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Tyre Changing- Truck and Bus Risk Assessment

Tyre Changing- Truck and Bus Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
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  • • Includes 2 Years of Free Compliance Updates

Tyre Changing- Truck and Bus Risk Assessment

Product Overview

Identify and control organisational risks associated with Tyre Changing – Truck and Bus through a structured, management-level Risk Assessment that focuses on systems, planning and governance rather than task-by-task instructions. This document supports executive Due Diligence, strengthens WHS Risk Management processes, and helps demonstrate compliance with the WHS Act while reducing operational and legal liability exposure.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, WHS Duties and Consultation: Assessment of officer due diligence, PCBU responsibilities, consultation with workers and HSRs, and integration of tyre-related risks into the broader WHS management system.
  • Procurement of Vehicles, Wheels, Tyres and Equipment: Management of specification, selection and purchasing controls to ensure trucks, buses, rims, tyres, jacks and lifting equipment are fit-for-purpose and compliant with relevant standards.
  • Contractor Management and Outsourced Tyre Services: Evaluation of contractor selection, prequalification, competency verification, and monitoring of third-party tyre service providers and mobile repairers.
  • Competency, Licensing and Training Systems: Assessment of licence requirements, competency frameworks, induction and refresher training for drivers, mechanics and tyre technicians involved in tyre changing activities.
  • Procedures, Safe Systems of Work and Documentation: Development and control of policies, documented procedures, permits and work instructions that govern tyre changing for heavy vehicles in depots, workshops and roadside environments.
  • Plant, Tools, Maintenance and Calibration Systems: Management of inspection, maintenance and calibration programs for jacks, rattle guns, torque wrenches, inflation cages, compressors and associated plant.
  • Workplace Design, Traffic Management and Work Environment: Evaluation of depot layout, workshop design, segregation of pedestrians and vehicles, lighting, ground conditions and environmental factors affecting tyre work.
  • Fleet and Tyre Management Programs: Implementation of tyre selection, rotation, pressure monitoring, inspection schedules and defect reporting to minimise blowouts, failures and unplanned roadside interventions.
  • Roadside and Remote Work Management: Protocols for managing breakdowns, remote and after-hours tyre changes, including communication systems, lone worker controls and coordination with tow and recovery services.
  • Fatigue, Work Scheduling and Supervision: Assessment of shift patterns, call-out arrangements, supervision levels and workload to control fatigue and decision-making risks during tyre changing operations.
  • Personal Protective Equipment and Emergency Preparedness: Management of PPE selection, provision and use, along with first aid, emergency response planning, fire safety and rescue considerations for tyre-related incidents.
  • Incident Reporting, Investigation and Continuous Improvement: Systems for capturing tyre-related near misses and incidents, conducting root cause analysis, implementing corrective actions and reviewing risk controls over time.

Who is this for?

