Turf Laying Maxi Rolls Safe Work Method Statement

Maxi roll turf installation requires minimum three workers per active installation team - one machine operator for the forklift or telehandler, one leading ground worker to guide the front edge of unrolling turf, and one trailing worker to monitor alignment and coordinate with the operator. This team size is necessary because individual maxi rolls weigh 150-400kg making manual lifting impossible and unsafe. During unrolling, the leading worker must control dispensing speed by applying resistance to the roll edge preventing it from accelerating uncontrollably down slopes or across smooth ground. The trailing worker monitors the strip's trajectory watching for lateral drift off the intended straight line and communicates directional corrections to the operator using hand signals or radio. A single ground worker cannot simultaneously control roll speed and monitor alignment, creating loss of control risks where rolls veer into obstacles, installations gaps develop from poor alignment, or workers are struck by runaway rolls. The machine operator cannot see alignment from the equipment position due to the large roll obscuring sightlines and requires ground crew guidance for steering inputs. Some operations employ four-worker teams on larger projects adding a dedicated spotter to monitor for site hazards, coordinate with other work crews, and ensure exclusion zones remain clear. For installations on slopes or complex sites, additional workers provide redundancy if control difficulties arise. Attempting maxi roll installation with fewer than three workers compromises safety through inadequate control and should not proceed. Project scheduling must ensure adequate crew availability before accepting turf delivery as shortages cannot be remedied by reducing team sizes.

Newly installed maxi roll turf requires initial irrigation within 30-60 minutes of installation during warm weather conditions (temperatures exceeding 25°C). This critical establishment window prevents desiccation of exposed roots and ensures survival of transplanted grass plants. Turf harvested using mechanical equipment undergoes significant stress from root severance, soil disturbance, and exposure to air and sunlight. During transport and installation, the turf continues respiring and losing moisture through transpiration from leaf surfaces. Without prompt irrigation replacing this lost moisture and re-establishing root-to-soil contact, turf deteriorates rapidly showing yellowing, wilting, and ultimately death of grass plants within 24-48 hours. The consequences of delayed irrigation are severe and often irreversible. Turf experiencing moisture stress shows yellowing starting at leaf tips and margins within 6-12 hours of installation in hot conditions. If irrigation is delayed beyond 4-6 hours, significant portions may fail to establish requiring replacement. Establishment failures create costly remediation including removal of dead turf, soil reworking, and re-installation of replacement sections delaying project completion and eroding profit margins. Beyond establishment timeframes, newly installed turf requires daily irrigation for minimum 7-10 days maintaining consistent moisture in the root zone (top 50-100mm of soil) whilst roots penetrate into underlying soil. Irrigation frequency then gradually reduces as root establishment progresses. Site managers must coordinate irrigation capability before scheduling turf installation - delivery should not occur unless immediate watering capacity is confirmed through automated irrigation systems, manual hose watering, or water cart availability. For large installations, staged delivery matching installation capacity ensures no turf sits awaiting installation beyond safe timeframes.

Ground preparation is critical for successful maxi roll turf establishment and safe installation operations. The prepared surface must meet several specific standards before installation proceeds. Firstly, final grading must achieve specified levels and falls typically within ±10mm tolerance for sports fields or ±20mm for general landscape areas. Use laser levels or string line grids at 3-5 metre intervals verifying elevations match design specifications. Adequate falls (minimum 1:100 gradient) must be established preventing water ponding that causes turf deterioration. Secondly, soil compaction must provide stable base for mobile plant operations whilst maintaining sufficient friability for root penetration. Light rolling with smooth roller achieving 85-90% Standard Compaction provides this balance - excessive compaction inhibits root growth whilst inadequate compaction creates soft spots where forklift wheels penetrate causing ground failure. Third, surface texture must be fine and smooth through final raking or box blade work removing stones, clods, and debris exceeding 20mm size that would create surface irregularities through installed turf. Fourth, soil pH should be adjusted to species-appropriate range (typically 6.0-7.0 for most turf species) through lime or sulphur application incorporated during cultivation. Fifth, starter fertiliser should be incorporated providing essential nutrients for establishment particularly phosphorus promoting root development. Typical application rates are 50-100kg/hectare of complete NPK fertiliser with elevated phosphorus ratio. The prepared surface should be moist but not saturated - irrigation 24-48 hours before installation provides ideal moisture content. Excessively dry soil inhibits root penetration whilst saturated conditions create muddy surfaces damaging turf during handling and preventing mobile plant access. If preparation was completed more than 7 days before installation, surface cultivation may be required removing crusting or weed germination that occurred during delays. Finally, all underground services including irrigation pipes, electrical cables, and drainage lines must be installed, tested, and buried flush with final grade before turf installation preventing damage during laying operations.

