Bark Blower Truck Safe Work Method Statement

Delivery hoses operate under substantial air pressure (typically 0.5-2.0 bar depending on system specifications and material characteristics) creating powerful forces within the hose. If the discharge end is released or inadequately controlled by ground personnel, the hose whips violently under pressure, thrashing in unpredictable patterns as escaping air propels the hose end. This whipping action creates severe impact hazards capable of striking workers, bystanders, or property. The heavy hose (80-120kg for typical 100-metre lengths) combined with pressure-induced movement generates substantial impact forces. Hose whip incidents commonly occur when ground personnel misjudge the force required to control discharge during initial pressure application, when they release the hose thinking flow has ceased but residual pressure remains, when hoses snag on obstacles causing sudden directional changes, or when workers become fatigued during extended operations reducing grip strength. Material blockages within hoses can cause pressure surges when cleared, creating sudden force increases that overcome operator control. Coupling failures between hose sections can also result in separation under pressure with catastrophic whipping of disconnected sections.

Consequence: Severe impact injuries including fractured limbs, facial trauma, skull fractures, eye injuries from direct hose strikes, lacerations from contact with hose couplings, and potential fatalities if workers are struck in head or chest by uncontrolled hose weighing 80-120kg moving at high velocity under pressure.

Material exits the discharge hose at velocities of 60-100 km/h propelled by high-pressure air. At this velocity, bark chips, wood fragments, and any foreign objects mixed within the material become dangerous projectiles. Eye injuries from material particles striking unprotected eyes can cause corneal damage, foreign body embedding, or permanent vision impairment. Facial impacts cause lacerations and bruising. If material contains foreign objects (rocks, metal fragments, broken glass) inadvertently loaded with the bulk material, these present extreme projectile hazards capable of penetrating skin or causing severe blunt trauma. The discharge stream also creates secondary projectile hazards by striking surfaces and causing ricochets—material bouncing off hard surfaces, walls, or pavement travels in unpredictable directions striking nearby workers. Discharge directed toward windows, vehicles, or structures causes property damage from high-velocity impact. Operators unfamiliar with discharge force may inadvertently direct streams toward hazardous areas before recognizing and correcting aim. Wind conditions affect discharge stream direction, causing drift from intended target areas potentially directing material toward workers, bystanders, or property.

Consequence: Permanent eye damage including loss of vision from foreign bodies penetrating cornea or retina, facial lacerations requiring surgical repair, dental damage from material striking mouth, penetrating injuries from foreign objects within material stream, and property damage from material striking windows, vehicles, or building facades.

Despite reducing manual handling compared to traditional mulch placement methods, bark blower operations still involve substantial manual handling of heavy hoses. Deployment requires dragging 80-120kg hoses across properties, often over rough terrain, stairs, or obstacles. Hoses must be lifted over fences, garden beds, and established plantings to reach application areas. During operation, ground personnel must maintain firm control of discharge ends while managing powerful discharge forces attempting to push the hose backward and sideways. The combination of hose weight, awkward cylindrical shape, and discharge forces creates substantial physical demands. Workers adopt awkward postures when maneuvering hoses around obstacles or directing discharge into specific garden areas. Extended operations lasting several hours cause cumulative fatigue particularly affecting lower back, shoulders, and forearms. Insufficient crew size for hose length deployed exacerbates manual handling risks—one worker attempting to control hoses that should require two or three workers. Wet weather increases hose weight as materials absorb moisture, and wet hoses become slippery reducing grip security.

Consequence: Lower back disc injuries from repetitive bending and lifting during hose deployment, shoulder rotator cuff injuries from overhead hose positioning, forearm and grip strength fatigue reducing ability to control discharge forces safely, muscle strains from awkward postures maintained during discharge direction, and slips or falls when pulling heavy hoses across wet or uneven surfaces.

The centrifugal blower unit generates noise levels typically ranging from 95-105 dB(A) measured at the truck operator position, exceeding the 85 dB(A) threshold requiring hearing protection under WHS regulations. Ground personnel experience noise from material turbulence within hoses creating rumbling and rattling sounds, and from material discharge impact with ground surfaces producing sharp impact noises. Noise levels vary with blower speed, material type and moisture content, and distance from discharge point, but regularly exceed 85 dB(A) at ground crew positions during active blowing. The intermittent high-intensity nature of bark blower noise (starting and stopping as hoppers are refilled, adjusting flow rates) creates particular hearing damage risk as workers may not consistently maintain hearing protection during quieter periods between blowing cycles. Communication difficulties in high-noise environments lead to misunderstood instructions or missed warning signals, contributing to operational errors and safety incidents. Prolonged exposure without adequate protection causes noise-induced hearing loss which is permanent and irreversible.

