Forest Mulcher Attachment Safe Work Method Statement

Forest mulcher attachment operation requires appropriate high-risk work licence for the carrier machine being used, not a separate licence specifically for the mulcher itself. For excavator-mounted mulchers, operators must hold Excavator Licence (Class C1 for excavators 5-120 tonnes capacity). For skid steer loader-mounted mulchers, requirements vary by machine design: wheeled skid steers with seat-operated controls require Forklift Truck Licence (Class LF) as they meet the regulated definition; tracked skid steers and some specialized designs may not require specific licensing but operators should complete manufacturer training and competency assessment. Agricultural tractor-mounted mulchers do not require high-risk work licences under current WHS regulations, though operators should hold relevant operator competency certificates and complete equipment-specific training. All operators regardless of licensing requirements must receive training specific to forest mulcher operations covering: mulcher-specific hazards including flying debris and exclusion zones; underground service location and protection; slope stability and rollover prevention; mulcher operational techniques for different vegetation types; emergency procedures including shutdown and fire response; and maintenance and inspection requirements. Employers remain responsible under WHS Act Section 19 to ensure all operators are adequately trained and competent regardless of formal licensing, meaning generic excavator licence alone is insufficient—operators must receive mulcher-specific training addressing unique hazards. Maintain training records documenting licence verification, equipment-specific training completion, and competency assessments for compliance verification and insurance requirements.

When forest mulcher operations must occur in areas with underground electrical cables that cannot be safely exposed or physically protected, implement layered controls prioritizing isolation over operational controls. First preference: arrange temporary de-energisation of cables by the electrical asset owner for duration of mulching work—whilst logistically challenging, this eliminates electrocution risk completely. Second preference: expose cables using hydro excavation or careful hand digging, install heavy-duty concrete slab protection over exposed sections rated to withstand mulcher contact forces, clearly mark protected service corridors with highly visible barrier tape and signage, limit mulcher depth penetration to maximum 50mm in protected areas using depth control systems or manual technique. Third preference if isolation and protection are not practicable: establish 3-metre minimum setback from identified service routes prohibiting mulcher operation within this corridor, clear vegetation in setback zones using hand tools or carefully controlled smaller equipment, install barrier fencing preventing inadvertent mulcher entry into setback areas, assign dedicated spotter monitoring mulcher positioning relative to service corridors with authority to immediately halt operations if boundaries are approached. For all scenarios: obtain Dial Before You Dig responses and conduct electromagnetic cable location verifying service positions, mark service routes using high-visibility paint or pegs at 3-metre intervals creating obvious visual references operators can see from machine cabins, brief operators on service locations providing marked site plans and photographs of marking systems, implement two-way radio communication between operators and ground personnel for continuous position monitoring. If electrical cables must be worked over without exposure, consider depth-limited mulching technique maintaining maximum 75-100mm ground penetration significantly reducing strike probability whilst accepting that clearing may be incomplete requiring supplementary manual finishing. Never rely solely on operator care without physical barriers or isolation—this represents inadequate control given catastrophic consequences of electrical cable strikes. Document risk assessment and control selection justifying approach chosen and demonstrating systematic consideration of hierarchy of controls.

Forest mulcher attachments require rigorous maintenance following manufacturer specifications due to extreme operating conditions and severe mechanical loading. Daily pre-start inspections before each shift should include: visual inspection of housing checking for cracks or damage; teeth examination verifying all teeth are present, wear is within acceptable limits (typically replace at 50% original length), and no broken or loose teeth exist; hydraulic hose inspection checking for leaks, abrasion, cuts, or damage to reinforcement braiding; structural inspection examining mounting points, welds, and high-stress areas for cracks or damage; lubrication checks ensuring grease fittings are serviced and rotating components have adequate lubrication; guard and deflector verification confirming all safety components are fitted and undamaged. Every 8-10 operating hours (typically daily for full-time operations): grease all lubrication points per manufacturer specifications—mulcher bearings require frequent lubrication due to heavy loading and contamination exposure; check hydraulic motor oil level if separate reservoir; inspect chain or belt drives if fitted checking tension and wear; verify mounting bolts are tight using torque specifications preventing loosening from vibration; clean accumulated debris from mulcher components preventing corrosion and allowing inspection access. Every 40-50 operating hours (weekly for full-time operations): change hydraulic motor oil and filter following manufacturer specifications; inspect carbide teeth using wear gauges replacing teeth worn beyond service limits; examine mulcher drum for cracks, erosion, or metal loss from impact damage; check hydraulic system pressure and flow rates verifying performance is within specifications; inspect all welds looking for cracks initiating at weld toes or in heat-affected zones. Every 200-250 operating hours (monthly): replace all hydraulic hoses regardless of visible condition as internal deterioration occurs from pressure cycling; rebuild or replace hydraulic motor per manufacturer intervals; inspect and replace drive chains or belts showing wear or damage; complete comprehensive structural inspection including ultrasonic or magnetic particle testing of critical welds in high-stress areas. Maintain detailed maintenance records documenting all inspections, services, parts replacements, and hours operated. Track carbide teeth consumption, hydraulic hose failures, and component wear patterns identifying trends suggesting operational issues or specification mismatches. Engage qualified hydraulic technicians and structural welders for repairs—field repairs using incorrect procedures or materials can create safety hazards. Many component failures in forest mulchers result from deferred maintenance or operation beyond specifications—establish conservative maintenance intervals and adhere to schedules rigorously given extreme consequences of failures during operation.

