Awareness Around Heavy Equipment Operations
The Problem
Heavy equipment is essential on many construction sites, but it also poses significant hazards if not operated or approached safely. Every year, workers are injured or killed due to incidents involving heavy machinery. These accidents often result from blind spots, poor communication, or workers entering restricted zones. Today, we’ll cover how to stay safe around heavy equipment by recognising the hazards and following safe work practices.
Identify the Hazards
- Blind Spots: Operators may not see workers behind or beside the machine.
- Struck-by Incidents: Workers can be hit by moving equipment, swinging booms, or falling loads.
- Pinch Points: Being caught between moving parts or between machinery and fixed structures.
- Unstable Loads: Loads that are not properly secured may fall or shift unexpectedly.
- Operator Error: Fatigue, distractions, or insufficient training can lead to incidents.
Safety Practices and Preventative Measures
Stay Clear of Operating Zones
- Always keep a safe distance from working machinery.
- Do not approach operating equipment unless you've made clear eye contact with the operator.
Know the Blind Spots
- Familiarise yourself with the blind spots on each type of equipment.
- Avoid standing or walking in areas where visibility is restricted.
Use Spotters and Communication
- Use trained spotters when visibility is limited or operations are complex.
- Agree on clear hand signals or use two-way radios for effective communication.
Mind the Swing Radius
- Stay outside the swing area of excavators, cranes, or similar equipment to avoid being struck.
Pre-Use Equipment Inspections
- Operators must carry out daily pre-start checks.
- Confirm that warning devices (such as reverse alarms) and mirrors or cameras are functional.
Wear High-Visibility PPE
- All workers in areas with operating equipment must wear high-visibility clothing as per AS/NZS 4602.1.
Follow the Site Traffic Management Plan
- Stick to designated walkways and pedestrian zones.
- Obey all site-specific traffic signage and controls.
Stay Focused
- Avoid using mobile phones, earbuds, or anything that diverts your attention near heavy equipment.
Real-Life Case or Scenario
On a recent job, a worker was seriously injured after walking behind a reversing loader. The operator, unaware of the worker’s presence, backed up into them. The reverse alarm was not functioning, and the worker hadn’t made eye contact. This incident could have been prevented through proper communication and a functioning safety check.
Employee Responsibilities
- Maintain situational awareness at all times around heavy equipment.
- Stay in designated pedestrian zones and avoid restricted areas.
- Wear your high-vis PPE and follow site safety instructions.
- Communicate with operators or spotters before entering any equipment work zone.
Employer Responsibilities
- Provide and maintain machinery with working safety systems like alarms, cameras, and mirrors.
- Train workers and operators on communication protocols and hazard zones.
- Develop and implement traffic management plans in line with WorkSafe NZ’s Good Practice Guidelines.
- Ensure all spotters and operators are trained and competent.
Discussion & Questions
- "What are the biggest challenges you’ve faced while working near heavy equipment?"
- "Has anyone experienced a near-miss? What could have been done differently?"
Encourage workers to share their experiences and suggestions.
Commitment/Action Plan
Starting today, let’s commit to staying alert and communicating clearly around heavy machinery. Always follow traffic control measures, wear high-vis gear, and check in with the operator or spotter before entering equipment work zones.
Wrap-Up
Heavy equipment is critical to the job, but it brings serious risks if not respected. By staying alert and following safety protocols, we can keep ourselves and our workmates safe. Thanks for your commitment to safety.
Standards Overview
- Under the Health and Safety at Work Act 2015, all PCBU’s (Persons Conducting a Business or Undertaking) must ensure the health and safety of workers while operating or working around machinery.
- WorkSafe NZ’s Good Practice Guidelines for Mobile Elevating Work Platforms and Traffic Management Plans outline key practices for controlling risks associated with heavy equipment.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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