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Working Safely Around Heavy Equipment

Caught In Between | OSHA Fatal Four

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 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.
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  • Improper Maintenance: Equipment failures can lead to uncontrolled movements or accidents.

Safety Practices and Preventative Measures

  1. Equipment Inspections:

    • Inspect heavy machinery before use, checking for leaks, worn parts, or malfunctioning systems.
    • Report and tag defective equipment immediately for repair.
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  2. Establish a Safe Work Zone:

    • Use barricades, cones, or flagging to create a designated work area.
    • Restrict unauthorized personnel from entering the zone.
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  3. Spotters and Communication:

    • Always use trained spotters to guide operators in tight or busy areas.
    • Use standardized hand signals and maintain clear communication via radio if necessary.
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  4. 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.
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  5. Follow Equipment Safety Rules:

    • Never ride on equipment unless it is designed for passengers.
    • Wear high-visibility clothing to ensure operators can see you.
    • Maintain a safe distance from swinging arms, buckets, or other moving parts.
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  6. Secure and Stabilize Loads:

    • Ensure that all loads are properly secured and balanced.
    • Use appropriate rigging equipment for lifting and moving heavy materials.
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  7. Be Aware of Ground Conditions:

    • Check for soft or uneven ground that could cause equipment to tip over.
    • Avoid working near trenches or edges without proper supports.

Real-Life Case or Scenario

Where possible, use an actual incident that you have experienced or been involved in.

E.g. In a recent incident, 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 equipment to your supervisor.

Employer Responsibilities

  • Provide regular training on heavy equipment safety for all workers.
  • Ensure all machinery is inspected and maintained regularly.
  • 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 employees to share experiences or safety tips related to heavy equipment.

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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

  • OSHA Standard 1926.600 outlines requirements for heavy equipment safety, including inspections, operator training, and safety protocols.
  • OSHA emphasizes the use of spotters, proper signaling, and equipment inspections to prevent injuries.
OSHA Occupational Safety and Health Administration

Legal Disclaimer

This toolbox talk is provided for informational and educational purposes only. It is not intended to be a substitute for professional legal, safety, or regulatory advice. The information presented is based on best practices and general industry standards but may not apply to all workplace situations.
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It is the responsibility of the employer, supervisors, and workers to ensure compliance with applicable federal, state, and local laws, regulations, and standards. The authors, presenters, and distributors of this toolbox talk assume no liability for the use or application of the information provided.
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Participants are encouraged to consult appropriate legal, safety, or regulatory professionals to address specific concerns or questions. Always follow your organization's policies and procedures for workplace safety and hazard mitigation.

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