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Tyre Changing - Tractor and Off-Road Risk Assessment

Tyre Changing - Tractor and Off-Road Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
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  • • Includes 2 Years of Free Compliance Updates

Tyre Changing - Tractor and Off-Road Risk Assessment

Product Overview

Identify and control organisational risks associated with tyre changing on tractors and off-road plant using this management-level Tyre Changing - Tractor and Off-Road Risk Assessment focused on governance, planning and systems. Strengthen WHS risk management, demonstrate due diligence under the WHS Act, and reduce operational liability exposure across your agricultural and off-road operations.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, WHS Duties and Contractor Management: Assessment of officer due diligence, PCBU responsibilities, contractor selection, induction, and integration of tyre changing activities into your WHS management system.
  • Procurement of Plant, Tyres and Equipment: Management of specification, selection and purchasing of tractors, rims, tyres, jacks and inflation equipment to ensure compliance, compatibility and safe lifecycle performance.
  • Design and Layout of Workshop and Field Tyre Changing Areas: Evaluation of workshop layout, traffic flow, lighting, ground conditions and field set-up to minimise crush, vehicle movement and environmental risks.
  • Maintenance, Inspection and Asset Management of Plant and Tyres: Systems for scheduled inspections, defect reporting, tyre condition monitoring and maintenance records for tractors, attachments and associated equipment.
  • Risk Management, Procedures and Documentation: Establishment of formal risk assessments, safe operating procedures, permits, and record-keeping frameworks for all tractor and off-road tyre changing activities.
  • Competency, Training and Supervision: Requirements for competency-based training, verification of skills, supervision levels and refresher programs for employees and contractors involved in tyre work.
  • Plant Isolation, Energy Control and Stability Management: Protocols for immobilisation of plant, lockout/tagout, chocking, jacking stability, and control of stored energy in tyres and rims.
  • Manual Handling, Ergonomics and Use of Mechanical Aids: Assessment of lifting, pushing and positioning risks, and the selection and use of cranes, hoists, tyre handlers and other mechanical aids.
  • Remote, After-Hours and Field Tyre Changing Management: Controls for remote and roadside work, communication systems, journey management, lone work, and environmental exposure in off-road locations.
  • Emergency Preparedness, First Aid and Incident Response: Planning for crush injuries, tyre explosions, equipment failure and vehicle roll-away incidents, including first aid, rescue and escalation procedures.
  • Personal Protective Equipment (PPE) and Workplace Environment: Specification and management of PPE, noise, dust, heat, weather, and housekeeping controls in workshops and field locations.
  • Monitoring, Review and Continuous Improvement: Systems for audits, inspections, incident investigations, corrective actions and periodic review of tyre changing controls and performance.

Who is this for?

