Managing High-Risk Hazards in Arboriculture and Landscaping

Wood Chipper Operation Safe Work Method Statement (SWMS)

WHS Compliant for Australian Arborists and Landscapers
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This Safe Work Method Statement (SWMS) provides a framework for the safe operation of wood chippers on Australian worksites. Operating a wood chipper is a high-risk activity that can lead to fatal injuries if not managed correctly. This document is essential for PCBUs and workers in the arboriculture, landscaping, and land-clearing industries to meet their obligations under the Work Health and Safety (WHS) Act.

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Overview

What this SWMS covers

Operating a wood chipper is a common task in arboriculture, landscaping, and land clearing for managing wood waste. The machine works by feeding branches and logs into a hopper, where high-speed rollers grab the material and force it against a set of sharp, rotating blades. The wood is rapidly broken down into small chips, which are then expelled at high velocity through a discharge chute. This process is extremely efficient but introduces severe risks that require strict safety protocols. A typical wood chipping operation involves positioning the machine on stable ground, establishing a wide exclusion zone, conducting thorough pre-start checks, systematically feeding material, and performing safe shutdown and maintenance procedures. This SWMS provides the necessary framework to ensure every step is conducted with safety as the top priority, addressing the high-risk nature of this work.

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Why this SWMS matters

The potential for life-altering or fatal injuries makes a SWMS for wood chipper operation non-negotiable. The most severe hazard is entanglement and being pulled into the in-feed chute, which is almost always fatal. Safe Work Australia has recorded numerous incidents of this nature. Additionally, the high-velocity ejection of wood chips and other debris can cause serious eye injuries or blunt force trauma. The extreme noise levels, often exceeding 110 dB, can cause permanent hearing loss without proper protection. Under Australian WHS Regulations, PCBUs must manage these high risks through a safe system of work, and a SWMS is the primary tool for documenting this system. It ensures that operators are competent, safety features are functional, and emergency procedures are in place, thereby protecting workers and ensuring the business complies with its legal safety obligations.

Reinforce licensing, insurance, and regulator expectations for Wood Chipper crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Entanglement and Being Pulled into the Machine

high

Loose clothing, gloves, ropes, or even branches can get caught by the feed rollers, pulling the operator into the cutting mechanism. This is the most severe hazard associated with wood chippers.

Consequence: Fatality, dismemberment, or catastrophic amputation.

Struck by Ejected Material

high

Wood chips, knots, stones, or other debris can be ejected at high velocity from both the in-feed and discharge chutes, striking the operator or others in the vicinity.

Consequence: Serious eye injuries, blindness, facial fractures, or head trauma.

Noise-Induced Hearing Loss

high

Wood chippers generate extreme noise levels, often well above the 85 dB exposure standard, which can cause permanent hearing damage over time.

Consequence: Permanent tinnitus and hearing loss.

Cuts and Lacerations from Blades

high

Contact with the sharp cutting blades during maintenance, jam clearing, or if guards are removed, will cause severe injuries.

Consequence: Deep lacerations, amputation of fingers or hands.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Use of Modern, Guarded Machinery

Engineering

Ensure the wood chipper is a modern design equipped with all manufacturer-supplied safety features.

Implementation

1. Only use chippers with a bottom-feed stop bar or other presence-sensing device. 2. Ensure the in-feed chute is of sufficient length (at least 1500mm) to prevent operators from reaching the blades. 3. Verify that all guards, especially around the cutting mechanism and drive belts, are in place and secure. 4. Regularly test the emergency stop functions before each use.

Establishment of Exclusion Zones

Administrative

Create a clearly defined work area around the chipper to prevent unauthorised access and protect others from ejected debris.

Implementation

1. Establish a minimum 20-metre exclusion zone around the chipper. 2. Use signs and high-visibility cones or tape to mark the zone. 3. Ensure the discharge chute is aimed away from people, property, and public areas. 4. Allow only the trained operator and a designated safety observer within the zone.

Safe Feeding and Operating Procedures

Administrative

Implement and enforce a strict procedure for feeding material into the chipper.

Implementation

1. Feed branches butt-end first. 2. Allow the machine to pull the material in; do not push it with hands or feet. 3. Keep hands and feet outside the in-feed chute at all times. 4. Move away from the feed chute as the material is being processed. 5. Feed smaller branches in a bundle to reduce the risk of kickback.

Lock-Out Tag-Out (LOTO) for Maintenance

Administrative

Implement a LOTO procedure to prevent the machine from starting unexpectedly during maintenance or jam clearing.

Implementation

1. Turn off the machine and remove the key from the ignition. 2. Disconnect the spark plug or battery to isolate the power source. 3. Wait for all moving parts, especially the cutting drum, to come to a complete stop. 4. Attach a personal danger tag and lock to the ignition. 5. Only the person who applied the lock may remove it.

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Personal protective equipment

Hard Hat

Requirement: AS/NZS 1801

When: At all times within the exclusion zone to protect from falling branches or ejected debris.

Hearing Protection (Class 5)

Requirement: AS/NZS 1270

When: Mandatory for the operator and anyone within the exclusion zone. A combination of earplugs and earmuffs is recommended.

Full-Face Visor or Safety Goggles

Requirement: AS/NZS 1337.1

When: At all times during operation to protect against high-velocity wood chips and dust.

Cut-Resistant Gloves

Requirement: AS/NZS 2161.3

When: When handling branches and feeding the machine. Must be short-cuffed to prevent entanglement.

Steel-Capped Boots

Requirement: AS/NZS 2210.3

When: At all times on site to protect feet from falling logs and equipment.