Consequence: Permanent noise-induced hearing loss affecting high-frequency sound detection initially, progressing to broader frequency hearing impairment with continued exposure, tinnitus (persistent ringing in ears) causing sleep disruption and concentration difficulties, and communication challenges in noisy environments even when wearing hearing aids due to inability to distinguish speech from background noise.

Bark blower discharge creates substantial dust clouds particularly when blowing dry materials in windy conditions. Organic dusts from decomposing bark, wood chips, and composted materials contain fungal spores, bacterial particles, and fine organic particulate matter. Inhalation causes respiratory irritation with symptoms including coughing, throat irritation, and breathing difficulty particularly in workers with pre-existing respiratory conditions. Some individuals develop allergic sensitisation to fungal spores or organic proteins within the dust, experiencing increasingly severe reactions with repeated exposure. Aspergillosis and farmer's lung are recognized occupational respiratory diseases associated with organic dust exposure. Some hardwood bark dusts are classified as potential carcinogens under IARC classifications, presenting long-term cancer risk with chronic unprotected exposure. Dust reduces visibility creating navigation hazards when working near excavations, traffic areas, or other construction site hazards. Dust deposition on vehicle windscreens and equipment controls creates operational safety concerns. Workers with asthma or chronic obstructive pulmonary disease experience acute exacerbations when exposed to organic dusts, potentially requiring medical treatment.

Consequence: Chronic respiratory disease including occupational asthma requiring ongoing medication and possible work restriction, allergic alveolitis (farmer's lung) causing progressive lung scarring and breathing impairment, acute respiratory distress requiring medical treatment, and potential increased cancer risk from chronic exposure to hardwood dusts classified as carcinogenic.

Material blockages within delivery hoses occur when oversized particles, compacted material, or foreign objects lodge in hose sections or at coupling connections. Blockages cause pressure buildup in the hopper and blower system potentially exceeding design limits and causing equipment damage or coupling failures. Operators attempting to clear blockages commonly shut down the blower, then attempt to dislodge material by manipulating hoses, applying external force, or operating controls to pulse pressure. When blockages clear suddenly, the resulting pressure surge creates violent hose movement and discharge stream restart without warning. Workers positioned near the discharge end during clearing attempts may be struck by suddenly resuming material discharge or by hose movement during pressure normalization. Some operators mistakenly attempt to clear blockages by inserting objects into hose ends or couplings while system pressure is active, creating entrapment and entanglement risks. Compressed air pockets trapped behind blockages release with explosive force when blockages clear, amplifying hose whip and discharge force beyond normal operating levels.

Consequence: Impact injuries from hose movement during pressure surge events, material discharge injuries if workers are positioned in discharge path when flow suddenly resumes, hand and arm entrapment or crushing if workers insert hands into hose ends during clearing attempts, and potential coupling separation injuries if pressure surge causes connection failures.

Delivery hoses stretched across properties create trip hazards for bark blower crew members, other trades working in the area, and site personnel moving through the location. Hoses crossing walkways, access routes, or work areas are often not clearly visible particularly when covered by vegetation or newly applied mulch. Workers walking backward while directing discharge hoses cannot see obstacles behind them, creating trip and fall risks from concealed hazards, terrain changes, or other site features. Freshly applied mulch creates slippery, unstable walking surfaces particularly on slopes or when material is applied thickly. Mulch depth changes are difficult to detect visually, causing missteps when workers encounter sudden depth variations. Wet mulch is particularly slippery reducing traction and increasing likelihood of falls. Working on sloped terrain whilst managing heavy hoses compounds slip and fall risks due to reduced stability and awkward weight distribution. Falls whilst holding active discharge hoses can result in loss of control creating secondary hazards from uncontrolled discharge and hose whip.

Consequence: Fractures from falls onto hard surfaces or obstacles, ankle sprains and ligament damage from slips on unstable mulch surfaces, lacerations from falls into garden beds containing stakes, edging materials, or plant material with thorns, and secondary injuries from hose discharge striking workers who have fallen or lost control of equipment.