Safe Work Method Statement for Load Skates and Machinery Moving Equipment

Load Skate

AS 4991 Compliant - 500+ Heavy Moves Protected
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Load skate operations involve moving heavy machinery, equipment, and structures using roller dollies, machinery skates, or load movers on construction sites. These devices allow manual or powered movement of loads ranging from hundreds to thousands of kilograms across flat surfaces. Workers face significant risks from load instability, toppling hazards, crushing incidents, and manual handling injuries when positioning equipment. Construction sites often have uneven surfaces, obstacles, and confined spaces that increase the complexity and danger of load skate operations. The Work Health and Safety Act 2011 requires comprehensive risk assessment and control measures for heavy equipment movement, with specific attention to load stability, surface conditions, and worker positioning. Australian Standards including AS 4991 for lifting devices provide technical requirements for skate design and capacity. Successful load skate operations require careful planning, proper equipment selection, trained personnel, and continuous monitoring to prevent catastrophic failures that can result in serious injury or death.

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Overview

What this SWMS covers

Load skate operations involve the use of roller dollies, machinery skates, or load movers to manually or mechanically relocate heavy equipment, machinery, and structures on construction sites. These wheeled devices support loads ranging from several hundred kilograms to multiple tonnes, allowing controlled movement across prepared surfaces. The work encompasses load assessment, skate selection and positioning, path preparation, coordinated movement execution, and equipment recovery. Construction environments present unique challenges including uneven surfaces, debris, overhead obstructions, confined spaces, and proximity to other workers and structures. Operations require multiple personnel for large loads, communication systems, mechanical assistance devices, and emergency response capabilities. Safety protocols must address load stability analysis, surface condition verification, personnel positioning requirements, and immediate response to loss of control. Equipment inspection, maintenance procedures, and documentation of movements are critical for operational safety and regulatory compliance. Load skate operations demand specialized training, risk assessment procedures, and systematic approaches to prevent catastrophic failures that can result in serious injury or death.

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Why this SWMS matters

Load skate operations carry extreme safety risks due to the potential for catastrophic load failure and crushing injuries. Serious workplace incidents have occurred where heavy equipment toppled during movement, crushing workers between loads and fixed structures. The Work Health and Safety Act 2011 requires comprehensive hazard identification and control measures for heavy equipment movement, with specific attention to manual handling methods and load stability. Load skates can fail catastrophically if skates dislodge on uneven surfaces, loads shift during movement, or equipment exceeds skate capacity. Construction sites amplify these risks with uneven terrain, debris, confined workspaces, and proximity to other personnel. Without proper SWMS procedures, workers risk fatal crushing injuries from toppling loads, severe injuries from being pinned against walls or equipment, musculoskeletal injuries from manual pushing/pulling forces, and property damage from uncontrolled movements. Australian safety regulators have issued specific alerts about load skate hazards following serious incidents involving workers being crushed by falling equipment. This SWMS ensures systematic hazard identification, implementation of engineering controls like proper skate selection and surface preparation, administrative controls including training and communication protocols, and PPE requirements to prevent incidents while enabling safe heavy equipment movement.

Reinforce licensing, insurance, and regulator expectations for Load Skate Safe Work Method Statement crews before they mobilise.

Hazard identification

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

Risk register

Load toppling and crushing injuries

high

Top-heavy or unstable loads can topple during movement, crushing workers between the load and fixed structures like walls, equipment, or vehicles.

Consequence: Fatal or severe crushing injuries, permanent disability, head trauma, or death from being pinned by falling equipment.

Skate dislodgement and loss of control

high

Load skates can dislodge from under equipment when encountering obstacles, uneven surfaces, or when load shifts during movement.

Consequence: Sudden loss of load control, equipment falling or rolling uncontrollably, crushing injuries, or property damage.

Load shifting and instability

high

Heavy loads can shift position during movement, particularly on uneven surfaces or when encountering obstacles, causing loss of balance.

