Falls are a major cause of death and serious injury in Australian workplaces.

Most people who are seriously injured or killed, fall from a height of four metres or less.

In the transport industry, workers engaged in loading/unloading and maintenance tasks are placed at risk if working from the tray or trailer, including climbing over or around loads.

Certain work tasks introduce fall from height hazards and require risk management. Examples include:

• entering and exiting the cabin
• loading or unloading goods or livestock
• arranging and restraining loads
• checking the load at a loading bay or en route to the destination
• tarping or un-tarping
• undertaking maintenance.

Several businesses and workers may be involved in loading and unloading freight, such as:

• the transport operator
• the business operating the workplace where freight is being loaded/unloaded
• the business(es) controlling mobile plant at the workplace.

Under the work health and safety laws, each business shares responsibility for the health and safety of those involved in the work, to the extent of their capacity to influence and control the work.

Everyone must work together to ensure the risks associated with working at heights are eliminated, or if this is not possible, minimised.

Legal obligations

There are specific laws about working safely at heights: See sections 78 – 80 of the Work Health and Safety Regulation 2025.

There are also general work health and safety laws that will apply to you in any situation, including when working at heights.

Read the Code of practice – Managing the risk of falls at workplaces or the simple safety tips for working at heights fact sheet to learn more.

Plan the work

Whether it’s a routine task or a one-off job, you and your workers should stop and plan the work to eliminate or control the risk of a fall.

Wherever possible, perform the work from ground level.

When planning the work, look for alternatives that eliminate or minimise working at height.

Hazards and risk controls

If the need to work from a height cannot be eliminated, you must manage the risk of a fall.

Use measures to prevent a fall, such as:

• cabin access equipment e.g. handrails, steps
• reduce the risk of injury when accessing or exiting the cabin by:
  • training drivers to maintain three points of contact and face the cabin when climbing in and out
  • keeping soles clean and replacing footwear when the tread is worn (consider lace-up boots, as they provide better ankle support)
  • parking in well-lit areas, with an even surface
  • placing handrails/handles on both sides of the cabin opening
  • installing, maintaining and when necessary replacing non-slip surfaces on steps
  • ensuring steps and handrails are within easy reach
  • ensuring steps have consistent dimensions e.g. same distance apart, same treads
  • installing lights in steps to aid visibility.

You must consult with your workers when:

• identifying hazards and assessing risks
• deciding how to eliminate or minimise risks
• proposing changes that may affect their health and safety.

Listen to your workers' views on how to safely perform the work and draw on their experience and ideas.

^{Truck steps with dual handrails installed.}

^{Cab lighting to illuminate entry/exit point.}

^{Decal on cab showing 3 points of contact required.}

Access to and from vehicles

To reduce the height at which drivers need to access a load and to allow access to anchor points, some trucks are fitted with retractable or foldaway steps.

They reduce the risk of sprains, strains and falls at lower levels.

Portable step platforms are also available for use.

^{Retractable steps to access a tray.}

^{Truck access solution.}

Work on the ground or with a safety solution

Wherever possible, enable your workers to work from the ground as this is the best way to prevent falls from height.

• Provide suitable equipment to load and unload from the ground
• Pre-configure the load to suit the equipment
• Pre-sling the load where possible
• Use load restraints that enable access from the ground or use aids such as a lead rope or pole to assist reaching loads.

If unable to work from the ground, then a safe way to access and work on the trailer must be provided. This can include safety equipment such as guard rails, work platforms, retractable ladders or steps with handrails.

Many vehicles today have been designed or modified so that drivers do not have to work at heights. For example, some fuel trucks and bulk-liquid tankers have valves, fittings and hoses located so that filling and dispensing can be carried out from ground level. Many tip trucks and trailers are now fitted with tarping systems that are operated from ground level. Tarping of general cargo can also be undertaken from ground level by using tarping gantries or tarp spreaders mounted on a forklift.

^{Automated tarp controlled from cab.}

Use a fall prevention device

If working at height is unavoidable, you need to manage the risk of a fall. A fall prevention device is best because it will prevent your workers from falling. Examples include temporary work platforms and guard rails installed on vehicles.

Some guard railing designs can fold flat until required.

^{Pneumatic guard railing installed on tanker.}

^{Mobile truck access platform.}

Work-positioning systems

Work-positioning systems with harnesses are common. Some workplaces have installed overhead frameworks that provide anchor points or cables, to which the fall protection device is attached before accessing the tops of vehicles.

These structures are very effective but only if drivers and workers are trained in these systems.

Anchor points or cables in the containers or on the trailer are also popular. They allow drivers to clip a harness on and undertake inspections of their load with reduced risk of falling to the ground. Some are work-positioning systems, others are only fall arrest systems.

Work-positioning systems, such as travel-restraint systems, are preferred as they substantially reduce the risk of a fall by not allowing the person to move beyond a designated point.

Fall arrest system

A fall arrest system restricts the distance a person can fall but does not prevent the fall.

Only use a fall arrest system if a work-positioning system, guard rail or elevated work platform is not practicable – and only if a person can be rescued immediately.

If a fall occurs, a person using a fall arrest system could suffer suspension intolerance from being suspended in a harness. Workers must be provided information training and instruction in relation to the use of these systems and related equipment.

^{Fall arrest system.}

Emergency and rescue procedures

Whenever there are risks from working at height, emergency procedures must be established, and first aid equipment provided.

Typical injuries from falls can include unconsciousness, blocked airway, impalement, serious head or abdominal injuries and fractures.

The procedures must be tested so they are effective. Workers must be provided with suitable and adequate information, instruction and training in relation to the emergency procedures.

Emergency and rescue may be more straightforward at a fixed location such as a depot or loading facility, but can be difficult if the driver has stopped on the side of the road. In this instance, procedures should be in place so that, where possible, the driver stops at a location with other people in attendance, to assist in case of fall. All drivers should have accessto a mobile phone, a pager, or some other device or procedure for alerting emergency services (or someone) when help is needed.

Working at height – key points

• Plan loading and unloading work activities to avoid the need to work at height on the vehicle.
• Provide safe and secure access to loads.
• Look for good, well-designed access when buying vehicles.
• Retro-fit equipment on existing fleet if necessary and practicable.
• Provide protective equipment such as slip-resistant safety footwear.
• Keep vehicles and equipment in good working order.
• Inspection and maintenance of equipment (e.g. harnesses) must be undertaken by a competent person in line with the manufacturer’s recommendations.
• Equipment must be within service date and inspected prior to use.
• Respond to ideas from workers for preventing falls from vehicles.
• Ensure supervisors check how workers are getting on and off vehicles.
• Harness-based systems should only be used where a fall prevention device is not reasonably practicable.