If a maxi roll shows signs of slipping from the carpet pole during lifting or transport, immediate action is required to prevent uncontrolled load dropping causing injury or equipment damage. At first indication of movement (roll sliding laterally, rotating on pole, or listing to one side), immediately stop all machine movement freezing the current position. Do not attempt to reposition or adjust whilst load is moving as this typically accelerates failure. Alert ground workers using horn or verbal warning to evacuate immediate area - maintain minimum 5-metre clearance from unstable loads. If safe to do so without excessive load tipping, slowly lower load to ground using controlled hydraulic descent rather than allowing uncontrolled drop. Position load on flat, stable ground if available avoiding slopes or soft spots. If load stability is severely compromised preventing safe lowering, sound continuous horn warning and allow controlled drop to ground from minimum practical height - accept equipment and turf damage rather than risk injury attempting to save failing load. After load is grounded safely, investigate cause of slippage before attempting re-lift. Common causes include: inadequate pole insertion into roll core (minimum 1 metre insertion required), roll moisture creating slippery surface reducing friction, roll packaging damage allowing roll to compress or deform during lift, excessive forward tilt on carriage causing roll to slide forward off pole, or debris on carpet pole surface reducing friction. Rectify identified causes before re-attempting lift. For wet rolls showing persistent slippage, wrap hessian sacking or rope around pole contact area increasing friction. Verify carpet pole security in mounting brackets checking locking pins fully engaged. Adjust carriage tilt to slight backward angle preventing forward roll movement. Inspect turf roll for damage from initial slippage or drop - rolls showing significant deformation, packaging tears, or internal compression may be unsuitable for installation requiring replacement. Document incident including circumstances, corrective actions implemented, and any damage sustained for incident investigation and continuous improvement. Brief all operators on incident learnings preventing recurrence.

Safe edge trimming techniques during maxi roll turf installation require specific cutting practices preventing laceration injuries from sharp turf knives. The fundamental principle is always cut away from your body and other workers without exception. This means positioning the turf and your body such that knife movement occurs in a direction away from your legs, torso, and arms throughout the entire cutting stroke. For straight boundary edges, kneel or squat beside the turf with the edge to be trimmed positioned on the side away from your body. Place a straightedge (timber plank or metal rule) along the desired cutting line with the excess turf on the far side of the straightedge from your position. Position knife against straightedge and execute cutting stroke moving away from your body toward the excess turf. Never pull knife toward yourself even when this seems more convenient or natural. For curved edges around obstacles like trees or garden beds, position yourself on the inside of the curve (between obstacle and turf) with cutting direction moving away from your body toward the excess material. Make multiple short cuts following the curve rather than attempting long sweeping cuts that require awkward reaches or twisting postures compromising control. Use sharp blades allowing clean cutting without excessive force - dull blades requiring hard pressure are far more likely to slip or break through material unexpectedly. Retractable utility knives should have blades extended only the minimum necessary length (typically 15-20mm) to penetrate turf thickness reducing exposure if slip occurs. After each cut, immediately retract blade into handle preventing inadvertent contact when repositioning or setting knife down. Never leave knives with exposed blades on ground where workers kneeling or bending may contact them. Store knives in sheaths or belt-mounted holders when not actively cutting. Maintain minimum 2-metre separation between workers conducting trimming operations preventing accidental contact if slips or falls occur. For complex fitting around irregular obstacles, create cardboard templates matching required shapes, position templates on turf, and cut around template edge rather than attempting freehand fitting requiring multiple trial cuts increasing injury exposure. Always wear cut-resistant gloves on non-cutting hand when holding turf during trimming providing protection if knife slips or blade breaks through turf unexpectedly. Brief all workers on knife safety emphasising that speed is never worth injury risk - methodical, controlled cutting is always safer than rushed work.