Office of Industrial Relations

Workplace Health and Safety Queensland

Preventing workers falling from trucks

Campaign report
The transport industry has a high rate of injuries and fatalities resulting from workers falling off trucks and trailers.

The goal of this campaign is to reduce falls related incidents within the transport industry and its associated supply
chain.

This report provides information about the outcomes of the campaign and practical guidance to enable businesses to
better manage their own falls risks.

Key issues The campaign

According to the Work-related injuries and fatalities The campaign’s main objectives were to work with
involving a fall from height, Australia1 report: industry to find out what the problems were and
develop practical tools and case studies to address
• there were 12 fatalities in the transport industry these. It involved:
during the period 2008 to 2011
30 workshops held across Queensland in 2013.
• falls from trucks resulted in 3100 serious injury Targeted at transport operators and the supply chain,
claims from 2009 to 2011 the workshops aimed to:
• increase awareness about the risks of falls
• truck drivers accounted for approximately half of the • facilitate industry consultation to identify the factors
falls from trucks claims contributing to how and why falls occur.

• the average time away from work for truck drivers 145 workplace assessments in 2014.
after a fall was six weeks. The workplace assessments focused on:
• working on or getting in and out of the cab of a truck
• working on, walking and climbing on a trailer
• working around trucks at ground level on site.

Development of a simple facilitated falls risk

identification process.
The process was piloted by WHSQ at 12 workplaces
from mid-2014.

1
Safe Work Australia: http://www.safeworkaustralia.gov.au/sites/swa/
about/publications/pages/work-related-injuries-fatalities-involving-fall-
from-height-australia
 Assessment results

WHSQ inspectors observed...

poor design, high risk activities

and risk taking behaviours
...in more than 30% (one third) of the assessments.

The risk of falls from trailers was Of the high risks recorded, most
associated with: were associated with:

14.4% Poorly designed ladders or steps

13% Climbing at height onto the trailer to

secure loads
Climbing on the top of the trailer
10% where there are unprotected
openings 71% 16%
working on and working on and
8% Ladders or steps unsafely located on
the trailer
around trailers around cab of
the truck
Climbing at height up or between
8% ramps and crates on the trailer to
access loads

6.5% Climbing at height onto the trailer or

carrier to load or unload

6.5% Jumping down from the trailer

Using tyres as steps to climb onto the 11%

5% trailer/walking on trailers that have
become slippery with contaminants
activities at
ground level

The risk of falls from the cab The risk of falls at ground level
of the truck were noted in the were noted in the following
following areas: areas:
• No ‘three points of contact’ to the entry of the cabs. • Walking on surfaces around load areas and ramps
• Climbing at height to perform mechanical contaminated with water, diesel, mud or ice.
maintenance on the truck. • Walking on surfaces around load areas and ramps
• Climbing at height to clean the truck. that have ground hazards and/or signs of unsafe
levels of wear and tear.
• Using unsafe access steps around load areas and
ramps.

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 Campaign resources

The transport industry used the Risk identification and action plan
tool to develop the industry initiatives listed below. The tool shows Risk identification and
businesses how to conduct a low-level risk identification process on action plan tool
their trucks and trailers, and implement a solution in consultation with (pdf, 529KB)
workers.

Industry initiatives
Working on or getting in and out of the
Followmont
cab of the truck
Risk: Slippery footholds on trucks
Patrick Stevedoring Pty Ltd Solution: Non-slip material applied to footholds
Risk: Hidden handholds inside truck doors Followmont consulted with its drivers to identify that some
Solution: Coloured handholds of its older trucks had slippery footholds. Drivers provid-
ed feedback on how the trucks were being accessed and
Patrick Stevedoring identified that the internal handholds which footholds posed the highest risk. Followmont scoped
on some of their trucks were hard to see. Because drivers suitable non-slip materials for the footholds and presented a
could not see the internal handholds, they were sometimes proposal to management detailing the process, benefits and
using the inside of the door to climb up into the cab. The risk costs of trialling the non-slip material.
of falls was increased because the inside of the door is not
designed to support the weight of a driver or be used as a Followmont is undertaking a trial on some vehicles with a
point of contact. view to modifying other high risk trucks in its fleet as part of
its regular maintenance program.
Patrick mechanics identified the options using the Risk iden-
tification and action tool. They evaluated the identified risks Toll Group, Karawatha depot
and their options, and agreed to trial changing the colour of
the handholds on the highest risk trucks to yellow, using an Risk: Slippery handholds on the doors of prime movers
inexpensive and long lasting paint. Solution: Non-slip material applied to handholds

Patrick has since retro-fitted half its Brisbane fleet with this Toll Karawatha workers identified that some of the hand-
safety feature, as well as distinguishing the cabin access holds to help drivers climb in and out of their cabins on
handles on any new prime movers purchased. Patrick is also the prime movers had a tendency to become slippery from
making it safer for drivers to access their cabins at night. water, diesel and other substances.
Using the same process with the Risk identification and
action plan tool, workers suggested fitting spotlights on the After consulting with drivers and mechanics, Toll is trialling
driver’s side mirror to angle down on to the driver’s steps. applying non-slip materials to the handholds.

