Tyre Changing Heavy Vehicles Safe Work Method Statement

Workers performing heavy vehicle tyre changing require comprehensive training covering both general tyre changing procedures and specific high-risk aspects of multi-piece rim work. Training should include identification of rim types and configurations, understanding of multi-piece rim hazards including consequences of rim component failures, complete deflation verification procedures, rim component inspection and damage recognition, locking ring installation and verification techniques, mandatory safety cage use during inflation, proper use of tyre changing equipment including rim spreaders and bead seating equipment, vehicle jacking and fall prevention procedures, and wheel handling using mechanical aids. For workers dealing with split rim configurations, specific detailed training in locking ring types, component compatibility verification, manufacturer specifications for various rim designs, and assembly/disassembly sequences is essential. Training must be hands-on practical instruction under supervision, not just theoretical classroom content. Competency should be assessed through both written tests covering hazard understanding and practical demonstrations of procedures including deflation verification, rim disassembly, component inspection, reassembly, and safe inflation practices. Refresher training should be provided annually to reinforce critical safety messages and address any new rim types or equipment introduced. Documentation of training including dates, content covered, competency assessment results, and trainer qualifications should be maintained, providing evidence of due diligence and supporting incident investigation if required.

Multi-piece rims can be identified by examining rim construction and locating manufacturer markings on rim components. Key indicators include: visible locking rings which are thick metal rings that fit into grooves on rim edge and can be pried out with tools, side rings or split rings that are separate components between rim base and locking ring, rims that visibly separate into multiple pieces, and markings on rim components including manufacturer name, rim size designation, and component part numbers. Common multi-piece rim types include: DC (Demountable Contoured) rims with locking ring retaining a removable flange, BD (Base and Disc) rims where the rim and wheel disc are separate bolted components, and various divided rim configurations. Single-piece tubeless rims similar to passenger vehicle wheels but larger are relatively safe and do not have removable locking rings or separate rim components. If uncertain about rim type, treat the wheel as multi-piece and apply full safety procedures including mandatory safety cage use. Reference materials including rim identification guides with photographs of various rim types, manufacturer specification sheets, and wall posters showing common dangerous rim configurations should be available in tyre service facilities. When encountering unfamiliar rim types, photograph the rim and components, note all visible markings, and consult supervisors or rim specialists rather than proceeding with uncertain identification. The consequences of misidentifying a multi-piece rim as single-piece and inflating without safety cage protection are too severe to accept uncertainty.

Any rim components found to be damaged, worn, or incompatible must be replaced before rim reassembly and inflation proceed. Specific actions include: if cracks are found in locking rings, rim bases, or other components, immediately replace the cracked component with new parts from compatible matched sets - cracked components must never be welded or repaired, only replaced. If severe corrosion is found particularly in locking ring grooves, if corrosion has created pitting or dimensional changes, replace affected components. If locking rings or other components show significant wear including worn locking ring lands, rounded edges, or dimensional changes from original specifications, replace with new components. If components from different manufacturers or specifications are mixed, source compatible matched component sets rather than proceeding with incompatible parts. Document component replacement decisions in service records including description of damage, components replaced, and new component specifications. If replacement components are not immediately available, quarantine the wheel and rim components preventing attempted assembly with damaged or incompatible parts. Contact component suppliers or rim specialists to source correct replacement parts with verification of compatibility. The conservative principle should be: when uncertain about component serviceability or compatibility, replace rather than reuse. The cost of new locking rings and rim components is trivial compared to the consequences of rim component failure during inflation. Never proceed with assembly using components that show cracks, severe wear, distortion, or uncertain compatibility, as the risk of catastrophic failure during inflation is unacceptable.

