Worker fatally injured in split rim incident (18 October 2025)
SafeWork NSW has observed a rise in incidents involving split rim wheels. These wheels, which come in various sizes, can explode if the Original Equipment Manufacture’s (OEM) guidelines are not followed.
Workers and businesses are reminded to exercise extreme caution when checking or removing tyres, particularly those fitted with split rims. Incorrect handling can lead to catastrophic failures and serious injuries.
On 17 October 2025 during an inspection of a 60-tonne reach stacker, a defect was identified with the inner left wheel assembly. A tyre technician was engaged to attend site and repair the defect. While removing the outer wheel assembly to access the defective inner tyre, the outer tyre has exploded resulting in fatal injuries.
Safety information
Consider ‘reasonably practicable’ control measures to manage the risks associated with working with and around split rims.
Ensure:
- you always follow the OEM guidelines when performing maintenance or repair on plant
- tyres are deflated as the first step of inspection before removing it from the plant
- you do not inflate tyres beyond the maximum cold pressure recommendation by the manufacturer. his information should be available on the tyre and in the OEM maintenance guidelines and manual
- you use airlines fitted with adjustable pressure regulators to prevent exceeding maximum pressure
- you never use airlines that have no inline gauge to check tyre pressure
- you use a suitable tyre cage and restraints for the inflation of all types of wheel assemblies you always keep away from the sidewall (e.g. the flat area on either side of the rolling direction of the tyre) even when the wheel is restrained
- You maintain a safe distance during inflation by using a long air hose with at least 3 metres length after the gauge and trigger and a clip-on air check
- when inflating, once the bead is seated and sufficient air is in the tyre to hold pressure, leave for a period and leak check with leak solution before continuing to inflate the tyre to its recommended pressure
- tyres are inspected for any defects, this can include wavy tyre walls, side wall damage, delamination inside and outside, perishing on tyres more than five years old
- defective tyres are never used and are always thrown out immediately
- if a tyre has been overloaded, or the pressure has dropped below 80 percent, you remove the tyre from the rim and inspect it before refitting and inflating. Running with pressure below 80 percent can lead to fatigue failures, like zipper failure (a circumferential fracture of the side wall of the tyre)
- for dual-wheel assemblies, always use a pressure gauge to measure the pressure as it is hard to see if the pressure has dropped below 80 percent
- workers are reminded of the dangers of split rims by placing warning stickers above each tyre on your vehicles
- workers are adequately trained, always follow procedures and the appropriate number of workers are assigned to the task
- a safe work method statement (SWMS) is in place for changing split rims.
Related guidance material
- Code of practice - Managing the risks of plant in the workplace (PDF, 1987.96 KB)
- Tyres, compressed air and split rims information
- Split rims and compressed air, guidance material - Safe Work Australia
- General guide for split rims - Safe Work Australia
- Video Split rim wheels