Consequence: Equipment toppling, crushing hazards, structural damage to load, or injury to workers attempting to stabilize shifting loads.

Manual handling and musculoskeletal injuries

medium

Workers manually pushing, pulling, or guiding heavy loads can suffer strains from excessive force requirements or awkward postures.

Consequence: Back injuries, muscle strains, hernias, joint damage, or long-term musculoskeletal disorders.

Surface and environmental hazards

medium

Uneven surfaces, debris, slopes, or weather conditions can affect skate performance and load stability during movement.

Consequence: Loss of control, equipment damage, slips and falls, or movement path deviations.

Communication and coordination failures

medium

Poor communication between team members during coordinated movement can lead to conflicting actions or delayed responses to problems.

Consequence: Loss of control during movement, collisions with obstacles, or inability to stop movement safely.

Equipment failure and maintenance issues

medium

Damaged or inadequately maintained skates, wheels, or attachment points can fail under load, causing loss of support.

Consequence: Sudden equipment drop, crushing injuries, or uncontrolled movement requiring emergency intervention.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Load assessment and capacity verification

Administrative

Comprehensive assessment of load characteristics including weight, dimensions, center of gravity, and stability before selecting equipment and procedures.

Implementation

1. Weigh load using calibrated scales or calculate from specifications 2. Assess center of gravity and stability characteristics 3. Verify load dimensions against movement path constraints 4. Document load characteristics in movement plan 5. Confirm skate capacity exceeds load weight by minimum 25% 6. Identify attachment points and load distribution requirements 7. Assess special requirements for top-heavy or unstable loads

Surface preparation and path planning

Engineering

Preparation of movement surfaces and paths to ensure skates operate on solid, flat, smooth surfaces free from obstacles.

Implementation

1. Clear all debris, cables, and obstacles from movement path 2. Level uneven surfaces using shims or temporary ramps 3. Cover cable pits or trenches with load-rated plates 4. Mark movement path with hazard tape or barriers 5. Ensure minimum 1 meter clearance on all sides 6. Test surface firmness and skate performance on sample load 7. Prepare contingency paths for emergency redirection 8. Document surface conditions and preparation measures

Equipment selection and inspection

Engineering

Selection of appropriate skates and thorough inspection before use to ensure equipment integrity and proper capacity.

Implementation

1. Select skates with adequate capacity (25% safety margin minimum) 2. Inspect skate plates, rollers, and attachment points for damage 3. Verify non-slip surfaces between skate and load 4. Check wheel/roller condition and lubrication 5. Test skate movement on level surface before loading 6. Ensure skates are designed for intended load characteristics 7. Document equipment inspection results 8. Replace any damaged or questionable equipment

Personnel positioning and communication

Administrative

Safe positioning of workers and establishment of communication protocols to prevent workers from being caught between loads and structures.

Implementation

1. Never position workers between load and fixed structures 2. Maintain minimum 2 meter clearance from load edges 3. Establish clear communication signals for start/stop/direction 4. Use spotters to monitor load stability and obstacles 5. Assign specific roles (pushers, guides, spotters) 6. Implement emergency stop signals and procedures 7. Ensure all personnel understand their roles and responsibilities 8. Rotate personnel to prevent fatigue during long moves

Load securing and stability measures

Engineering

Proper securing of load to skates and implementation of stability measures to prevent shifting during movement.

Implementation

1. Secure load to skates with appropriate fasteners 2. Use load-rated straps or chains for additional stability 3. Install temporary bracing for top-heavy loads 4. Verify load is evenly distributed across all skates 5. Test load stability before movement begins 6. Monitor for signs of load shift during movement 7. Stop immediately if load instability is detected 8. Re-secure load before resuming movement

Training and competency requirements

Administrative

Ensuring all personnel involved in load skate operations have appropriate training and demonstrated competency.

