drive-on loading 5. For machines under 200kg, require teams of minimum three workers for any manual repositioning using proper manual handling techniques 6. Instruct workers to maintain stable footing and avoid working on slopes or uneven ground when manually guiding machines 7. Use directional rollers or skids under machines to assist repositioning rather than attempting to lift full weight 8. Prohibit attempts to manually lift or position machines on inclines where machines could roll causing crush injuries

Personal Protective Equipment for Remote Control Operations

Personal Protective Equipment

Require operators to wear high-visibility clothing ensuring they are visible to excavator operators and other plant operators working nearby. Steel-cap boots provide foot protection if machines tip during positioning or if operators work near trench edges with falling material hazards. Hard hats protect against overhead hazards from excavator booms swinging over operator positions. Hearing protection is required if operators work near excavators or other noisy equipment despite the remote roller operation being relatively quiet. Safety glasses are required during maintenance activities involving hydraulic systems or cleaning.

Implementation

1. Require Day/Night high-visibility vests per AS/NZS 4602.1 for all trench roller operators and ground personnel 2. Mandate steel-cap safety boots rated 200 joules per AS/NZS 2210.3 for all personnel near trench edges or operating equipment 3. Require Type 1 hard hats per AS/NZS 1801 when operators work in areas where excavators are swinging loads overhead 4. Provide Class 3 hearing protection for operators positioned within 10 metres of operating excavators or heavy equipment 5. Issue safety glasses with side shields for operators conducting maintenance on hydraulic systems or cleaning equipment 6. Supply gloves with good grip for operating remote controls particularly during wet weather making controls slippery 7. Inspect PPE daily for serviceability and replace damaged high-visibility vests with faded or dirt-obscured reflective strips 8. Enforce PPE compliance through site supervision and refuse access to work areas for personnel without required PPE

Download complete control procedures

Personal protective equipment

Requirement: Day/Night vest per AS/NZS 4602.1 Class D/N

When: Required for all operators and ground personnel working near trenches where remote control rollers and excavators operate

Requirement: Steel-cap boots rated 200 joules per AS/NZS 2210.3

When: Required for all personnel involved in trench roller operations, machine positioning, or working near trench edges

Requirement: Type 1 industrial safety helmet per AS/NZS 1801

When: Required when working in areas where excavators are operating overhead or materials are being placed into trenches

Requirement: Class 3 earmuffs or earplugs per AS/NZS 1270

When: Required when positioned within 10 metres of operating excavators or working extended periods near heavy equipment

Requirement: Medium impact rated per AS/NZS 1337

When: Required during machine maintenance, hydraulic system inspection, or cleaning operations

Requirement: Synthetic grip gloves with water resistance

When: Required when operating remote controls particularly during wet weather or extended operation periods

Inspections & checks

Before work starts

✓Verify operator has completed site induction and demonstrated competency with remote control trench roller operation
✓Conduct visual inspection of machine checking for hydraulic leaks, loose components, and damage to drums or frames
✓Test remote control system functionality including all travel directions, vibration activation, and emergency stop button
✓Verify dead-man switch requires constant trigger pressure and releases cause immediate machine shutdown
✓Test failsafe programming by switching remote off during operation and confirming machine stops within 2 seconds
✓Check remote control battery charge level and verify spare batteries are available and charged on site
✓Inspect trench configuration identifying operator positioning zones with adequate visibility and setback from edges
✓Mark operator setback lines minimum 1.5-2 metres from unsupported trench edges using spray paint or marker posts
✓Verify trench support systems are in place where required by depth and soil conditions per excavation SWMS
✓Confirm atmospheric testing equipment is available and calibrated if any personnel may need to enter trenches
✓Coordinate with excavator operators confirming communication protocols and work sequence for material placement and compaction
✓Assess radio frequency environment noting locations of potential interference sources requiring clearance management