Blenners

Risk: Getting in and out of trucks safely

Solution: Training and improved safe work procedures

Blenners identified a need to improve processes and training

around entering and exiting trucks, as its drivers embark and
disembark their truck cabins up to 50 times a day.

Blenners’ drivers reviewed the company’s fleet and its safe

work procedure (SWP) was updated with current pictures of
its different trucks. Depot managers then delivered toolbox
talks using the revised SWP to retrain drivers in safely enter-
ing and exiting truck cabins.

The yellow handholds are much easier to see at night.

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Working, walking and climbing on a trailer Working around trucks at ground level

Arkwood Organic Recycling Australian Amalgamated Terminals (AAT)

Risk: Ladders, and the dangers of falling off a truck Risk: Different operators, freight and vehicles on one site
Solution: Improving existing ladders and installing safer Solution: Consultation across the supply chain resulting in
ladders truck stands and training

Arkwood Organic Recycling identified that some of its tipper AAT operate a multi-user terminal at the Port of Brisbane,
trailers had either unsafe ladders or no ladders at all. This with a number of different businesses, vehicles, trailers and
was a risk, as drivers frequently need to climb up on the load types coming into the terminal.
trailers to view or adjust the load.
AAT formed two consultative groups to consider how to
Consultation with Arkwood’s mechanics and drivers generat- address the risks of falls from steel transporters and roll-
ed a range of solutions which have since been implemented, on, roll-off (RORO) high and heavy machinery transporters.
including: Some of the known falls risks for these load types were iden-
• installing new, safely designed ladders on trailers tified and solutions created around best practice, including:
• adding hi-visibility non-slip material to the rungs of the • transport operators to provide a spotter or second person
existing ladders to make them easier to climb to assist drivers when loading machines 
• providing refresher training during toolbox talks for drivers • access stands to be used for accessing/egressing trucks,
and workshop staff on how to use ladders safely tarping and load restraint operations
• attaching ‘3 points of contact’ stickers next to the ladders • training to be provided to drivers by transport operators
and near the doors on the trucks as a reminder for drivers. on their access/egress requirements (e.g. using ramps
rather than jumping from trailers)
• having a designated fixed stand area within the terminal
• discharging RORO cargo to specific areas close to stands
• new site rules including no jumping or stepping off
trailers.

AAT has since implemented a number of additional control

measures. One of the more significant controls has been
introducing truck stands to assist drivers accessing and
working on trailers. AAT prepared instructions on how to use
these and delivered on-site training for operators.

AAT recently developed a short safety film including the use

of the truck stands, truck driver safe zones during operations
and traffic management. This film is part of AAT’s online
‘Three points of contact’ stickers will be placed on all induction package.
vehicles

Toll Group, Karawatha Depot

Risk: Lack of access at height onto the trailer

Solution: Introduce portable ladders

Staff in Toll’s North Queensland depot identified there was a

lack of safe access to restrain freight at height when trucks
were away from the depot.

Toll developed a process for drivers to report risks at exter-

nal sites, and for them to consult with other drivers about
what type of equipment might help to reduce the risks.
This process led to Toll identifying and purchasing portable
ladders to use at sites that did not have sufficient working
from height standards. Toll provided training in how to use The mobile stand helps prevents workers from having to
the new portable ladders. climb on the trailer

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 Byrne Brothers

Risk: Slippery sites

Solution: Improved work instructions and tool box talks

Bryne Brothers identified that drivers were climbing over the

bonnet to clean trucks and that they were jumping out of
cab, creating the risk of slipping and falling at ground level
due to waste material on and around the wash bays.

Bryne Brothers reviewed its truck and bowl specifications,

purchasing policy and wash bay waste removal process. It
identified that a safe access system should be installed and
that the wash bay stairs should be cleaned when the wash
bay is cleaned.

The company prepared instructions for washing the trucks,

how to operate the slump stand and the wash bay. Bryne
Brothers used toolbox talks to explain these new work
instructions.

Bryne Brothers is continuing to address falls risks and is now

investigating applying ‘three points of contact’ stickers to
the side of truck cabs.

Future actions

WHSQ will:
• distribute this report and tool to the transport industry and its supply chain
• facilitate truck, equipment and trailer manufacturers to further review the risk of falls when designing or modifying
their products, with a particular focus on the risks associated with trailers and poorly designed ladders and steps
• incorporate a focus on workers climbing at heights on the trailer to secure the load, as part of the Safe handling
when securing loads campaign in 2015–16
• expand engagement intervention over the next two years using the risk identification and action plan tool.

More information
For more information on work health and safety,
visit worksafe.qld.gov.au or call us on 1300 362 128.

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© The State of Queensland 2015

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