Implementation

1. Provide specific training on load skate hazards and procedures 2. Train in communication signals and emergency procedures 3. Demonstrate competency through supervised practice 4. Annual refresher training on load skate operations 5. Document training records for all personnel 6. Assess understanding of center of gravity and stability principles 7. Train in equipment inspection and maintenance 8. Include training on risk assessment and hazard recognition

Emergency response and recovery procedures

Administrative

Established procedures for responding to loss of control, equipment failure, or other emergencies during load movement.

Implementation

1. Develop and practice emergency stop procedures 2. Establish evacuation routes and safe zones 3. Prepare emergency communication protocols 4. Have rescue equipment readily available 5. Train personnel in emergency response procedures 6. Document emergency equipment locations 7. Conduct regular emergency drills 8. Review and update emergency procedures annually

Personal protective equipment

PPE

Appropriate PPE for workers involved in load skate operations to protect against potential injuries.

Implementation

1. Hard hat for overhead hazard protection 2. Safety boots with steel toe caps 3. High-visibility vest for site work 4. Gloves for manual handling tasks 5. Hearing protection near operating machinery 6. Eye protection for debris hazards 7. Appropriate clothing for weather conditions 8. First aid kit readily accessible

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Personal protective equipment

Hard hat

Requirement: AS/NZS 1801 Type 1 or 2

When: All load skate operations due to overhead falling hazards

Safety boots

Requirement: AS 2210.3 with steel toe caps

When: Working around heavy equipment and potential falling objects

High-visibility vest

Requirement: Class D or higher AS/NZS 4602

When: Working on construction sites with moving equipment

Safety gloves

Requirement: Cut and impact resistant

When: Manual handling of equipment and skate positioning

Eye protection

Requirement: Safety glasses AS/NZS 1336

When: Working with potential flying debris or equipment failure

Hearing protection

Requirement: Disposable earplugs or earmuffs

When: Working near other construction equipment or machinery

Inspections & checks

Before work starts

  • ✓Inspect load skates for damage, cracks, or wear
  • ✓Verify skate capacity against load weight with 25% safety margin
  • ✓Check roller/wheel condition and lubrication
  • ✓Test skate movement on level surface
  • ✓Assess load stability and center of gravity
  • ✓Clear and prepare movement path
  • ✓Verify communication equipment functionality
  • ✓Confirm emergency equipment availability

During work

  • ✓Monitor load stability throughout movement
  • ✓Check for signs of skate dislodgement
  • ✓Verify team communication and coordination
  • ✓Monitor surface conditions for changes
  • ✓Watch for obstacles in movement path
  • ✓Check worker positioning and safety clearances
  • ✓Monitor weather conditions if outdoors
  • ✓Listen for unusual noises from equipment

After work

  • ✓Inspect skates for damage after use
  • ✓Check load for any movement or damage
  • ✓Document movement completion and any issues
  • ✓Clean and store equipment properly
  • ✓Report any incidents or near misses
  • ✓Update maintenance records
  • ✓Review procedures for improvement

Step-by-step work procedure

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

Field ready
1

Load Assessment and Planning

Conduct comprehensive assessment of the load and develop a detailed movement plan.

Safety considerations

Never underestimate load weight or stability - inaccurate assessment leads to catastrophic failure.

2

Equipment Selection and Inspection

Select appropriate skates and thoroughly inspect all equipment before positioning.

Safety considerations

Damaged equipment must be replaced - compromised skates can fail catastrophically.

3

Surface and Path Preparation

Prepare the movement surface and path to ensure safe, controlled movement.

Safety considerations

Uneven surfaces are the primary cause of load skate failures and serious incidents.

4

Load Positioning and Securing

Position skates under the load and secure equipment using proper techniques.

Safety considerations

Ensure load is evenly distributed and skates cannot dislodge during movement.

5

Team Briefing and Communication Setup

Brief all team members on procedures, assign roles, and establish communication protocols.

Safety considerations

Clear communication prevents conflicting actions that can cause loss of control.

6

Movement Execution

Execute the load movement with continuous monitoring and coordination.

