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 recognise 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 objects or other machinery.
- Blind Spots: Operators often have limited visibility, increasing the risk of collisions.
- Unstable Loads: Poorly secured or shifting loads can fall, causing injuries or fatalities.
- Improper Maintenance: Equipment failures can lead to uncontrolled movements or accidents.
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 so it can be repaired or taken out of service.
Establish a Safe Work Zone:
- Use barricades, cones, or flagging to create a designated work area.
- Restrict unauthorised personnel from entering the zone.
Spotters and Communication:
- Always use trained spotters to guide operators in tight or busy areas.
- Use standardised hand signals and maintain clear communication via two-way radio if necessary.
Stay Alert in Equipment Blind Spots:
- Understand the blind spots for all equipment on-site and avoid standing or walking in those areas.
- Make eye contact with the operator before approaching equipment.
Follow Equipment Safety Rules:
- Never ride on equipment unless it is specifically designed for passengers.
- Wear high-visibility clothing so operators can see you at all times.
- Maintain a safe distance from swinging arms, buckets, or other moving parts.
Secure and Stabilise Loads:
- Ensure that all loads are properly secured and balanced.
- Use appropriate lifting and rigging equipment for handling heavy materials.
Be Aware of Ground Conditions:
- Check for soft or uneven ground that could cause equipment to tip over.
- Avoid working near trenches or edges unless properly shored or protected.
Real-Life Case or Scenario
A worker was struck by a reversing forklift because they entered a blind spot without alerting the operator. This could have been prevented with proper communication and adherence to the work zone protocol. Struck-by and caught-in incidents are avoidable if everyone follows safety procedures.
Employee Responsibilities
- Always stay aware of your surroundings when working near heavy equipment.
- Wear high-visibility clothing and use appropriate PPE.
- Follow all site rules for equipment operation and stay out of restricted zones.
- Immediately report unsafe conditions or faulty equipment to your supervisor.
Employer Responsibilities
- Provide regular training on heavy equipment safety for all workers.
- Ensure all machinery is inspected and maintained according to manufacturer and regulatory guidelines.
- Designate safe zones and provide clear signage around equipment operations.
- Provide spotters and enforce proper communication protocols on the job site.
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 adhering to safety protocols. Starting today, take a moment to assess the risks before entering work zones and use the proper safety measures every time.
Wrap-Up
Working safely around heavy equipment is critical for preventing injuries and saving lives. By following these practices, we can ensure that everyone on-site goes home safely at the end of the day. Thank you for your attention and dedication to safety.
Standards Overview
WorkSafe New Zealand provides guidance under the Health and Safety at Work Act 2015 (HSWA) for managing the risks of using heavy equipment.
This includes:
- Conducting risk assessments
- Providing proper training and supervision
- Ensuring plant and machinery are well-maintained and fit for purpose
- Keeping workers separated from operating equipment where possible
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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