During work

✓Monitor operator positioning ensuring they maintain required setback distance from trench edges throughout operation
✓Observe operator control technique verifying they maintain stationary positions while operating and do not walk backwards toward edges
✓Verify remote control responsiveness remains immediate and consistent with no delays or intermittent control issues
✓Watch for signs of trench wall instability during compaction including cracking, bulging, or loose material falling from edges
✓Confirm coordination between excavator and roller operators follows agreed sequence with adequate spacing maintained
✓Monitor for radio frequency interference symptoms including sluggish control response or need for repeated commands
✓Check that operators immediately stop work if any control anomalies are observed and conduct system testing before resuming
✓Verify no personnel enter trenches during compaction operations without implementing confined space entry protocols
✓Monitor atmospheric conditions if trenches are deep or known to have potential gas accumulation risks
✓Ensure excavator operators radio announce before swinging loads over areas where roller operators are positioned
✓Verify operators maintain visual contact with machines at all times during operation for situational awareness

After work

✓Drive machine to extraction point at trench edge and shut down engine after completing compaction work
✓Use excavator with certified slings or chains to extract machine from trench and place on transport trailer
✓Conduct post-operation inspection of machine noting any damage, hydraulic leaks, or mechanical issues developed during shift
✓Clean remote control unit removing mud and dust that could interfere with control operation
✓Charge remote control batteries overnight ensuring fresh batteries available for next operational period
✓Document any control system issues including interference problems or delayed responses requiring investigation
✓Report trench wall instability observed during operations requiring additional support before next work period
✓Inspect drums for damage or material buildup requiring cleaning before next use
✓Store machine in designated secure area preventing unauthorised operation or weather exposure to control systems
✓Debrief with excavator operators and supervisors discussing coordination effectiveness and any near-miss incidents

Step-by-step work procedure

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

Field ready

Pre-Operational Remote Control System Testing

Before commencing trench compaction work, conduct comprehensive testing of the remote control system to verify all functions respond correctly and safety systems operate effectively. Start by ensuring the machine is positioned on level ground in an open area away from trench edges, personnel, and obstacles. Check the remote control unit battery charge level indicator—typical units show charge status via LED lights or display screens. Replace batteries if charge is below 50% to prevent mid-operation power loss. Power on the machine using the key switch or master power button—wait for indicator lights confirming systems are active. Power on the remote control unit and verify it establishes communication with the machine receiver—most systems indicate successful pairing via steady indicator lights or specific light patterns. Test each control function systematically starting with travel controls. Press the forward travel control and observe the machine moves forward smoothly. Release the control and verify the machine stops immediately due to dead-man switch function—it should not coast or continue moving after control release. Test reverse travel with the same observation of immediate stop upon release. Test the vibration activation control—when activated, you should see and feel the drum vibrating. Test the emergency stop button—when pressed, all machine functions should cease immediately and require system reset before operation can resume. Test the failsafe function by simulating signal loss: start the machine operation and have an assistant switch off the remote control unit. The machine should stop all functions within 2 seconds when radio signal is lost. If any test reveals delayed response, no response, or failure to stop when expected, do not proceed with operation—investigate the cause and repair before commencing work.

Safety considerations

Never bypass pre-start testing regardless of time pressure. Control system failures during operation in trenches create serious risks as machines may not respond when hazards appear. Always test emergency stop functionality—this is your primary safety control if the machine begins moving unexpectedly toward personnel or edges. Test dead-man switches by releasing controls unexpectedly rather than gently—this simulates actual scenarios where you might drop the remote or be startled.

