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Nearly 1 of every 5 workplace fatalities occurs in the construction industry. It is increasingly important to create a culture of safety and reduce the risk of workplace accidents, and organizations that prioritize safety over speed and convenience can reduce danger for themselves and other crew members working onsite. 

One major construction jobsite hazard is operating and working around heavy equipment. OSHA has for operating heavy machinery and equipment. 

This article outlines common hazards and safety practices for operating heavy equipment safely in construction, including best operational procedures to avoid accidents or injuries. 

Common Safety Hazards with Heavy Equipment

Leaks

Leaks in heavy machinery can cause slips, trips and falls and could become a fire hazard. These machines often use flammable fuels, lubricants and hydraulic fluids, making them susceptible to catching fire in the presence of sparks, extreme heat or electrical faults. 

Collapsed Loads

A collapsed load occurs when a load being carried or transported by a piece of equipment collapses or becomes unstable, potentially leading to accidents and injuries. This can happen due to overloading, improper loading or inadequate securing of the load. 

Power Lines

Be aware of both overhead and underground power lines. In the case of working near power lines, contractors can request de-energization and grounding through the power company. Always assume power lines are energized and dangerous.

Struck-By-Instances and Blind Spots

Struck-by hazards include flying, falling, swinging or rolling objects.

Blind spots can cause workers to be struck or run over. It’s important to have a spotter who can keep the area clear and communicate with the equipment operator to avoid hazards occurring in blind spots.

Dangerous Surfaces

When loading and unloading equipment off the truck or trailer at the jobsite, avoid dangerous surfaces. Make sure loading and unloading takes place on level ground to avoid rollovers. Pay attention to uneven ground or inclines.

Cave-Ins and Trench Collapse

Be sure to have a worker who is trained on trench requirements, including the use of protective systems and soil classifications. They are responsible for identifying and eliminating any hazards before a worker enters the area and while work is ongoing. Any trench that is deeper than five feet needs to to prevent accidents.

Safety Protocols for Operating Heavy Equipment

Know the equipment.

Know the lifting loads and load capacity for each piece of equipment. Don’t overload or overwork the equipment. Don’t use the equipment for something it’s not intended for.

Provide equipment with rollover protective structure (ROPS). Top-loading vehicles should have cab shields and canopy protection.

Use the equipment properly.

Always wear a seat belt and maintain three points of contact (two feet and one hand, or two hands and one foot) when entering and exiting the equipment. This creates a stable, triangular base of support to reduce the likelihood of falling. Workers should never enter or exit equipment that is moving or in operation, and never carry anything with them as they enter or exit.

Make sure workers have completely shut off the equipment, engage the parking brake and release any pressure from hydraulic controls. In addition, they should be sure to take the keys with them to avoid any unauthorized use.

Increase lighting and visibility for night work. Stay aware of the conditions throughout the day and avoid working in high winds.

Conduct equipment checks.

Perform a visual inspection to make sure the equipment is in good working order. Check tires and treads and check all components for cracks or damage.

Routine safety checks should include checking fluid levels, filters, tire pressure and making sure all guards and shields are in place. Make sure all warning lights, gauges and alarms are functioning correctly. 

Employ a spotter.

Use a spotter who can use radio or hand signals to communicate with workers and operators to compensate for blind spots. The spotter should wear high-visibility clothing and stay visible to the operator at all times. 

Anyone in the vicinity of equipment while it's in use must make eye contact with and alert the operator — and absolutely make sure the operator sees them — before approaching a vehicle. Keep all non-essential workers out of the areas where heavy equipment is operating. Set up a limited-access zone and be aware of swing radius.

Wear personal protective equipment.

Personal Protective Equipment (PPE) can include gloves, safety glasses for eye protection, ear plugs or earmuffs for hearing protection, sturdy boots and hard hats. Workers should wear high-visibility clothing so they can be seen easily by others. Never wear loose clothing that can get caught in moving parts. Tie up long hair to keep it out of the way.

Pay attention.

Workers must stay mindful and be aware of their surroundings, paying attention to potential obstacles. Workers should always stop working if they are feeling tired or sick, and avoid overexertion. Never operate heavy equipment when on any medication that could cause drowsiness.