Safety cage operation requires systematic procedures ensuring wheels are properly contained and all personnel are protected throughout inflation. Procedures include: before placing wheel in cage, verify locking ring installation is correct by visual inspection around complete circumference and gentle prying to confirm secure engagement in groove. Position wheel assembly in cage ensuring it is stable and will not shift during inflation, using cage restraints or positioning devices if provided. Connect air supply to valve stem using remote inflation equipment if available, or position manual air chuck accessible from outside cage. Close and secure safety cage door, verifying latch is fully engaged. All personnel must position themselves outside the cage structure, not just outside the door opening, as rim components can project through cage openings if failures occur. Personnel should stand to the side of cage, never directly in front of or behind cage where maximum projection risk exists. Use remote inflation controls to commence inflation, or if manual controls are required, operate from outside cage reaching in only briefly to activate controls then immediately withdrawing to protected position. Monitor pressure gauge during inflation, watching for proper bead seating which typically occurs at 40-50 psi for heavy vehicle tyres. Listen for unusual sounds including air leaks, rim component movement, or other anomalies requiring immediate halt of inflation. Continue inflation to specified service pressure using incremental pressure increases, monitoring throughout process. After reaching service pressure, maintain remote position while allowing tyre to stabilise for 5-10 minutes, as some failures occur during initial stabilisation period. Only after pressure has stabilised and no anomalies are observed should cage be opened and wheel removed. These procedures apply to ALL heavy vehicle tyre inflation regardless of rim type, operator experience, or time constraints.

Roadside mobile tyre service presents unique challenges requiring enhanced safety procedures beyond workshop-based service. Before departing for service calls, verify service vehicle is equipped with all necessary tools, spare components, safety equipment including warning signs and high-visibility clothing, and wheel handling equipment suitable for roadside use. Upon arrival at breakdown location, assess site before exiting vehicle, observing traffic volume and speed, sight distance, road geometry, and weather conditions. Determine appropriate traffic management level based on risk assessment, implementing warning signs positioned at appropriate distances upstream, activating all vehicle warning lights, and wearing high-visibility clothing. For high-risk locations including highways, roads above 80 km/h speed limit, or restricted sight distances, engage qualified traffic controllers or request police traffic management rather than accepting inadequate protection. Position service vehicle to provide maximum protection for workers, generally between workers and approaching traffic where possible, though never position vehicles in ways that create greater traffic hazards. Assess ground stability before jacking vehicles, using boards or pads under jacks if ground is soft, and implementing conservative jacking practices given less controlled environment. For inflation, because permanent safety cages are impractical for mobile service, implement alternative controls: ensure all rim components are verified compatible and correctly installed, conduct initial low-pressure inflation (40-50 psi) to seat beads with all personnel maintaining minimum 10-metre distance from tyre with barriers preventing inadvertent approach, after beads are seated and initial inflation shows no anomalies complete inflation to service pressure maintaining safe distances, use extended air hoses allowing inflation from maximum distance, position portable barriers or vehicle components between workers and tyre during inflation. Document roadside service operations including traffic management measures implemented, ground conditions, inflation procedures followed, and any safety concerns encountered. For severe weather, night operations, or locations where adequate traffic management cannot be implemented, consider whether alternative responses including vehicle recovery to workshop facilities are safer than roadside service. Authorise workers to decline unsafe service without penalty, prioritising worker safety over service delivery.

If rim component failure or separation occurs during inflation, immediate actions include: if operating safety cage, maintain remote position and do not approach cage until situation has stabilised and pressure has dissipated. If failure occurs during roadside or non-caged inflation (which should never happen if procedures are followed), all personnel should immediately take cover behind substantial barriers including vehicles or structures, protecting against rim component projectiles. Once initial event has stabilised, assess casualties requiring immediate first aid or emergency services, calling 000 if serious injuries have occurred. Isolate the incident area preventing unauthorised approach until hazard assessment is complete, as damaged rim components may still be under pressure or structurally unstable. Assess tyre and rim condition from safe distance, determining whether additional failures are possible. Do not approach or attempt to move damaged rim components until confirmed they are not under pressure. If injuries have occurred, activate emergency response procedures including first aid by qualified personnel, emergency services notification, and notification of management and work health and safety personnel. Photograph incident scene from multiple angles before disturbing evidence, documenting rim component positions, damage patterns, and any identifying markings on components. Quarantine all rim components involved in failure for investigation, maintaining them in damaged condition without cleaning or repair attempts. Notify work health and safety regulators as required for serious incidents including fatalities, serious injuries requiring hospitalisation, or dangerous incidents. Conduct comprehensive incident investigation including review of procedures followed, component compatibility verification, assessment of whether inflation was conducted in safety cage, examination of damaged components for manufacturing defects or misassembly, and identification of systemic improvements to prevent recurrence. Provide support to affected workers including post-incident debriefing, access to counselling services if traumatic exposure occurred, and participation in investigation process. These procedures should be included in training and reinforced through regular safety discussions, as personnel need to understand emergency responses before incidents occur to enable effective response under stress.