This Risk Assessment is designed for Business Owners, Farm Managers, Fleet Managers and Safety Officers responsible for planning, overseeing and auditing tractor and off-road tyre changing operations across workshops and field locations.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Contractor Management
  • • Lack of clear allocation of WHS duties under WHS Act 2011 for persons conducting a business or undertaking (PCBUs), officers, workers and contractors involved in tractor and off‑road tyre changing
  • • Inadequate due diligence by officers to ensure safe systems of work, resourcing, and verification for tyre changing activities
  • • No formal process to assess and manage WHS risks when engaging mobile tyre service providers or contractors
  • • Poor coordination of WHS responsibilities where multiple PCBUs share the workplace (farms, depots, workshops, roadside sites)
  • • Outdated or non‑existent WHS policies specific to high‑risk plant and tyre handling operations
  • • Failure to consult with workers and health and safety representatives (HSRs) about tyre changing risks and controls
  • • Inadequate incident reporting and investigation systems leading to repeat events and systemic issues not being addressed
2. Procurement of Plant, Tyres and Equipment
  • • Purchase of tractors, rims, wheels and off‑road tyres that are incompatible or lack appropriate design for the loads, pressures and conditions in which they are used
  • • Procurement of tyre changing equipment (bead breakers, jacks, lifting devices, cages, air lines, torque tools) that does not meet Australian Standards or is unsuitable for large agricultural and off‑road tyres
  • • Lack of engineering and safety specification input when purchasing new plant or attachments leading to increased tyre loading, instability and premature failure
  • • Inadequate provision for guarding, restraining devices, or inflation cages in original equipment specifications
  • • Sourcing cheap or second‑hand rims and tyres without verifiable history, identification markings or compatibility information
  • • Failure to specify safe inflation systems (e.g. remote inflators, pressure regulators, whip‑checks) at time of purchase
3. Design and Layout of Workshop and Field Tyre Changing Areas
  • • Inadequate workshop layout leading to interaction between moving vehicles, forklifts and workers performing tyre changes
  • • Insufficient space, lighting or ground conditions for safe handling of large tractor and off‑road tyres in the workshop or in field locations
  • • Poorly designed storage systems for rims and tyres resulting in collapse, falling objects or manual handling injuries
  • • Lack of designated exclusion zones around tyre inflation areas, particularly when inflating large off‑road tyres with risk of explosion or sidewall failure
  • • Unsafe or uneven surfaces at field repair sites leading to instability of jacks, stands and vehicles
  • • Inadequate drainage and housekeeping causing slips, trips and falls around tyre changing equipment
4. Maintenance, Inspection and Asset Management of Plant and Tyres
  • • Lack of systematic inspection and maintenance of tractors, rims, tyres, jacks, stands and lifting devices leading to undetected defects and failures
  • • Use of tyre changing tools and equipment that are damaged, uncalibrated, not tagged, or past service intervals
  • • No central register or tracking of tyres, rims and associated components, resulting in mix‑ups, incorrect assemblies or re‑use of condemned equipment
  • • Failure to follow manufacturer’s recommendations for torque settings, tyre pressures and load ratings
  • • Insufficient processes for identifying and quarantining damaged or non‑conforming rims, tyres and components
  • • Inadequate maintenance of compressed air systems (including valves, hoses, couplings and regulators) increasing the risk of hose whip or over‑pressurisation
5. Risk Management, Procedures and Documentation
  • • Absence of a documented risk management process specific to tractor and off‑road tyre changing activities
  • • Reliance on informal or verbal instructions rather than formal procedures, increasing variability in practices
  • • No documented Safe System of Work (SSOW), Safe Operating Procedures (SOPs) or SWMS for high‑risk tyre changing activities
  • • Risk assessments not updated when plant, tasks, locations or equipment change
  • • Procedures that do not align with current Australian Standards, manufacturer instructions or industry best practice
  • • Complex or overly generic documentation that workers find difficult to understand or apply in the field
6. Competency, Training and Supervision
  • • Workers and contractors performing tractor and off‑road tyre changing without adequate training, competency assessment or experience
  • • No formal verification of competency (VOC) for high‑risk tasks such as large tyre inflation, bead seating and rim assembly
  • • Inadequate supervision of new or young workers, especially during high‑risk tyre operations and field repairs
  • • Lack of refresher training leading to skill fade and non‑compliance with procedures over time
  • • Training that is limited to theory and does not adequately cover practical risk recognition, emergency response or safe decision‑making in remote areas
  • • Inconsistent induction processes resulting in varying understanding of tyre‑related hazards, company policies and reporting requirements
