Position of the vehicles following the incident. Image source – Department of Primary Industry and Regional Development NSW, 2024.
Introduction
Uncontrolled vehicle movement remains one of the most significant risks in mining, quarrying, and heavy industries. When vehicles or trailers roll unexpectedly, they pose serious dangers to workers, particularly during maintenance and inspection activities.
A recent workplace incident at Possum Brush Quarry serves as an important reminder of the potential consequences when vehicles are not fully secured. In this blog, we will explore best practices for immobilising vehicles, the importance of effective safety equipment, and how Wheel Chocks can help reduce the risk of rollaway incidents.
The Incident: A Reminder of Workplace Risks
On December 3, 2024, a worker at a quarry sustained serious injuries while performing maintenance on a truck trailer. The unintended movement of the trailer resulted in the worker becoming trapped, requiring emergency response efforts to free him.
Key Details of the Incident:
- The worker was addressing a locked brake on a truck trailer that had stopped on a sloped haul road.
- Despite Wheel Chocks being placed, the truck’s park brake was not engaged at the time of the repair.
- The truck and trailer rolled backward, making contact with another vehicle, and trapping the worker.
- Emergency responders used jacks and removed the wheels to safely release the worker.
This incident highlights the importance of ensuring vehicles are properly immobilised before conducting maintenance or inspections.
Key Safety Learnings
1. Always Secure Vehicles Before Maintenance
- Vehicles should be parked on level ground whenever possible.
- If parking on a slope is necessary, additional safety precautions such as Wheel Chocks and secondary braking systems should be used.
2. Ensure the Park Brake is Applied
- Before exiting any vehicle, the handbrake should be fully engaged.
- Operators should be trained on vehicle braking systems to understand how they function and potential risks.
3. Use Maxi Brakes and Wheel Chocks Together
- Maxi brakes provide a fail-safe mechanism in case of air pressure loss, ensuring the vehicle remains stationary.
- Wheel Chocks serve as an additional layer of protection, particularly on uneven terrain or during maintenance work.
4. Conduct a Risk Assessment Before Working Under Vehicles
- Before starting repairs or inspections, a full hazard assessment should be conducted.
- Where possible, relocate vehicles to level ground to reduce risks.
- Establish exclusion zones to ensure only authorised personnel are present.
How to Prevent Uncontrolled Vehicle Movement
For Drivers:
✔ Park on level ground whenever possible.
✔ Engage the handbrake fully before exiting the vehicle.
✔ Turn off the engine and remove the key to prevent accidental movement.
✔ Chock the wheels before conducting any maintenance or inspection work.
✔ Be trained on emergency braking systems and how to secure the vehicle.
For Equipment Owners & Operators:
✔ Install park brake warning systems to alert drivers if the brake is not engaged.
✔ Ensure competent workers undertake maintenance using suitable equipment such as Stacko™ Load Support Blocks, jacks, vehicle pits, or hydraulic hoists.
✔ Conduct regular vehicle inspections in accordance with manufacturer guidelines.
✔ Provide ongoing training to workers on how to correctly and safely immobilise vehicles.
Final Thoughts: Safety is a Shared Responsibility
Every workplace accident serves as a learning opportunity to reinforce the importance of risk management, proper training, and the use of effective safety solutions. Uncontrolled vehicle movement is a preventable hazard, and with the right protocols in place, workers can be protected from harm.
By using reliable safety equipment, following best practices, and ensuring workers are properly trained, we can significantly reduce risks and help every worker return home safely.
National Plastics are Australian pioneers in the research, design, and production of industry leading Wheel Chock technology for mining and quarrying operations.
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