Inspections & checks

Before work starts

  • ✓Check that all guards and safety devices (e.g., emergency stop bar) are in place and functional.
  • ✓Inspect the in-feed and discharge chutes for damage or blockages.
  • ✓Check blades for sharpness and security; ensure bolts are tight.
  • ✓Verify the machine is on level, stable ground and wheels are chocked.
  • ✓Ensure the exclusion zone is clearly marked and free of personnel.

During work

  • ✓Listen for any unusual noises or vibrations from the machine.
  • ✓Regularly check that the discharge chute remains clear and is not blocked.
  • ✓Monitor the work area to ensure no one enters the exclusion zone.
  • ✓Ensure the operator is not becoming fatigued.

After work

  • ✓Allow the machine to cool down before conducting maintenance.
  • ✓Clean the machine of all debris according to the manufacturer's instructions.
  • ✓Inspect the machine for any damage that may have occurred during operation.
  • ✓Secure the machine against unauthorised use.

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready
1

Pre-Start Inspection and Setup

Conduct a thorough visual inspection of the wood chipper, checking for loose bolts, damaged guards, and fluid leaks. Test the emergency stop bar and other safety controls. Position the chipper on firm, level ground with the discharge chute directed to a safe area. Chock the wheels and establish a 20-metre exclusion zone with cones and signs.

Safety considerations

An incomplete pre-start check can lead to catastrophic failure. Never operate a damaged or faulty machine.

2

Starting the Machine

Ensure all personnel are outside the exclusion zone. Following the manufacturer's instructions, start the chipper and allow it to warm up to operating speed. Listen for any unusual sounds that might indicate a mechanical problem.

Safety considerations

Keep hands and feet clear of all moving parts during startup. Ensure you have a clear line of sight around the machine.

3

Feeding Material into the Chipper

Organise branches and logs so they can be fed butt-end first. Feed the material into the in-feed chute and allow the machine's rollers to pull it in. Do not use your hands or feet to force material into the machine. Once the material is engaged, step back from the chute and to the side.

Safety considerations

This is the most dangerous step. Never place any part of your body into the in-feed chute. Be prepared for unexpected kickback.

4

Handling Jams and Blockages

If the machine becomes jammed, immediately hit the emergency stop bar and shut down the engine. Isolate the power source by removing the key and disconnecting the battery or spark plug. Wait for the cutting drum to come to a complete stop. Only then, use a long stick or other tool to clear the blockage. Never use your hands.

Safety considerations

The cutting drum can continue to spin for several minutes after the engine is off. Never attempt to clear a jam on a running or spinning machine. Follow LOTO procedures.

5

Shutdown and Securing

Once all material has been processed, allow the machine to run for a few minutes to clear the chutes. Shut down the engine according to the manufacturer's procedure. Remove the key and secure it to prevent unauthorised use. Clean the machine and conduct a post-operational inspection.

Safety considerations

Be aware of hot surfaces on the engine and exhaust. Ensure the machine is fully secured before leaving it unattended.

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Frequently asked questions

What is the most important piece of PPE when using a wood chipper?

While all PPE is important, hearing and eye/face protection are absolutely critical. Wood chippers operate at dangerously high decibel levels, and the risk of high-velocity projectiles is constant. A combination of safety goggles and a full-face visor, along with Class 5 hearing protection, is essential.

Can I operate a wood chipper alone?

It is strongly recommended by safety authorities that at least two competent people are present during operation. One person feeds the machine while the other acts as a safety observer, with immediate access to the emergency stop controls. Working alone significantly increases the risk if an incident occurs.

What should I do if my glove gets caught?

You should never try to pull your hand back, as this can increase the force pulling you in. The immediate action is to hit the emergency stop bar with your free hand or body. This is why it is crucial to know the location of the stop bar and always work in a position where you can activate it instantly.

How do I safely feed short or small pieces of wood?

Never use your hands to push small pieces into the chute. Instead, use a longer branch or a designated push stick to guide the smaller material in. Alternatively, bundle small off-cuts with a larger branch to feed them through as a single unit.

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Overview of Wood Chipper Operation

A wood chipper is a machine used to reduce tree limbs, branches, and other wood waste into smaller woodchips. The process involves feeding material into an in-feed chute, where it is grabbed by rollers and fed into a cutting mechanism. The resulting chips are then forcibly ejected through a discharge chute. Chippers are vital for efficient vegetation management, but their powerful feeding and cutting systems present extreme hazards. Safe operation requires comprehensive training, strict adherence to procedures, and a well-maintained machine. This SWMS covers pre-start checks, worksite setup, feeding techniques, and emergency procedures to mitigate the inherent risks.

Why This SWMS is Critical for Safety

The operation of a wood chipper is one of the most dangerous tasks in the landscaping and arboriculture industries. Incidents involving chippers often result in death or catastrophic injuries, such as amputation. The primary hazard is a worker being caught and pulled into the machine by the feed rollers. Other significant risks include being struck by projectiles ejected from the chutes, entanglement of loose clothing, and severe noise-induced hearing loss. A SWMS is a legal requirement and a moral necessity. It forces a systematic approach to safety, ensuring that exclusion zones are established, emergency stops are functional, operators are properly trained, and appropriate PPE is used. By following this SWMS, PCBUs can demonstrate due diligence and create a structured, safe system of work that protects their employees from the life-threatening dangers of wood chipper operation.

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Risk Rating

BeforeHigh
After ControlsLow

Key Controls

  • • Pre-start briefing covering hazards
  • • PPE: hard hats, eye protection, gloves
  • • Emergency plan communicated to crew

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