The injuries 35-year-old Ryan Freeman suffered after being hit by an exploding tractor tire at work were so extensive and devastating, “I’m not supposed to be alive to tell you about it,” he says. 

Ryan is the co-owner of OK Tire in Elmira, Ontario, where the incident occurred four years ago. Today, he leads what he calls a ‘new normal’ life. Pain is a constant companion, and he can no longer do some of his favourite activities. But the husband and father of three is grateful to ‘still be here.’

The explosion came as a profound shock to Ryan and co-owners Eric Brubacher and Robert Bowman. The business had prided itself on its health and safety practices, including training, procedures, and good housekeeping. “We thought we had everything in place,” says Ryan, “and it still happened.” So, what went wrong? 

Ryan shares his story and what OK Tire learned in the aftermath of the incident. The biggest lesson? “Health and safety doesn’t fall somewhere in the middle of a business’ priorities. It is the most important thing.”

WSPS Consultant Troy Nel shares that belief and has valuable tips for OK Tire and other companies in the Vehicle Service and Repair Sector on how to identify hidden risks. 

The incident and aftermath

An employee at OK Tire was putting air into a new tractor tire that was clamped into a tire changer. The tire exploded just as Ryan left his office and walked onto the shop floor. 

The rim of the tire shot towards Ryan, who threw up his arm and twisted away slightly to protect himself. The rim hit his entire left side and stomach. “My back, ribs, and leg were broken, and my arm was completely dismantled.” Surgeons removed his spleen and put numerous plates and screws into his back, arm and ribs. 

Ryan’s recovery was long and difficult. Remarkably, he returned to work full-time after seven months. “It was quite the journey, and I’m glad I’m on the other side of it now.” 

The Ministry investigation

After Ryan’s injury, co-owner Eric contacted the Ministry of Labour, Immigration, Training and Skills Development (MLISTD), secured the scene, and blocked off the area. He was also able to provide a video of the actual incident. These actions were praised by the MLITSD inspectors when they arrived. 

Eric explained the procedure for airing up tires, and the conclusions he’d reached about the immediate cause of the explosion. The shop had two types of gauges to measure air pressure in the tires: new auto inflation gauges, which shut off air when the appropriate pressure is reached; and older gauges, which do not shut off automatically. The employee who inflated the tire had used one of the old gauges. 

The inspectors noticed that the shop had inflation cages for smaller tires, but not for the big agricultural (tractor) tires. “We didn’t know that the bigger cages existed,” says Ryan. 

The shop made two ‘impactful ‘changes as a result of the ministry’s visit. “The old gauges are gone,” says Ryan. “We only use auto inflation gauges to air up tires now. We also purchased a safety inflation cage for ag tires.” 

Everyone at OK Tire also has a new level of safety consciousness. “Now, I tell my team, ‘Don’t rush and don’t skip steps. If you are not sure about something, ask someone. Don’t do it until you are confident.”

How to prevent incidents like this one 

WSPS' Troy Nel says tire explosions occur frequently in tire repair shops and organizations that have in-house vehicle maintenance. Ryan’s story illustrates the terrible impact they can have, and the importance of proactive prevention. 

He applauds the improvements that OK Tire has made with guidance from the MLITSD. “They now have engineering controls in place to ensure that if something goes wrong, people are protected.”

How do you identify the right controls before an incident occurs? “By carrying out a job hazard analysis, especially on high-risk work,” says Troy. This involves looking at the job, as well as the people, materials, equipment, process and working environment, to identify risks.”  

Job Hazard Analysis

A job hazard analysis (JHA) is a systematic process used to identify, evaluate, and control potential hazards associated with specific job tasks. “Observe the work as it’s carried out and consult with workers performing the task as you go through this process,” notes Troy. 

Here are the steps involved in a job hazard analysis:

•  Select and prioritize jobs to analyze. “Start with those that you know have the highest risk,” says Troy.
• Break down each job into a series of specific, sequential tasks. For example, if the job is to fill a tire with air, the tasks might be to:
  1. take the tire off the vehicle
  2. move the wheel to the tire changer machine and connect it 
  3. inflate the tire
  4. put the tire back on the vehicle. 
• Identify potential hazards and controls associated with each step. If we look at step 1 in the example above, says Troy, we could ask questions such as: “What could happen if the car is not jacked up and secured properly? It could fall. What impact is there from lifting a heavy tire? The worker could develop a musculoskeletal disorder (MSD). What can happen when a worker removes a lug nut with a power tool? It could produce flying debris that could injure workers or bystanders.” 
  After identifying the hazards in each task and determining their risk level, consider how the hazard could be prevented or controlled. “For example, to ensure the vehicle is secured properly, first identify vehicle lift points and check for structural integrity. When lifting a vehicle, only raise it a few inches, then perform a test to ensure it is secured before fully raising the vehicle,” says Troy.
• Consider factors involving people, the equipment, materials, environment, and process (PEMEP) that could increase risks. For example: 
  
  • People: “Are they trained? Are they following procedures? Are they wearing protective equipment, if required? Are they rushing?”
  • Equipment: “Do employees have access to the proper equipment? Are you maintaining the equipment?
  • Materials: “Can materials inflict injuries because they are sharp or hot, or have the potential to explode?
  • Environment: “Are hazardous activities occurring in an area that bystanders can access?”
  • Process: “Is there an established process that encompasses the training, the equipment, the materials, the layout, etc.”
•  Describe each hazard. List the causes, the affected individuals, the potential consequences, and the contributing factors.
• Select, install, maintain, and review control measures using the hierarchy of controls. Controls include: eliminating the risk, putting in engineering controls, administrative controls (such as changing up the task and providing training), and personal protective equipment. “Prioritize elimination and engineering controls,” says Troy. 

How WSPS can help 

WSPS consultants can conduct a walkthrough of your workplaces to help identify risks associated with tire repair and servicing. Connect with a consultant today. 

Training

• Hazard and Risk: Identify, Assess, Control and Evaluate (3 hours, eCourse) 
• Musculoskeletal Disorders Prevention Awareness (Free, 1 hour, eCourse)

Resources 

• Hazard Assessment Template
• Auto Manufacturing Risk Assessment Results

Canadian Centre for Occupational Health and Safety (CCOHS) Resources

• Tire Precautions
• Single-piece Rim Wheels
• Servicing Split Rim Wheels
• Garages - Inflating Tires on Wheels with Split Rims or Rims using Retainer Rings
• Job Safety Analysis

The information in this article is accurate as of its publication date.