Safety in the work place

Working with OTR tyres for earth-moving machinery carries serious risk. Their massive size and weight, the magnitude of air or gas pressures involved, and the presence of combustible materials all create the conditions for catastrophic failure. The uncontrolled release of stored energy can cause severe — even fatal — injuries. The seven principles below are the foundation of every safe OTR tyre repair operation.

1. Always Complete a Job Safety Analysis

Before any work begins, a safety assessment must be conducted to identify health and safety hazards and mitigate exposure to risks. For all new or unfamiliar tasks, every employee involved should first complete a Job Safety Analysis (JSA).

A JSA should be a standard part of your organisation's Risk Assessment Management system — not an afterthought when something feels off, but a deliberate first step on every job.

2. Use the Correct PPE

Appropriate personal protective equipment must be worn at all times whilst inspecting or working with any type of tyre. The specific PPE required varies by task and by site — but the principle is non-negotiable.

PPE that's sitting in a locker isn't doing its job. Every member of the team should know exactly what PPE the task requires, where it's stored, and how to verify it's still in serviceable condition.

3. Secure the Tyres

All tyres must be restrained with appropriate devices to ensure they cannot fall, roll, or shift during inspection or while repair processes are being carried out.

Even partially deflated, an OTR tyre weighs hundreds of kilos — gravity does the rest if it's not properly secured. Use the correct restraints for the size and orientation of the tyre, and check them before any work begins.

4. Adhere to Relevant Standards

Tyre repair must only be performed in accordance with relevant published standards — such as AS 4457.2-2008 in Australia — in conjunction with your internal company procedures.

Standards differ by region. Always consult the relevant regional codes and the recommendations from your equipment and consumable suppliers. If you're working across multiple jurisdictions, default to the strictest applicable standard.

5. Prepare Your Staff for the Job

Personnel must have the necessary competencies, accurate information, and appropriate tools and equipment in serviceable condition before starting any task.

Comprehensive training is essential — and refresher training matters as much as initial training. Skills decay over time, especially safety-critical ones that aren't used daily. Schedule periodic refresher sessions, even for experienced operators.

6. Identify the Hazards

Before beginning any maintenance, service, or repair to tyres and rims, every member of the team must have a clear understanding of the hazards associated with the task and the means of controlling them.

It is virtually impossible to anticipate every hazard that may be encountered, so each task must be evaluated individually using an escalated risk assessment process. The goal is to accomplish the work in the safest manner possible — not to assume previous experience covers every variation of the job.

7. Daily Before-and-After Checks

A workplace inspection should be performed at the beginning of every work day or shift. The repair shop supervisor — or a delegated team member — should conduct this inspection daily to ensure the working environment is safe.

The minimum daily checklist:

• Turn on all lights and verify each is working properly.
• Inspect the air compressor before starting it — check cleanliness, oil level, air hoses, and line connections.
• Verify each air regulator is set to the correct pressure for its application.
• Drain water and oil from traps at air regulators before the shift begins.

These checks take five minutes. They prevent the kinds of small failures that compound into serious incidents.