Trench Assessment and Operator Positioning Zone Establishment

Assess the trench configuration before lowering the machine into the excavation, identifying where you will position yourself to maintain visual contact with the roller while remaining safely setback from edges. Walk the trench length observing its depth, width, whether support systems are installed, and identifying the most stable ground for operator positioning. Check for overhead powerlines or other overhead hazards near your intended operating positions. Identify areas of unstable ground including recent fill, wet soils, or cracks indicating potential edge failure. Determine the appropriate setback distance from the unsupported edge—typical requirement is 1.5 to 2 metres from edge, but increase this distance if trench is deep (exceeding 2 metres), if soil appears cohesionless, or if compaction vibration may destabilise edges. Use spray paint or marker posts with flagging tape to mark a visual reference line parallel to the trench edge showing your minimum setback position. Mark this line at 2-metre intervals along the full length of trench where you will operate. Identify specific operator zones where visibility into the trench is adequate to see the roller throughout its travel. If sections exist where visibility is poor due to trench configuration, mark these as areas requiring machine shutdown and repositioning rather than attempting blind operation. Verify that your operating positions are not in traffic routes where vehicles or other equipment may pass behind you. Communicate with excavator operators identifying where they will dump material and where you will position yourself to maintain clearance from excavator swing radius.

Safety considerations

Falls into trenches cause serious injuries even when depths are relatively shallow. Never position yourself closer than marked setback lines regardless of visibility challenges—if you cannot see the machine from safe positions, implement alternative approaches such as having a second worker act as spotter. Trench edges can fail suddenly particularly when subject to compaction vibration, so conservative setback distances are essential. Ground that appears stable when you first assess it can fail after compaction begins loading it with vibration.

Machine Placement into Trench Using Mechanical Lifting

Lower the remote control trench roller into the excavation using an excavator with certified lifting equipment rather than attempting manual handling. Attach lifting slings or chains to the dedicated lifting points designed into the roller frame—these are typically marked with lifting symbols or painted differently from the frame. If using chains, ensure they are positioned symmetrically to prevent the machine tipping during the lift. If using slings, check slings are not cut, abraded, or damaged and are rated for the machine weight with adequate safety factor. An assistant should guide the machine as the excavator lifts it clear of ground level, ensuring the machine remains level and balanced. The excavator operator should lift slowly and smoothly to test the rigging before raising the machine to full height. Once confirmed stable, the excavator swings the machine over the trench to the starting position. Lower the machine into the trench slowly while ground personnel guide its position—personnel providing guidance must maintain positions outside the trench and should never be underneath suspended loads. Lower the machine until drums make contact with trench bottom material. Reduce lifting tension allowing the machine to settle on its own weight, then carefully disconnect lifting equipment. Ground personnel may need to enter the trench briefly to disconnect rigging—if trench depth exceeds 1.5 metres, implement confined space entry protocols including atmospheric testing. Once rigging is disconnected, all personnel must exit the trench before machine operation commences. Test the remote control from your marked operator position confirming you can see the machine clearly and controls respond normally.

Safety considerations

Never allow personnel to remain in trenches when machines are being lowered—falling machines cause fatal crushing. Never work under suspended loads regardless of how well rigging appears secured. If confined space entry is required to disconnect rigging, implement full atmospheric testing and standby person protocols. Verify excavator operator has clear hand signal communication with personnel guiding the placement—use standard signals for 'raise', 'lower', 'swing left/right', 'stop'.

Compaction Operations and Operator Positioning Discipline

Position yourself in the marked operator zone maintaining required setback from trench edges with clear visibility of the roller in the trench below. Stand with stable footing on level ground with your back to solid areas away from traffic routes. Begin machine operation by activating travel and vibration controls—modern machines typically require holding control triggers to maintain operation due to dead-man switch systems. Move the machine forward along the trench at slow walking pace—typical compaction requires multiple passes over the same area so there is no benefit to rushing. Watch the machine continuously as it moves ensuring it maintains straight travel and does not approach trench walls or encounter obstacles. The compaction process generates noise and vibration you will hear and may feel transmitted through the ground. This vibration is normal but watch for excessive vibration or sounds indicating the machine may be encountering hard objects in the fill material. When the roller reaches the end of your comfortable visibility range, stop the machine and reposition yourself to the next operator zone maintaining setback discipline—never walk backwards while operating or move closer to edges to extend your viewing range. If you must reposition while the machine is mid-trench, stop all machine operation first, move to your new position, re-establish stable footing and visibility, then resume operation. Coordinate with the excavator operator who will be placing additional fill material—establish a pattern where the excavator places material at one section, withdraws to a safe distance, radios you clearance to begin compacting, you complete compaction passes on that section, then radio back that you are clear allowing the excavator to proceed with the next fill placement. Never operate while the excavator is swinging loads over your position or over the trench section where your machine is working.

