Write a risk assessment for Artic dumper in quarry

A suitable risk assessment for operating an articulated dumper truck in a quarry should identify the task steps, the hazards at each stage, the likelihood and severity of harm, and the controls required before work starts. The assessment should cover driving, loading, travelling, reversing, tipping, parking, maintenance interaction, and emergency situations. A job-hazard-analysis approach is appropriate for complex work with multiple hazards and should be documented and certified. High-risk activities should be stopped until effective controls are in place, with priority given to engineering, work-practice, and administrative controls before PPE. [5] [7] [9]

• Mobile plant hazards: collision with other vehicles, striking pedestrians, entanglement during inspection or maintenance, brake or steering failure, tyre failure, poor visibility, and loss of control on gradients or rough haul roads.
• Vehicle movement and reversing: use a site traffic management plan with designated one-way systems where possible, controlled intersections, speed limits, berms, signage, lighting, radio/communication rules, and reversing only where unavoidable. Fit and maintain mirrors, cameras, alarms, lights, and other visibility aids; use trained banksmen only under a clear system of work.
• Loading operations: load only in designated areas on stable, level ground; avoid overloading or uneven loading; keep the operator in the cab unless a safe alternative procedure is established; maintain exclusion zones around loading plant; and ensure the loader operator and dumper driver use agreed signals or radio communication.
• Tipping operations: tip only on prepared, inspected tipping points with adequate edge protection or stop blocks where appropriate; check for soft ground, hidden voids, excessive side slope, overhead hazards, and people in the area; tip in a straight line where possible; never tip near unsupported edges; and lower the body before moving off.
• Rollover and collision prevention: enforce seat belt use at all times, maintain safe speeds for road and weather conditions, avoid sharp turns especially when loaded, keep loads within manufacturer limits, travel with the body lowered, and prohibit mobile phone distraction or unauthorized passengers.
• Ground conditions: inspect haul roads and tipping areas for rutting, mud, standing water, loose material, edge instability, overhead obstructions, and inadequate width; suspend operations in unsafe conditions until repaired or made safe.
• Pedestrian segregation: physically separate pedestrians from vehicle routes wherever possible using barriers, designated walkways, crossing points, and exclusion zones around loading and tipping areas. High-visibility clothing should be mandatory for anyone exposed to traffic.
• Operator competence and training: allow only trained, authorized, and medically fit operators to use the dumper. Training should cover machine controls, quarry traffic rules, reversing, tipping hazards, seat belt use, daily checks, defect reporting, emergency actions, and site-specific hazards. Refresher training and supervision are needed where risk, change, or poor performance indicates.
• Pre-use inspection and maintenance: complete and record daily checks on tyres, wheels, steering, brakes, horn, lights, mirrors/cameras, reversing alarm, seat belt, body props/locks, hydraulic leaks, fire extinguisher if fitted, access steps/handholds, and general structural condition. Remove defective vehicles from service until repaired.
• Dust and noise exposure: control dust on haul roads and loading/tipping areas by water suppression, road maintenance, speed control, and housekeeping. Assess operator exposure to respirable dust and noise; use enclosed cabs, filtration, and hearing protection where required. Keep windows closed when dust controls rely on cab filtration.
• PPE: minimum quarry PPE typically includes hard hat, high-visibility clothing, safety glasses as needed, gloves suited to the task, and safety footwear with toe protection and slip-resistant soles. Hearing and respiratory protection should be provided where assessment shows exposure cannot be adequately controlled by other means.
• Emergency procedures: establish arrangements for collision, rollover, fire, medical emergency, brake failure, and vehicle immobilization. Operators should know how to stop safely, raise the alarm, summon rescue, isolate the machine if safe, and never jump from an overturning vehicle if restrained by a seat belt. Recovery and rescue should be planned for remote quarry areas.
• Compliance and management: the employer should maintain a written risk assessment, traffic management plan, inspection and maintenance system, operator authorization records, PPE assessment, supervision, and periodic review. Controls must be reviewed whenever equipment, routes, ground conditions, or work methods change.

[6] [9] [4] For quarry vehicle movement, the most critical controls are segregation, visibility, and disciplined traffic rules. Pedestrians should not share haul routes with dumpers except at controlled crossings. Reversing should be eliminated where practicable through one-way systems and turning circles; where it cannot be eliminated, the area should be clear, visibility aids functional, and the maneuver controlled. Loading and tipping areas should be treated as high-risk zones with exclusion areas, competent supervision, and routine inspection of edges and ground bearing capacity. [1] [8] [4]

Operator competence is a core control measure. Operators should be formally trained, familiarized with the specific articulated dumper model and quarry rules, assessed as competent, and authorized in writing. Training records should be documented, refreshed periodically, and updated when conditions or equipment change. Supervisors should verify that operators follow safe systems of work, use seat belts, report defects promptly, and do not operate unsafe equipment. [3] [11] [14]

Pre-use inspection and maintenance should be part of the safe system of work. The machine must be checked before use and defects affecting safety must result in immediate withdrawal from service. Planned preventive maintenance should follow the manufacturer’s instructions, and maintenance tasks should use isolation, lock-off, and safe access arrangements. Records of inspections, defects, repairs, and maintenance should be retained as part of quarry safety management. [12] [11] [10]

Typical residual-risk controls for an articulated dumper truck in a quarry:

• Use only on routes designed for the dumper’s size, axle loads, and turning radius.
• Keep haul roads graded, drained, and wide enough for safe passing or enforce one-way travel.
• Provide edge protection, stop blocks, or stand-off distances at tipping points based on geotechnical assessment and site rules.
• Ensure ROPS/FOPS-equipped machines are used where required and keep the seat belt worn whenever the vehicle is in motion.
• Do not exceed payload limits and ensure loads do not obstruct visibility or create instability.
• Use positive communication between loader and dumper operators.
• Prohibit pedestrians from approaching a dumper unless the driver has stopped, made eye contact, and given clear permission.
• Park on firm level ground where possible, apply parking brake, lower the body, isolate as required, and chock wheels if necessary on gradients.
• Control dust with water suppression and road maintenance; assess need for respiratory protection where dust remains significant.
• Assess noise exposure and provide hearing protection where exposure criteria are met or where noisy plant areas are designated.
• Provide suitable PPE based on the hazard assessment and ensure fit, condition, and enforcement.
• Review the assessment after incidents, near misses, route changes, weather damage, or changes in plant or production.

[16] [13] [15] For PPE, quarry dumper operations commonly require head protection, high-visibility clothing, protective footwear, eye protection where there is flying material or dust, gloves for inspection and coupling/uncoupling tasks, hearing protection in high-noise areas, and respiratory protection where dust exposure cannot be adequately controlled by engineering measures. PPE should be selected from a documented hazard assessment, matched to the hazard, fit the wearer properly, be maintained in good condition, and never be treated as the primary control where safer engineering or administrative measures are reasonably practicable. [2] [5] [10]

In terms of quarry safety regulation and HSE-style compliance expectations, the employer should be able to demonstrate a suitable and sufficient risk assessment, a site traffic management plan, competent supervision, operator training and authorization, inspection and maintenance systems, pedestrian segregation, emergency arrangements, and documented PPE assessment and certification. The assessment should be reviewed periodically and whenever there is a significant change or incident. If a hazard presents a high risk of fatal or serious injury, operations should not continue until the risk is reduced. [14] [7] [9]