Tilt Tray Safe Work Method Statement

The most critical hazard in tilt tray operations occurs when loads become unstable during tray tilting, particularly when raising a loaded tray from ground level to horizontal transport position. Vehicles or equipment positioned on the tilted tray can roll backward if brakes are not properly set, if the load's centre of gravity shifts during tilting, or if securing chains are not attached before tray raising commences. The Newcastle incident where a prime mover rolled off a tilt tray and crushed the operator occurred during this critical phase of operation. The risk is heightened with wheeled loads that can roll freely, loads with high centres of gravity that become unstable as the tray angle changes, and operations on sloped or uneven ground where vehicle positioning affects tray tilt angles. Operators positioned at the rear control station are particularly vulnerable to being crushed between rolling loads and the tray or struck by loads falling from the tray. The transition period when the tray is neither fully lowered nor fully raised represents the highest risk phase as loads are angled and may shift unpredictably. Additional risk factors include wet or oily tray surfaces reducing friction, loads with deflated tyres or damaged suspension affecting stability, and operator error in sequencing of winching, securing, and tray raising operations.

Consequence: Crushing fatalities when operators are struck by rolling loads, severe injuries to ground personnel in the path of falling equipment, extensive damage to loads and tilt tray vehicles, and potential secondary incidents if loads strike bystanders or other vehicles.

Tilt tray hydraulic systems operate under high pressure to lift loaded trays weighing several tonnes. Hydraulic system failures including hose ruptures, cylinder seal failures, pressure relief valve malfunctions, or hydraulic fluid contamination can cause sudden uncontrolled tray movement. The most dangerous scenario occurs when a raised tray suddenly drops due to hydraulic pressure loss, potentially crushing operators or ground personnel positioned near the rear of the vehicle. Conversely, hydraulic system overpressure can cause rapid uncontrolled tray tilting, launching loads or causing the tray to strike overhead structures. Hydraulic systems deteriorate through normal wear, exposure to weather and road grime, vibration during transport, and inadequate maintenance. Pinhole leaks in high-pressure hoses can spray hydraulic fluid at pressures exceeding 3000 psi, causing serious injection injuries if fluid penetrates skin. Cold weather reduces hydraulic fluid viscosity affecting system performance, while overheating in hot conditions or during prolonged operation can cause thermal expansion and system overpressure. Operators may not recognise signs of impending hydraulic failure including slower than normal tray operation, unusual noises from hydraulic pumps or cylinders, or visible fluid leakage.

Consequence: Crushing injuries from unexpected tray movement, hydraulic injection injuries from high-pressure fluid spray, burns from hot hydraulic fluid contact, and equipment damage requiring costly repairs and operational downtime.

Tilt tray operations frequently occur on uneven construction sites, sloped roadside breakdown locations, or soft ground conditions where vehicle stability is compromised. When the tray is tilted with a load, the centre of gravity shifts dramatically rearward, creating substantial overturning forces. On sloped ground, this shift can exceed the vehicle's stability limit causing rollover, particularly with heavy loads positioned far back on the tray. Uneven ground causes differential settlement where one side of the vehicle sinks more than the other, creating lateral instability and potential sideways rollover. Soft ground conditions including recently disturbed earth on construction sites, saturated ground after rainfall, or road shoulders with inadequate compaction allow vehicle wheels or stabiliser legs to sink during loading operations. The dynamic forces generated as trays tilt and loads shift amplify stability problems, with sudden weight transfers potentially causing wheels to lift or stabilisers to fail. Operators may not adequately assess ground conditions before commencing operations, particularly under time pressure during roadside recoveries or urgent equipment relocations. Wind loading on large loads positioned on raised trays further compromises stability in exposed locations.

Consequence: Vehicle rollover causing crushing injuries or fatalities to operators and ground personnel, damage to tilt tray vehicles and loads, and potential environmental damage if hydraulic fluid or fuel is spilled from overturned vehicles.