Safety considerations

Maintain constant awareness of your position relative to the marked setback line—it is easy to drift toward the edge while focused on controlling the machine. If you feel yourself stepping backwards, stop operating immediately, verify your position, and move to safer ground before resuming. Never lean over trench edges attempting to see the machine—if visibility is poor, stop operations and reposition machine or yourself. Watch for signs of edge instability including cracks appearing, soil crumbling from edges, or materials beginning to slump—these indicate potential collapse requiring immediate evacuation of the area and engineering assessment.

Response to Control System Anomalies or Failures

During operation, remain alert for any changes in remote control responsiveness indicating developing problems. Normal operation should show immediate response to control inputs with the machine reacting within a fraction of a second. Signs of control issues include delayed response where you press forward but the machine takes 1-2 seconds to react, intermittent response where commands sometimes work and sometimes don't, reduced operating range where the machine only responds when you are very close, or complete loss of control where the machine does not respond at all. If you observe any of these symptoms, immediately press the emergency stop button on the remote control to halt the machine. Do not attempt to continue operation assuming the problem will resolve itself. Once the machine is stopped, attempt to re-establish control by power cycling the remote control unit—switch it off, wait 10 seconds, switch on, and verify communication re-establishes. Test all functions again from your safe position. If control responsiveness returns to normal, you may cautiously resume operations while remaining alert for recurrence. If problems persist or worsen, the machine must be extracted from the trench and control systems inspected by qualified technicians. If the machine loses all control and fails to respond to emergency stop commands or signal loss failsafe, you must treat this as an emergency scenario. Alert all nearby personnel to clear the area. If the machine is stationary when control is lost, it can likely remain in place until repairs are completed. If the machine is operating and will not stop via remote control, someone must enter the trench to access manual shutdown controls. This confined space entry requires full protocols including atmospheric testing, entry permits, harness systems, and standby personnel—never allow single personnel to enter trenches attempting emergency shutdown.

Safety considerations

Never continue operating when control anomalies are apparent hoping they will improve—control failures can worsen suddenly creating runaway scenarios. Press emergency stop at first sign of problems rather than waiting to confirm loss of control. If you must enter the trench to manually shut down uncontrolled machinery, implement full confined space protocols and risk assessment—consider whether allowing the machine to run until fuel exhaustion is safer than trench entry. Maintain spare remote control units and charged batteries on site allowing immediate system swapping rather than attempting field repairs under time pressure.

Machine Extraction and Post-Operation Inspection

Upon completing compaction work in a trench section, drive the machine to a designated extraction point near where the excavator can reach with lifting equipment. If the trench is long, identify multiple extraction points during initial setup rather than forcing the machine to travel excessive distances through rough terrain. Stop the machine and shut down the engine using the remote control or, if a shutdown function is not available via remote, someone must enter the trench to access the engine stop control—implement confined space protocols if entry is required. Coordinate with the excavator operator for machine extraction. Lifting personnel must enter the trench to attach slings or chains to the lifting points—implement confined space procedures including atmospheric testing if depth exceeds 1.5 metres. Once rigging is attached and personnel have exited the trench and confirmed clear, signal the excavator operator to commence lifting. The excavator lifts slowly testing the rigging, then raises the machine clear of the trench and swings it to ground level at a safe distance from the excavation. Lower the machine onto level ground and disconnect rigging. Conduct post-operation inspection walking around the machine checking for hydraulic leaks, damage to drums or frame, loose fasteners, or any issues that developed during the shift. Clean the remote control unit using a cloth to remove dust and mud that could interfere with button operation. Check the machine drums for heavy material buildup that could affect compaction effectiveness in the next operational period—clean drums if significant buildup exists. Document any operational issues or control anomalies experienced during the shift in the plant log or digital maintenance tracking system. Report significant issues to supervision and maintenance personnel. Store the machine on the transport trailer or in a designated secure area preventing unauthorised operation. Place remote control units on charge ensuring batteries are fresh for the next work period.