Safety considerations

Stop immediately if any signs of instability or problems occur.

7

Load Recovery and Equipment Storage

Safely recover the load from skates and store equipment properly.

Safety considerations

Maintain stability during recovery to prevent final-moment accidents.

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Frequently asked questions

What are the most critical hazards when using load skates?

The most critical hazards are load toppling and crushing injuries, particularly when moving top-heavy equipment. Workers have been seriously injured or killed when heavy loads toppled, pinning them between the equipment and walls or structures. Always maintain safe clearances and never position workers where they could be crushed.

How do I determine the right skate capacity for my load?

Select skates with at least 25% more capacity than the load weight. For example, a 2 tonne load requires skates rated for at least 2.5 tonnes. Consider the load's center of gravity, distribution, and any dynamic forces during movement. Always err on the side of higher capacity rather than risking equipment failure.

What surface conditions are safe for load skate operations?

Load skates should only be used on solid, flat, smooth surfaces free from obstructions. Avoid uneven ground, debris, cables, trenches, or slopes. Cover cable pits and trenches with load-rated plates. Test the surface with the skates before loading to ensure smooth operation.

How many workers are needed for load skate operations?

The number depends on load size and weight, but a minimum of 3-4 workers is typically required: 2-3 for pushing/pulling, 1-2 spotters for guidance, and a supervisor. For loads over 5 tonnes, consider mechanical assistance or additional personnel. Ensure all workers are trained and can communicate effectively.

What should I do if a load becomes unstable during movement?

Stop all movement immediately using predetermined signals. Do not attempt to stabilize the load manually. Evacuate the area if the load appears likely to topple. Only trained personnel with appropriate equipment should attempt recovery. Report the incident and conduct a post-incident review.

Are there specific Australian standards for load skates?

Yes, AS 4991 provides requirements for lifting devices including skates and dollies. The standard covers design, testing, and safe use requirements. Additionally, WHS regulations require risk assessments and safe work procedures for manual handling of heavy loads using skates.

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Overview

Load skates, also known as machinery skates, roller dollies, or load movers, are wheeled devices used to manually or mechanically move heavy loads across construction sites. These tools consist of steel plates with rollers or wheels that support equipment during relocation, allowing smooth movement without lifting. Load skate operations are common in construction for positioning machinery, switchboards, generators, prefabricated components, and heavy equipment. The work involves assessing load characteristics, selecting appropriate skate capacity, preparing movement paths, positioning skates, and executing controlled movement. Construction environments present unique challenges including uneven ground, obstacles, overhead hazards, and proximity to workers or structures. Operations may involve multiple workers coordinating movements, using mechanical assistance, or implementing specialized techniques for top-heavy or unstable loads. Safety protocols must address load stability, surface conditions, communication requirements, and emergency response procedures. Equipment maintenance, inspection routines, and documentation of movements are essential components of professional load skate operations.

Why This SWMS Matters

Load skate operations present extreme safety risks due to the potential for catastrophic load failure and crushing injuries. Serious incidents have occurred where top-heavy equipment toppled during movement, crushing workers between loads and fixed structures. The Work Health and Safety Act 2011 requires PCBUs to identify hazards and implement control measures for heavy equipment movement, particularly when using manual handling methods. Load skates can fail catastrophically if skates dislodge on uneven surfaces, loads shift during movement, or equipment exceeds skate capacity. Construction sites compound these risks with uneven terrain, debris, confined spaces, and proximity to other workers. Without proper SWMS procedures, workers risk fatal crushing injuries from toppling loads, severe injuries from being pinned against structures, musculoskeletal injuries from manual pushing/pulling, and equipment damage from uncontrolled movements. Australian safety regulators have issued specific alerts about load skate hazards following serious incidents. This SWMS ensures systematic hazard identification, implementation of engineering controls like proper skate selection and surface preparation, administrative controls including training and supervision, and PPE requirements to prevent incidents while maintaining operational efficiency.

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Load Skate SWMS Sample

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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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