7. Plant Isolation, Energy Control and Stability Management
  • • Inadequate isolation of tractors and off‑road plant during tyre changes leading to unintentional movement or activation
  • • Failure to control stored energy such as suspended loads, hydraulic pressure, compressed air, and tyre pressure during maintenance
  • • Insufficient chocking, jacking and support systems for heavy vehicles and machinery, increasing risk of collapse or roll‑away
  • • Lack of standardised procedures for lock‑out/tag‑out (LOTO) when working on tyres, wheels and associated components
  • • Reliance on single jacks without use of stands or secondary supports in system design and procedures
  • • No formal verification or sign‑off step to confirm plant stability before workers commence tyre work
8. Manual Handling, Ergonomics and Use of Mechanical Aids
  • • Systemic reliance on manual lifting, pushing and rolling of heavy tractor and off‑road tyres leading to musculoskeletal disorders
  • • Insufficient availability or inappropriate selection of mechanical aids such as tyre handlers, dollies or lifting attachments
  • • Poor ergonomic design of workstations, tool storage and tyre racks increasing bending, twisting and over‑reach
  • • Lack of formal assessment of manual handling risks for tyre changing activities in workshops and field locations
  • • Time pressure and productivity targets that discourage the use of mechanical aids or team lifting
  • • Inadequate training and supervision in correct use of mechanical handling equipment
9. Remote, After‑Hours and Field Tyre Changing Management
  • • Tyre changing conducted in remote or off‑road locations without adequate communication, supervision or emergency support
  • • Lack of formal journey management and lone worker systems for after‑hours or remote tyre repairs
  • • Inadequate assessment of environmental conditions (weather, terrain, traffic, wildlife) at field sites
  • • Insufficient equipment and resources carried in service vehicles to complete tyre tasks safely in the field
  • • Fatigue associated with extended shifts, night work and emergency call‑outs for tyre failures
  • • Poor location information and access arrangements for emergency services responding to incidents at remote tyre sites
10. Emergency Preparedness, First Aid and Incident Response
  • • Lack of planning for emergencies arising from tyre explosions, vehicle collapse, crush injuries or air hose failures
  • • Inadequate first aid resources and trained personnel for typical tyre‑related injuries (crush, lacerations, eye injuries, fractures)
  • • No clear procedures for raising the alarm and coordinating response in workshops or remote tyre sites
  • • Insufficient practice of emergency drills, leading to confusion or delays in real incidents
  • • Failure to preserve incident scenes or collect accurate information for investigation and prevention
  • • Psychological impact on workers exposed to serious tyre‑related traumatic events not being recognised or managed
11. Personal Protective Equipment (PPE) and Workplace Environment
  • • Over‑reliance on PPE instead of higher order controls in tyre changing systems
  • • Inconsistent PPE standards between sites, shifts and contractors leading to gaps in protection
  • • Incorrect selection, fitting, maintenance or replacement of PPE such as safety footwear, eye and hearing protection, gloves and high‑visibility clothing
  • • Inadequate protection from environmental conditions (heat, cold, UV, rain) during field tyre work, leading to heat stress or reduced concentration
  • • Lack of enforcement of PPE requirements by supervisors and managers
12. Monitoring, Review and Continuous Improvement
  • • Failure to monitor performance of tyre changing systems, leading to undetected non‑compliance and drift from safe practices
  • • Lack of meaningful WHS performance indicators specific to tyre‑related risks and incidents
  • • Infrequent or superficial inspections and audits of tyre changing activities, equipment and documentation
  • • Inadequate review of incident, near miss and inspection data to identify systemic issues and trends
  • • Poor communication of lessons learned, resulting in repeated tyre‑related incidents across different sites or teams

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
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • Safe Work Australia – Managing Risks of Plant in the Workplace Code of Practice: Guidance on plant selection, operation, inspection and maintenance.
  • Safe Work Australia – Hazardous Manual Tasks Code of Practice: Requirements for identifying and controlling manual handling and ergonomic risks.
  • Safe Work Australia – Managing the Work Environment and Facilities Code of Practice: Standards for safe workshops, field work environments and amenities.
  • Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace Code of Practice: Where tyre sealants, solvents or related chemicals are used.
  • AS 4024 (series) – Safety of Machinery: Principles for guarding, controls and safety systems associated with tyre handling and lifting equipment.
  • AS/NZS 45001:2018: Occupational health and safety management systems — Requirements with guidance for use.
  • AS 2759: Steel cord conveyor belts and related plant safety principles, referenced where similar mechanical handling and guarding risks apply.
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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Safe Work Australia Aligned