Falls from Elevated Decks During Loading and Unloading
HighCar carrier operators must access upper deck levels up to 3 metres above ground to drive vehicles onto elevated platforms, secure loads, and remove restraints during unloading. Upper deck access typically involves walking on narrow deck surfaces with vehicle width clearances of only 200-300mm either side, creating fall exposure when moving between vehicles or accessing deck edges. Many car carriers have minimal edge protection on upper decks to allow vehicle access, leaving workers exposed to unprotected edges during vehicle positioning and load securing activities. The risk is heightened during wet weather when deck surfaces become slippery, during high-wind conditions affecting stability, when working in poor lighting during early morning or evening deliveries, and when operators are fatigued during extended delivery sequences. Additional fall hazards exist when operators must lean over deck edges to attach or release restraint straps, access ramp controls located near unprotected edges, or position wheel chocks requiring bending near deck perimeters. Unlike fixed work platforms with engineered fall protection systems, car carrier decks are mobile equipment with operational requirements limiting the extent of permanent edge protection that can be installed.
Consequence: Falls from upper deck levels can result in critical head and spinal injuries, multiple fractures, permanent disability, or death. Even falls from lower deck heights can cause serious injuries when landing on hard surfaces or striking vehicle components or carrier structures during the fall.
Vehicle Collision and Crushing During Loading Operations
HighLoading vehicles onto car carrier decks requires driving vehicles up steep ramps and positioning them on narrow deck surfaces with minimal clearance to carrier rails and adjacent vehicles. Operators can be crushed between vehicles and carrier structures when attempting to guide vehicles during parking, when standing in the confined space between vehicles to access securing points, or when vehicles roll unexpectedly due to inadequate parking brake application or transmission engagement. The precision required for vehicle positioning means operators often work immediately adjacent to moving vehicles, with limited escape routes if vehicles deviate from intended paths. Visibility challenges for drivers accessing upper decks via steep ramps can result in vehicles striking carrier structures or operators positioned on decks. New or unfamiliar vehicles with different handling characteristics, steering angles, or brake performance may behave unpredictably during the loading process. Ground-level personnel guiding vehicles during loading can be struck by vehicles if communication with drivers is inadequate or if drivers misjudge vehicle position. The sequential nature of loading, where some vehicles must be loaded before others can access their positions, creates situations where operators work in close proximity to multiple vehicle movements.
Consequence: Crushing injuries causing severe trauma to limbs, torso, or head, potentially resulting in permanent disability or death. Vehicle collision with carrier structures can cause significant equipment damage and project delays whilst alternative transport is arranged.
Hydraulic Ramp Failure and Deck Collapse
HighCar carrier upper deck access depends on hydraulically operated ramps that extend and retract to allow vehicle loading and then secure in travel position. Hydraulic system failures including cylinder seal failures, hose ruptures, control valve malfunctions, or loss of hydraulic pressure can cause sudden ramp collapse during loading operations, potentially crushing operators positioned beneath ramps, causing vehicles on ramps to slide or tip, or trapping personnel between ramp sections and carrier structures. Hydraulic components deteriorate through normal wear, exposure to weather and road contaminants, and metal fatigue from thousands of operation cycles. Overloading ramps beyond their design capacity by attempting to load excessively heavy vehicles can exceed structural limits causing collapse. Inadequate maintenance including failure to replace worn hydraulic seals, insufficient hydraulic fluid levels, or damaged hydraulic hoses increases failure risk. Operator error including activating ramp controls while personnel are in hazardous positions, attempting ramp operation on sloping ground creating uneven loading, or failing to verify ramp locking mechanisms are engaged before driving vehicles onto ramps all contribute to collapse incidents. Cold weather affects hydraulic fluid viscosity reducing system effectiveness, whilst hot weather can cause hydraulic fluid expansion and pressure increases.
Consequence: Sudden ramp collapse can crush operators positioned beneath, cause vehicles to slide from carrier with potential for serious impact injuries, trap workers between moving ramp sections, and result in catastrophic equipment damage requiring extensive repairs and investigation.
