Working Safely Around Heavy Equipment
The Problem
Heavy equipment is essential for getting the job done on most worksites, but it also poses significant risks. Struck-by and caught-in/between incidents involving heavy equipment are among the leading causes of workplace injuries and fatalities. Today, we’ll discuss how to recognize these hazards and follow safe practices to prevent accidents around heavy machinery.
Identify the Hazards
- Struck-by Incidents: Workers can be struck by moving equipment, swinging parts, or falling loads
- Caught-in/Between Incidents: Workers can become trapped between equipment and fixed structures or other machinery
- Blind Spots: Operators often have limited visibility, increasing the risk of collisions with people or objects
- Unstable Loads: Poorly secured or shifting loads can fall, leading to serious injuries or fatalities
- Improper Maintenance: Equipment failures may result in uncontrolled movements or operational hazards
Safety Practices and Preventative Measures
Equipment Inspections
- Inspect heavy machinery before use, checking for leaks, worn parts, or malfunctioning systems
- Report and tag defective equipment immediately to ensure it is repaired or taken out of service
Establish a Safe Work Zone
- Use barricades, cones, or flagging to clearly define a designated work area
- Restrict unauthorised personnel from entering the zone
Spotters and Communication
- Always use trained spotters to guide operators in tight or high-traffic areas
- Use standardised hand signals and maintain clear communication, such as two-way radios, when needed
Stay Alert in Equipment Blind Spots
- Know the blind spots for all equipment on-site and avoid entering those zones
- Make eye contact with the operator before approaching any equipment
Follow Equipment Safety Rules
- Never ride on equipment unless it is specifically designed for passengers
- Wear high-visibility clothing so that operators can easily see you
- Maintain a safe distance from swinging arms, buckets, or other moving parts
Secure and Stabilise Loads
- Ensure all loads are properly secured and evenly balanced
- Use appropriate lifting and rigging equipment for moving heavy materials
Be Aware of Ground Conditions
- Inspect the ground for soft, uneven, or unstable surfaces that could cause equipment to tip
- Avoid working near trenches or edges unless they are properly shored or protected
Real-Life Case or Scenario
A worker was struck by a reversing forklift after entering the operator’s blind spot without making their presence known. This incident could have been prevented through proper communication and by following established work zone protocols. Struck-by and caught-in/between incidents are avoidable when all workers follow site safety procedures and remain aware of equipment hazards.
Employee Responsibilities
- Always stay aware of your surroundings when working near heavy equipment
- Wear high-visibility clothing and use the appropriate personal protective equipment (PPE)
- Follow all site rules for equipment operation and stay out of restricted zones
- Immediately report any unsafe conditions or faulty equipment to your supervisor
Employer Responsibilities
Discussion & Questions
- “What hazards have you encountered while working around heavy equipment?”
- “How can we improve communication between operators and ground personnel?”
Encourage team members to share experiences or safety tips related to heavy equipment.
Commitment/Action Plan
Let’s commit to staying vigilant around heavy equipment, maintaining clear communication, and following all safety protocols. Starting today, take a moment to assess the risks before entering any work zone—and always use the proper safety measures to protect yourself and those around you.
Wrap-Up
Working safely around heavy equipment is critical for preventing injuries and saving lives. By following these practices, we help ensure that everyone on-site goes home safely at the end of the day. Thank you for your attention and continued commitment to safety.
Standards Overview
The Canadian Centre for Occupational Health and Safety (CCOHS), along with provincial and territorial safety authorities, provides guidance for managing the risks associated with using heavy equipment. This includes:
- Conducting thorough risk assessments
- Providing proper training and supervision for equipment operators
- Ensuring machinery and equipment are well-maintained and fit for purpose
- Keeping workers physically separated from operating equipment wherever possible
Disclaimer
“The information provided in this toolbox talk is intended for informational and educational purposes only. It is not a substitute for professional legal, safety, or regulatory advice. The content reflects general best practices and industry standards but may not be applicable to all workplace environments or jurisdictions.
It is the responsibility of employers, supervisors, and workers to ensure compliance with applicable federal, provincial, and territorial laws, regulations, and standards, including but not limited to those set by the Canadian Centre for Occupational Health and Safety (CCOHS) and relevant provincial occupational health and safety authorities. Site App Pro, its affiliates, agents, or representatives—as well as the authors, presenters, and distributors of this toolbox talk—assume no liability for the use or application of the information provided.
Participants are strongly encouraged to consult appropriate legal, safety, or regulatory professionals regarding specific workplace concerns or questions. Always adhere to your organisation’s policies and procedures for health and safety and hazard management.
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