Maintaining Safe Distances
The Problem
Maintaining safe distances is one of the most effective ways to prevent incidents, injuries, and fatalities on the worksite. When workers get too close to moving machinery, hazardous operations, or high-risk zones, the consequences can be severe. Today, we’ll address the importance of safe distances, highlight common hazards, and discuss practical solutions to ensure everyone stays safe.
Identify the Hazards
- Machinery operating too close to workers or structures
- Inadequate or poorly maintained barriers
- Poor communication between operators, spotters, and workers on the ground
- Unauthorised personnel entering exclusion zones
- Multiple activities occurring in close proximity
Safety Practices and Preventative Measures
Establish Clear Work Zones:
- Clearly define zones using barriers, signage, and lighting.
- Allocate zones for:
- Machinery operation
- Material handling and storage
- Pedestrian-only areas
- Vehicle access routes
- Machinery operation
- Establish and maintain exclusion zones around high-risk areas.
Barrier Requirements:
- Use solid barriers (e.g., concrete, fencing) for high-risk operations.
- Use soft barriers (e.g., cones, bunting, warning tape) for lower-risk activities.
- Ensure all barriers are:
- Highly visible and marked with appropriate signage
- Regularly inspected and maintained
- Fitted with reflective materials and lighting for night or low-light conditions
- Highly visible and marked with appropriate signage
Effective Communication Protocols:
- Implement clear communication methods:
- Standardised hand signals
- Two-way radios where verbal communication is not effective
- Standardised hand signals
- Ensure regular communication between spotters and operators
- Train workers in consistent communication protocols
Spotter Positioning:
- Assign spotters in:
- Machinery blind spots
- Busy pedestrian areas
- Areas requiring complex movements
- Machinery blind spots
- Spotters must:
- Wear high-vis clothing
- Maintain direct line of sight
- Use agreed-upon signals or communication devices
- Wear high-vis clothing
Emergency Procedures:
- Clearly define emergency assembly points and escape routes
- Maintain minimum safe distances during emergencies, such as:
- Machinery malfunction
- Contact with live services
- Fire or hazardous substance release
- Machinery malfunction
- Review and practise emergency procedures regularly
Traffic Management Measures:
- Implement a traffic management plan to:
- Separate vehicles and pedestrians
- Define vehicle accessways and work zones
- Enforce speed limits and signage requirements
- Maintain effective control measures where multiple machines operate nearby
- Separate vehicles and pedestrians
Real-Life Case or Scenario
On a recent construction site, a worker was seriously injured when they entered an active machinery zone without permission. The machine operator did not see the worker due to blind spots, and there were no barriers in place to restrict access. This could have been avoided with clear signage, effective barriers, and better communication protocols.
Employee Responsibilities
- Respect all exclusion zones and designated work areas
- Communicate clearly with machinery operators and spotters
- Use designated walkways and crossing points
- Report missing signage, damaged barriers, or unsafe conditions immediately
Employer Responsibilities
- Clearly define and mark all work zones and exclusion areas
- Provide and maintain visible signage and appropriate barriers
- Train workers on hazard identification, communication protocols, and traffic management
- Regularly inspect and maintain all safety systems
Discussion & Questions
- “Where on our site have you seen safe distances being ignored?”
- “How do we currently communicate with machine operators—what works well, and what doesn’t?”
- “What could we improve to better protect workers near machinery or moving vehicles?”
Commitment/Action Plan
Starting today, let’s all commit to recognising and respecting designated work zones. Before starting work, identify any ‘No-Go Zones’, confirm communication lines with operators, and report any concerns immediately. It’s everyone’s job to maintain safe distances.
Wrap-Up
Safe distances save lives. With proper planning, communication, and hazard awareness, we can protect each other and ensure everyone returns home safely. Thank you for taking safety seriously and putting these practices into action.
Standards Overview
WorkSafe New Zealand requires that effective separation is maintained between workers and machinery or vehicles, especially in high-risk areas such as near excavations, cranes, or live services.
Key regulations and guidance:
- Health and Safety at Work Act 2015
- WorkSafe NZ guidance on traffic management and mobile plant
- AS/NZS 3012 and relevant codes of practice for temporary works and safe distances
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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