Safe slope operations with forest mulchers require conservative approach recognizing that mulcher attachments significantly reduce safe operating angles compared to carrier machines without attachments. Start by understanding carrier machine manufacturer specifications for maximum safe slope angles with attachments—typically 15-25 degrees depending on machine type, with excavators generally more stable than skid steers. Reduce manufacturer specifications by 25% when operating forest mulchers to account for: additional weight (1-5 tonnes) raising center of gravity; extended reach beyond machine footprint when mulcher is positioned for cutting; dynamic loading from mulching impacts creating sudden weight transfers; and extremely slippery surface created by fine mulch providing almost no traction. Measure actual slope angles using inclinometer applications on smartphones or dedicated slope measurement tools before commencing work. Mark areas exceeding reduced safe angles with barrier tape and signage; prohibit mulching in these areas or implement alternative methods such as hand clearing or aerial cable systems. When working on permissible slopes: always approach straight uphill or straight downhill never traversing across slopes which creates maximum instability; engage low-range transmission and reduce ground speed to walking pace maintaining maximum control; maintain mulcher low and close to machine body rather than extended positions reducing leverage effects; work from high ground to low ground allowing retreat uphill if traction is lost; avoid creating windrows or piles of mulched material on slopes which generate even more slippery conditions by spreading mulch evenly as work progresses; deploy ground spotter positioned to observe machine stability from safe vantage point with clear view of tracks or wheels, able to warn operator of lifting or sliding indications. Watch for warning signs of instability including: tracks or wheels lifting from ground on uphill side; machine sliding sideways despite steering inputs; steering becoming unresponsive indicating loss of traction; unusual machine attitudes suggesting weight shift. If any stability warnings occur, immediately halt all motion, raise mulcher fully reducing weight extension, carefully reverse to firmer terrain using slow controlled movements. After rain or when encountering damp areas, reassess slope safety—water dramatically reduces traction making previously safe slopes hazardous. Consider installing aftermarket slope monitoring systems providing audible warnings when operating angles exceed preset limits. Train operators in proper weight transfer techniques counteracting slope effects through steering and boom positioning. Most critically, establish conservative policies prioritizing worker safety over production—if slopes appear marginal, implement alternative clearing methods rather than risking rollovers.

Forest mulcher operations present multiple serious injury risks requiring comprehensive emergency preparedness including first aid capability, communication systems, and medical evacuation planning. First aid requirements: minimum one worker on site must hold current First Aid Level 2 certificate (or equivalent providing CPE competency); first aid kit must be readily accessible containing supplies for major trauma including large trauma dressings for severe bleeding, triangular bandages for fractures and immobilization, eye wash for debris injuries, burns dressings for fire or hydraulic fluid injuries, and resuscitation equipment. Given remote locations common for mulcher work, consider enhanced first aid including wilderness first aid training for personnel, oxygen therapy equipment for serious trauma support, and automated external defibrillator (AED) for cardiac emergency response. Communication systems: all workers must carry charged mobile phones or two-way radios enabling emergency contact; verify communication coverage at work sites before commencing—if mobile coverage is inadequate, provide satellite phones or satellite emergency beacons (EPIRB/PLB); test communication daily confirming ability to contact emergency services (000) and company emergency contacts. Medical evacuation planning: identify and document nearest hospital emergency departments with trauma capabilities noting distance and estimated travel time; determine ambulance response time for site location recognizing that remote areas may have 30-60 minute response times; plan primary and alternate evacuation routes considering that injured workers cannot walk requiring vehicle transport; identify helicopter landing zones if air ambulance may be required for rapid evacuation from remote locations; brief all workers on evacuation routes and assembly points for emergency rendezvous with paramedics. Specific injury scenario planning: for severe bleeding from flying debris strikes, apply direct pressure using trauma dressings and elevate if practicable, call emergency services immediately, transport to hospital if ambulance delays exceed injury severity timeframes; for eye injuries from debris penetration, do not attempt removal of embedded objects, cover both eyes preventing movement, transport urgently to hospital or emergency services; for crush injuries from equipment incidents, immobilize suspected fractures using improvised or commercial splints, monitor for shock, arrange urgent medical transport; for rollover incidents with trapped operators, call emergency services immediately, assess whether occupant can be safely extricated or should wait for rescue personnel with hydraulic tools, provide first aid for accessible injuries, monitor continuously. Conduct emergency drills quarterly simulating serious injuries and testing communication, first aid response, and evacuation procedures verifying systems function and personnel know their roles. Review nearest medical facilities periodically confirming 24-hour operation, trauma capabilities, and updating contact information if changes occur.