Tilt tray operations on public roadways expose operators and ground personnel to substantial traffic risks as they work in active traffic environments during vehicle recovery operations. Loading a disabled vehicle onto a tilt tray requires the tilt tray truck to occupy a full traffic lane or road shoulder, with personnel working at the rear of the vehicle exposed to passing traffic. Despite traffic control measures, inattentive or speeding drivers may fail to recognise hazard warning signs and vehicle warning lights, striking workers or equipment. The concentration required for precision tray operation and load positioning distracts operators from monitoring approaching traffic. Night-time recovery operations present heightened risks due to reduced visibility despite vehicle warning lights and reflective clothing. Road geometry including curves, crests, and limited sight distances reduces the distance available for approaching drivers to recognise and respond to the work zone. High-speed roads and highways present extreme risk as vehicle approach speeds exceed 100 km/h in some cases. Adverse weather including rain, fog, or glare conditions further reduce visibility and driver reaction times. The duration of tilt tray loading operations, often 15-30 minutes for complex recoveries, represents extended exposure to traffic hazards.

Consequence: Fatalities or severe injuries to operators and ground personnel struck by passing traffic, secondary collisions involving approaching vehicles striking the tilt tray truck or disabled vehicle, and traffic disruption with potential for multiple-vehicle pile-ups in hazardous conditions.

Inadequately secured loads can shift during transport causing vehicle instability, or can slide uncontrollably from the tray during unloading operations. Load restraint failures occur when restraint capacity is inadequate for load weight and transport conditions, when restraints are improperly attached to insufficient anchor points, when restraint equipment is worn or damaged reducing its rated capacity, or when loads shift due to sudden braking or manoeuvring. The Load Restraint Guide published by the National Transport Commission specifies that loads must be secured to withstand forces of 0.8g forward, 0.5g rearward and sideways, and 0.2g vertical, but operators may not understand how to translate these performance standards into practical restraint configurations. Vehicles being transported may have unlocked steering allowing front wheels to turn during transport, shifting the load laterally. Articulated equipment including excavators with moveable booms can shift if boom positions are not secured. During unloading, operators may release restraints prematurely before the tray is fully tilted, or may underestimate the speed at which loads will slide down the tilted tray. Wheeled loads can accelerate rapidly on the tilted surface, potentially running over ground personnel or colliding with structures. Brakes on transported vehicles may not hold during the sliding descent, particularly if hydraulic or air brake systems have bled down during transport.

Consequence: Loads shifting during transport causing vehicle rollover or striking other road users, loads sliding uncontrollably during unloading causing crushing injuries, restraint equipment failures under dynamic loading creating projectile hazards, and damage to transported equipment and property.

Tilt tray winches are used to pull disabled vehicles or equipment onto the tilted tray when they cannot be driven under their own power. Winch operations present hazards including cable overload when pulling loads exceeding winch capacity, cable failures due to worn or damaged cables with reduced breaking strength, sudden cable recoil when cables break under tension creating a high-energy projectile, and entanglement hazards when cables are positioned incorrectly or personnel are in the cable's line of force. Operators may exceed winch capacity when attempting to recover heavily laden vehicles, vehicles with seized brakes or damaged drivetrains creating high resistance, or equipment stuck in mud or uneven ground. Steel winch cables deteriorate through abrasion, kinking, fatigue from repeated loading cycles, and corrosion, with internal wire breaks not visible during casual inspection. Synthetic winch ropes are increasingly common and eliminate the recoil hazard of steel cables, but can fail through abrasion on sharp edges, UV degradation, chemical attack, or melting if allowed to slip on winch drums under load. Personnel positioning during winching operations is critical - standing in line with cable under tension creates extreme hazard if cable fails and recoils.

Consequence: Severe or fatal injuries from winch cable recoil striking personnel, entanglement injuries if personnel are caught in moving cables or cable fittings, equipment damage from uncontrolled load movement if winch fails, and project delays while alternative recovery methods are arranged.