Safety considerations

Extraction operations create additional confined space entry exposures as personnel must enter trenches to attach and detach rigging. Never rush these entry activities due to production pressure—implement proper atmospheric testing and standby protocols. Never allow personnel to remain in trenches during lifting operations regardless of how stable rigging appears. Machines can slip from rigging or slings can fail causing falling equipment hazards. Post-operation inspection identifies developing mechanical problems before they cause failures during subsequent operations—treat inspections as mandatory safety activities not optional maintenance.

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Frequently asked questions

What qualifications or training are required to operate remote control trench rollers in Australia?

Remote control trench roller operation does not typically require a specific high-risk work licence under national WHS regulations, as the machines do not carry operators and are controlled remotely. However, operators must demonstrate competency through documented training addressing remote control system operation, trench safety awareness, confined space hazards, emergency procedures, and coordination with excavation equipment. Employers must verify operator competency before authorising remote control trench roller operation, documenting training completion, practical assessment, and ongoing supervision until competency is demonstrated. Many organisations implement internal competency standards requiring operators to complete theory training covering machine specifications, control systems, failsafe functions, and hazard recognition, followed by practical assessment demonstrating correct control technique, positioning discipline, and emergency response. Additionally, operators must complete site-specific induction addressing the particular trench configuration, support systems, coordination protocols, and communication methods for the project. If operators may need to enter trenches for machine maintenance or repositioning, they require confined space entry training including atmospheric hazard recognition, entry permit procedures, use of gas detection equipment, and emergency extraction methods. Maintain training records demonstrating competency verification, and conduct refresher training annually or when incidents reveal gaps in knowledge or procedural compliance.

How do I know if radio frequency interference will affect remote control operation on my site?

Identifying radio frequency interference risks requires assessment of the site environment for sources that may disrupt remote control communication. Common interference sources include high-power site radios or PA systems, power tool battery charging stations operating in bulk, mobile phone towers within 100 metres, electrical switchrooms or transformers, welding equipment creating electromagnetic interference, and even other remote control equipment operating on similar frequencies. Conduct initial testing by operating the remote control trench roller in various site locations while monitoring for sluggish response, intermittent control, or unexpected loss of signal. Test near identified interference sources to determine whether clearance distances resolve issues. Modern remote control systems using frequency-hopping spread spectrum (FHSS) technology are more resistant to interference than older fixed-frequency systems—verify your equipment specifications and consider upgrading older equipment if interference problems are severe. If interference is identified, implement management strategies including relocating site radios or charging equipment away from trench work areas, establishing minimum clearance distances from interference sources (typically 20-30 metres), scheduling compaction work during times when interference sources can be temporarily shut down, or selecting different work areas where interference is minimal. Document interference issues in plant logs noting the conditions under which problems occurred to identify patterns. Some equipment suppliers provide technical support analysing interference problems and recommending frequency changes or equipment modifications. Never continue operations if control response becomes unreliable regardless of production impacts—the safety risks of losing control in confined trenches outweigh project delays.

What should I do if the trench roller becomes stuck or tips over during operation?