Load Restraint Inadequacy Causing Vehicle Movement
HighEach vehicle loaded on a car carrier must be individually secured using wheel straps, chocks, and restraint systems to prevent movement during transport. Inadequate restraint can result from using insufficient number of restraints for vehicle weight, incorrect strap tension failing to prevent vehicle shifting, worn or damaged straps with reduced capacity, improper attachment points creating ineffective restraint geometry, failure to engage parking brakes or place transmissions in park, or incorrect wheel chock positioning. The variety of vehicle types transported means restraint requirements vary significantly - light passenger vehicles require different securing methods than heavy four-wheel drives or small plant equipment. Time pressure during loading sequences may result in operators rushing restraint procedures or failing to verify each securing point. Vibration and movement during transport can cause straps to loosen if initial tension was inadequate. Different deck levels experience different acceleration forces during cornering and braking, requiring load-position-specific restraint approaches. If vehicles shift during transport, the carrier's centre of gravity changes potentially leading to vehicle instability or rollover, whilst shifted vehicles may damage adjacent vehicles, contact carrier structures, or completely break free from restraints creating uncontrolled loose loads.
Consequence: Vehicle movement during transport can cause carrier rollover with potential for serious injuries or death to the operator, damage to transported vehicles, collision with other road users if vehicles break free from restraints, and prosecution under Chain of Responsibility legislation for inadequate load restraint.
Struck by Hydraulic Ramp During Deployment or Retraction
MediumHydraulic ramps on car carriers extend outward and downward during deployment and retract upward during securing for transport. Personnel positioned in the path of moving ramps can be struck causing impact injuries, crushing against carrier structures, or pinching between ramp sections and deck surfaces. Ramp control systems may be located in positions requiring operators to stand near moving ramps during activation, creating struck-by hazards if operators misjudge clearances or if ramps move faster than anticipated. Some car carrier configurations have multiple ramps operating simultaneously during deployment sequences, requiring operators to monitor several moving components whilst managing other tasks. Wind loading can cause ramps to swing during deployment in high-wind conditions, creating unpredictable movement paths. Bystanders unfamiliar with car carrier operations including construction site personnel or members of the public may approach the vehicle during ramp operation without awareness of moving components. Failed or worn hydraulic control valves may cause jerky or unexpected ramp movement rather than smooth controlled extension. Visual and audible warnings of ramp movement may be inadequate for alerting all personnel in the vicinity, particularly in noisy construction environments or when multiple vehicles and equipment are operating nearby.
Consequence: Impact injuries from moving ramps including fractures, crushing injuries, and soft tissue damage. Pinching between ramp sections can cause severe hand and finger injuries. Bystanders struck by ramps may suffer serious injuries and create legal liability for the carrier operator.
Visibility Restrictions and Reversing Incidents
MediumCar carriers are large multi-deck vehicles with significant blind spots around the rear and sides due to vehicle dimensions, loaded vehicles obstructing vision, and elevated deck structures blocking sight lines. When reversing to position the carrier for loading or unloading, or when manoeuvring in confined construction sites, operators have limited visibility of pedestrians, other vehicles, structures, and obstacles. Construction sites often have constantly changing layouts with materials, equipment, and workers moving through areas, creating dynamic hazards that may not be visible from the carrier cab. Reversing alarms and warning lights may not be sufficient to alert distracted workers or pedestrians wearing hearing protection in noisy environments. Site access routes may be narrow with minimal clearance to excavations, building edges, or other structures, requiring precise manoeuvring with limited visual reference points. Operators unfamiliar with specific site layouts must reverse based on spotter directions, requiring clear communication and mutual understanding of signals. Dust, poor weather, or inadequate site lighting further reduces visibility. The loaded height of car carriers may result in striking overhead structures including building elements, power lines, or tree branches during manoeuvring operations.
Consequence: Reversing incidents can result in pedestrians or workers being struck and crushed, collision damage to construction site structures or other vehicles, contact with overhead power lines creating electrocution risk, and vehicle rollover if edges of excavations or embankments are not identified during reversing.