This Risk Assessment is designed for Business Owners, Fleet Managers, Workshop Managers and Safety Professionals responsible for planning, overseeing and auditing tyre changing activities for trucks and buses across depots, workshops and roadside operations.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Consultation
  • • Lack of clear allocation of WHS duties for tyre changing on heavy vehicles under WHS Act 2011 leading to unmanaged critical risks
  • • Board and senior management not receiving adequate information about tyre-related risks, incidents and compliance gaps
  • • Inadequate consultation with workers, health and safety representatives (HSRs) and contractors undertaking truck and bus tyre work
  • • Absence of formal WHS objectives, targets and KPIs specific to heavy vehicle tyre management and roadside work
  • • Poor integration of tyre-related risks into the organisation’s overall WHS risk register and critical risk program
2. Procurement of Vehicles, Wheels, Tyres and Equipment
  • • Purchasing trucks, buses, rims and tyres that are incompatible, not fit for purpose, or not compliant with Australian Standards and OEM specifications
  • • Procurement of inferior or non-compliant jacks, stands, torque tools, bead breakers or inflation systems without safety features
  • • Lack of specification for safety-critical features (e.g. safety cages or restraints for inflation, mechanical lifting aids, wheel nut indicators) in purchase contracts
  • • No lifecycle consideration for inspection, maintenance, calibration and replacement of tyre-related tools and equipment
  • • Inadequate assessment of supplier competence and quality control for retreaded tyres, refurbished rims and specialised wheel components
3. Contractor Management and Outsourced Tyre Services
  • • Reliance on external tyre service providers without verifying their competence, WHS systems or compliance with organisational standards
  • • No clear agreement on responsibilities for risk assessment, safe systems of work, equipment maintenance and incident reporting for tyre changing work
  • • Inconsistent practices between contractors leading to variable safety standards, particularly for roadside or after-hours heavy vehicle tyre tasks
  • • Inadequate monitoring of contractor performance, including near misses, enforcement actions and non-conformances
  • • Contractor workers not inducted into site-specific risks, traffic management rules or emergency procedures for depots, bus yards and workshops
4. Competency, Licensing and Training Systems
  • • Workers performing heavy vehicle tyre changing without formal competency-based training or verification of skills
  • • Inconsistent understanding of critical risks such as split rim explosions, wheel separation, crush hazards and stored energy in tyres
  • • No structured refresher training or re-assessment following incidents, equipment changes or regulatory updates
  • • Supervisors unable to effectively verify competence or coach workers due to limited technical knowledge of heavy vehicle tyre risks
  • • Inadequate literacy, language or numeracy support leading to poor understanding of procedures, torque values and pressure specifications
5. Procedures, Safe Systems of Work and Documentation
  • • Absence of documented procedures for heavy vehicle tyre changing, inspection, rotation and roadside repairs
  • • Procedures not reflecting current equipment, OEM recommendations or regulatory requirements, leading to outdated or unsafe methods
  • • Procedures too generic, not clearly distinguishing between light vehicle and heavy vehicle, or between single-piece and multi-piece rims
  • • Lack of standardised documentation for pre-job risk assessment, permits, and authorisation for high-risk tyre tasks (e.g. split rims, roadside emergencies)
  • • Poor accessibility to procedures for workers in the field, especially during after-hours or remote roadside operations
6. Plant, Tools, Maintenance and Calibration Systems
  • • Tyre fitting and lifting equipment not inspected, maintained or calibrated in line with manufacturer requirements and standards
  • • Use of damaged or unsuitable jacks, stands, rattle guns, torque wrenches, bead breakers or inflation lines increasing risk of sudden failure or incorrect wheel assembly
  • • No formal system to remove defective equipment from service, leading to continued use of unsafe plant
  • • Calibration of torque tools not scheduled or recorded, causing under- or over-tightening and potential wheel loss
  • • Inadequate availability of mechanical aids and tyre handling equipment resulting in manual handling of heavy truck and bus tyres
7. Workplace Design, Traffic Management and Work Environment
  • • Inadequate workshop layout leading to interaction between moving vehicles, forklifts, pedestrians and tyre work areas
  • • Tyre changing carried out in poorly lit, uneven or cluttered areas increasing risk of slips, trips, falls and poor positioning of jacks and stands
  • • Insufficient separation between live traffic and tyre work zones in depots, bus yards and loading areas
  • • Lack of designated safe locations for roadside tyre changes resulting in ad-hoc, high-risk setups on road shoulders or narrow verges
  • • Poor environmental conditions (heat, cold, rain, noise, dust) affecting concentration, stability of equipment and safe communication
8. Fleet and Tyre Management Programs
  • • No systematic program for inspection, rotation, replacement and pressure management of heavy vehicle tyres leading to in-service failures
  • • Inconsistent recording of tyre history, including repairs, retreads and rim changes, making trend analysis and early intervention difficult
  • • Failure to identify recurring defects or patterns (e.g. specific axle positions, routes or loads) that contribute to tyre damage and sudden failures
  • • Running tyres beyond recommended age, tread depth or damage limits due to cost or scheduling pressures
  • • Ineffective communication between drivers, maintenance teams and tyre service providers regarding tyre condition and defects
9. Roadside and Remote Work Management
  • • Exposure of workers to live traffic when conducting roadside truck and bus tyre changes, particularly on high-speed or high-volume roads
  • • Inadequate pre-job assessment leading to tyre work proceeding in unsafe locations or conditions (e.g. poor visibility, narrow shoulders, severe weather)
  • • Lack of standardised controls for vehicle positioning, traffic warning devices and communication with road authorities or tow services
  • • Workers operating alone in remote or isolated locations without effective communication or emergency support
  • • Pressure to return vehicles to service quickly, leading to rushed assessments and incomplete wheel security checks
10. Fatigue, Work Scheduling and Supervision
  • • Tyre changing on heavy vehicles being performed at the end of long shifts, overnight or during irregular hours, increasing fatigue-related errors
  • • Inadequate supervision during high-risk tasks such as split rim work, roadside changes and work on large multi-axle vehicles
  • • Tyre work being squeezed between operational deadlines (e.g. scheduled bus runs, freight delivery times) leading to rushed or incomplete tasks
  • • Lack of coordination between dispatch, maintenance and tyre service providers regarding realistic timeframes for safe tyre work
  • • Supervisors not present or not competent to intervene during critical stages of heavy vehicle tyre work
11. Personal Protective Equipment and Emergency Preparedness
  • • Inconsistent provision, selection and use of PPE for heavy vehicle tyre work (e.g. eye, hand, hearing and foot protection)
  • • Workers unaware of how to respond to tyre explosions, rim failures, jack collapse or traffic incidents during tyre changing
  • • No specific emergency response planning for incidents involving trucks and buses during tyre work in depots or roadside locations
  • • Insufficient first aid equipment and training for likely tyre-related injuries (e.g. crush, amputation, eye injury, high-pressure injection)
  • • Lack of coordination with emergency services and road authorities for incidents occurring during roadside tyre operations
12. Incident Reporting, Investigation and Continuous Improvement
  • • Under-reporting of tyre-related incidents, near misses and equipment failures due to normalisation of risk or fear of blame
  • • Inadequate investigation of wheel-off incidents, tyre explosions, roadside near misses and equipment failures preventing learning and improvement
  • • Lack of data analysis to identify systemic causes such as training gaps, maintenance issues or scheduling pressures
  • • Corrective actions not tracked or verified, allowing repeat incidents and persistent non-conformances
  • • Workers not informed of investigation outcomes and lessons learned, leading to low engagement and repeated unsafe practices

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Model Code of Practice – How to Manage Work Health and Safety Risks: Guidance on systematic risk management processes.
  • Model Code of Practice – Managing Risks of Plant in the Workplace: Requirements for the safe use, maintenance and inspection of plant and equipment.
  • Model Code of Practice – Traffic Management in Workplaces: Guidance on separating vehicles and pedestrians and managing vehicle movements.
  • Model Code of Practice – Managing the Work Environment and Facilities: Requirements for safe workplaces, including workshops and depots.
  • Model Code of Practice – Managing Fatigue in the Workplace: Guidance on controlling fatigue risks for drivers and maintenance personnel.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS 2550 series: Cranes, hoists and winches – Safe use (referenced for lifting and jacking practices where applicable).
  • AS 4801 / ISO 45001: Occupational health and safety management systems – Requirements for systematic WHS governance and continuous improvement.
  • Relevant State and Territory Heavy Vehicle and Road Transport Regulations: For integration of tyre and vehicle safety requirements into fleet operations.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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