If the remote control trench roller becomes stuck in soft material, encounters obstacles, or tips onto its side during operation, stop all machine operation immediately using the remote control. Do not attempt to drive the machine out of stuck conditions by forcing controls or increasing power—this typically worsens the situation and can cause mechanical damage. Assess the situation from your position at ground level. If the machine is simply bogged in soft material but remains upright, you may attempt gentle control inputs to see if it will drive clear. If this is unsuccessful after 2-3 attempts, implement recovery procedures. Recovery typically requires an excavator to reach into the trench and either pull the roller clear using chains or provide support allowing it to drive to firmer ground. If the machine has tipped onto its side—which can occur if drums drop into voids or if compacting on excessive slopes—the machine must be mechanically righted before it can operate. This requires excavator lifting using proper rigging attached to structural lifting points. Before entering the trench to attach recovery rigging, implement confined space entry protocols if depth exceeds 1.5 metres, including atmospheric testing, entry permits, harness systems, and standby personnel. Never allow solo entry for recovery operations. Once rigging is attached and personnel have exited, the excavator slowly lifts or pulls the machine to restore normal position or extract it from the trench. Inspect the machine thoroughly before returning to operation—tipping or stuck situations can damage hydraulic hoses, bend frames, or affect drum alignment. Test all functions via remote control before resuming compaction work. Document stuck or tipping incidents in plant logs identifying the cause—common causes include insufficient material compaction before placing the roller, voids or soft spots in fill, excessive slopes, or material buildup on drums affecting stability.

How close to underground services can I operate remote control trench rollers safely?

Operating remote control trench rollers near underground services requires careful coordination with service location procedures and implementation of additional controls beyond those for general compaction. Before any trench work commences, services must be located using dial-before-you-dig services, electromagnetic detection, and ground-penetrating radar. Service locations should be clearly marked on the ground and in trenches. When compacting material near identified services, reduce compaction intensity by disabling high vibration settings or making fewer passes to minimise vibration transmission to services. Maintain minimum clearances from exposed services—typically 300mm horizontal clearance from the edge of underground pipes, cables, or conduits. When bedding or backfilling directly over services, use hand-operated compaction equipment initially until a protective layer of at least 300mm compacted material covers the service, then remote control rollers can operate above this protective layer. For critical services including high-pressure gas mains, high-voltage electrical cables, or major water mains, follow utility authority requirements which often specify hand compaction only within defined clearance zones. Coordinate with service installation crews who can advise when adequate protection exists for machine compaction to commence. If services are struck or suspected struck during compaction—indicated by unusual resistance, sudden settlement, or visible damage—stop all work immediately, evacuate the area, and notify the service authority. Gas leaks from struck gas mains can create explosion risks. Struck electrical cables can energise surrounding soil creating electrocution hazards. Implement emergency response protocols including area isolation, emergency service notification, and prohibition on resuming work until services are inspected, repaired, and clearance granted. Document all service location information in your daily SWMS briefing and mark service locations with highly visible markers in trenches where operators can see them during compaction work.

What atmospheric hazards should I be aware of when working around trenches even though I'm operating remotely?

Even though remote operation eliminates routine operator presence in trenches, atmospheric hazards remain a significant concern for any personnel who must enter trenches for machine repositioning, maintenance, or emergency situations. Trenches deeper than 1.5 metres can develop dangerous atmospheres due to oxygen displacement by heavier gases, accumulation of toxic gases from underground sources, or generation of hazardous atmospheres from decomposing organic materials. Oxygen deficiency occurs when heavier gases including carbon dioxide displace breathable air—this can happen in trenches passing through areas with underground organic deposits, near landfills, or where underground CO2 sources exist. Oxygen levels below 19.5% cause disorientation and rapid unconsciousness, and cannot be reliably detected without gas monitoring equipment. Toxic gases including hydrogen sulphide (rotten egg smell at low concentrations, no odour at dangerous levels), carbon monoxide (odourless, colourless, deadly), and methane (explosive in confined spaces) can accumulate in trenches particularly overnight or during extended periods without air movement. Trenches in urban areas may encounter sewer gases from damaged or old sewerage infrastructure. Before any entry to trenches deeper than 1.5 metres, conduct atmospheric testing using calibrated 4-gas monitors testing for oxygen percentage, carbon monoxide, hydrogen sulphide, and explosive atmospheres (lower explosive limit). Test at trench bottom where gases accumulate. If testing reveals unsafe atmospheres, implement forced ventilation using blowers to exchange trench air with fresh air, then re-test before permitting entry. Provide continuous monitoring to personnel who enter trenches using personal gas monitors with alarms. Develop emergency rescue procedures for unconscious personnel in trenches including mechanical extraction using harnesses and retrieval systems—never allow untrained personnel to enter trenches attempting rescue as this creates secondary victims. Even when atmospheric testing shows safe conditions initially, atmospheres can change rapidly if groundwater inflow begins or if wind stops providing natural ventilation, so maintain monitoring throughout entry periods.