Best Practices for Operating Heavy Equipment Safely

For optimal heavy equipment operation, prioritize pre-planning, follow established safety procedures, maintain clear communication, implement effective control measures, adhere to safety rules and regulations and have robust emergency preparations. 

Complete all required trainings.  

Create and communicate safety policies and procedures to your team. Heavy equipment operators should engage in a training program that covers equipment handling, safety protocols and basic maintenance. Additionally, operators should attend refresher courses to keep up with any updates to safety protocols. 

Make sure the operating manual for all heavy equipment is available to the operator and anyone working on maintenance and repairs. Workers should be trained on the proper procedures to safely operate all pieces of equipment they will be working on and only trained workers should be allowed to operate equipment. Be sure to check for certifications when applicable.

Include safety during pre-planning.

Identify potential hazards like unstable ground and overhead hazards. Make sure all operators are properly trained and certified for the specific equipment they will be operating. Lastly, inspect all equipment before the job begins.

Create a robust training program and written safety procedures. Be sure to have operators review the safety procedures regularly.

Communicate clear expectations.

Establish clear communication protocols for different situations, such as emergencies or changes in work procedures. Another good practice is to use the 5-minute safety share, which is a short, 5-minute safety talk led by a supervisor or designated person, focusing on a specific safety topic. 

This quick update is intended to reinforce safety knowledge, address potential hazards and promote a positive safety culture. Topics may include potential hazards, near misses and how they could have been prevented as well as safety updates to reinforce safe work habits.

Establish control measures.

Be sure to implement engineering controls, such as barriers, warning lights and alarms, to minimize hazards. In addition, you’ll want to implement administrative controls, such as work permits, safety briefings and regular safety inspections.

Follow safety rules and regulations.

Be aware of and adhere to all standards for heavy equipment operation. Follow the manufacturer’s instructions for equipment operation and maintenance. Pay attention to and adhere to all site-specific rules and warning signs. You can also keep up with safety standards by regularly following industry news, attending trade shows and conferences, as well as keeping track of new technology.

Prepare for emergencies.

Develop and implement emergency procedures, including first aid protocols and clear reporting procedures for accidents, near misses and other safety incidents. 

Create a culture of safety.

Creating a construction safety culture starts with leadership commitment and also involves material resources, training, clear policies and open channels of communication.

When each employee has a responsibility for safety —whether completing a daily site inspection or analyzing safety performance data to predict future risks — everyone becomes part of the solution.

You may also want to consider joining for more ideas on how to promote a culture of safety.

In addition, º£½Ç´óÉñ also offers a Safety Qualified program to help construction professionals learn how to create a culture of safety. This program provides relevant and engaging courses that are both free and easy to share.

Go beyond OSHA regulations.

The º£½Ç´óÉñ Safety Qualified program provides construction professionals with everything they need to know to create a culture of safety.

Take the course

Emerging Trends and Technology

With so many advancements in equipment and construction technology, it can be hard to keep up. Here are a few heavy equipment operations innovations to be aware of.

• AI and Automation

  The integration of AI and automation is making fast strides. Manufacturers can design equipment with built-in safety features, including collision avoidance systems and alerts for dangerous operating conditions.

• Remote Operation and Autonomous Machinery

  This technology can be used for heavy machinery like cranes, diggers and forklifts, and increases safety and efficiency.

• Data Analytics and Predictive Maintenance

  Telematics, a blend of telecommunications and informatics, allows real-time monitoring of machinery and provides data to help with predictive maintenance.

• Internet of Things (IoT) and Automation

  Connected systems allow operators to monitor machinery remotely and may allow dangerous tasks to be carried out from a safe distance. There is an increase in the use of remote-controlled equipment, such as drones and excavators, which minimizes the need for operators to be physically present in hazardous environments. 

Additionally, safety can be improved with smart sensors, cameras and collision avoidance systems. Real-time alerts can kick off an automatic shutdown when unsafe conditions are detected.

Stay Vigilant and Alert for Safe Equipment Operation

When operating heavy equipment, emphasizing a proactive safety culture can transform potential hazards into manageable challenges. Team leaders should prioritize safety and operational procedures during the planning phase and make sure all communications are clear and stored in a place that is accessible by all parties. 

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