How should weather conditions affect the decision to operate remote control trench rollers?

Weather conditions significantly impact the safety of remote control trench roller operations particularly regarding trench stability, visibility, and control system performance. Rain affects trench stability by saturating soils reducing cohesion and increasing collapse risk—light rain may not significantly impact shallow trenches in stable soils, but moderate to heavy rain in trenches exceeding 1.5 metres depth typically requires work suspension until conditions stabilise and engineering assessment confirms safety. Standing water in trench bottoms affects compaction effectiveness and can obscure obstacles or voids, and should be pumped out before compaction commences. Wet conditions increase the risk of operators slipping and falling, particularly near trench edges where ground becomes slippery. Rain affects remote control unit performance if water enters control buttons or electrical components—use weather-resistant control units or provide weather protection for standard units in wet conditions. Strong winds affect operator stability particularly when positioned near trench edges, and can blow dust obscuring visibility. Dust generation during dry, windy conditions reduces visibility of machines in trenches and can obscure trench edge positions creating fall hazards. Extreme heat affects equipment performance including hydraulic systems and batteries, and increases operator fatigue and dehydration affecting concentration. Cold conditions affect battery performance reducing operating duration between charges. Lightning during thunderstorms creates electrocution risks particularly in open areas—suspend all outdoor work when lightning is observed or thunder heard, as remote control operators are often the highest point in flat terrain. Fog significantly reduces visibility making it difficult to see machines in trenches and dangerous for positioning near edges. Establish weather monitoring protocols including checking Bureau of Meteorology forecasts before starting work, suspending operations when conditions deteriorate beyond safe thresholds, and implementing enhanced controls such as additional edge barriers or spotter assignments during marginal conditions. Document weather-related work suspensions demonstrating due diligence in managing environmental hazards. Remember that production pressure must never override weather-related safety decisions—trenches that collapse or operators who fall create far greater project impacts than weather delays.

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Remote Control Trench Roller Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Loss of Radio Control and Runaway Machine Scenarios

Operator Falls into Trenches While Operating Remote Control

Confined Space Hazards During Machine Repositioning or Maintenance

Vibration Transmission Through Ground to Operators

Trench Edge Collapse Near Operating Equipment

Coordination Failures with Excavator Operators Placing Fill

Manual Handling During Machine Transport and Positioning

Control measures

Dead-Man Switch and Failsafe Control Systems

Operator Positioning Protocols and Edge Setback Requirements

Radio Control System Testing and Interference Management

Confined Space Entry Procedures for Machine Maintenance

Coordination Protocols with Excavator Operators

Mechanical Lifting for All Machine Transport and Positioning

Personal Protective Equipment for Remote Control Operations

Personal protective equipment

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Pre-Operational Remote Control System Testing

Trench Assessment and Operator Positioning Zone Establishment

Machine Placement into Trench Using Mechanical Lifting

Compaction Operations and Operator Positioning Discipline

Response to Control System Anomalies or Failures

Machine Extraction and Post-Operation Inspection

Frequently asked questions

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