Motor Vehicles and Mechanized Equipment Safety

Types of Construction Vehicles and Equipment

Heavy Equipment

• Bulldozers
• Excavators
• Backhoes
• Loaders
• Graders
• Scrapers
• Compactors
• Trenchers

Lifting and Material Handling Equipment

• Cranes (mobile and tower)
• Forklifts
• Aerial lifts
• Concrete pumps
• Hoists
• Conveyors
• Material handlers

Transport Vehicles

• Dump trucks
• Concrete trucks
• Delivery trucks
• Pickup trucks
• Flatbed trucks
• Utility vehicles
• Water trucks

Specialty Equipment

• Pavement equipment (pavers, rollers)
• Drilling equipment
• Pile driving equipment
• Concrete placing equipment
• Demolition equipment
• Earth-moving equipment
• Compressors and generators

Common Hazards and Accidents

Struck-By Hazards

• Equipment in motion striking workers
• Backing vehicles
• Swinging loads or booms
• Tipping or overturning equipment
• Flying materials from equipment operation
• Falling loads
• Parts of equipment extending into traffic lanes

Caught-In/Between Hazards

• Unguarded moving parts
• Pinch points
• Equipment rollovers
• Between equipment and fixed objects
• In rotating equipment
• During coupling/uncoupling operations

Electrical Hazards

• Contact with overhead power lines
• Underground utilities
• Damaged cords or equipment
• Improper grounding
• Lightning strikes to equipment
• Energized equipment components

Other Hazards

• Falls while mounting/dismounting equipment
• Noise exposure
• Whole-body vibration
• Exhaust emissions
• Hydraulic system failures
• Fires and explosions
• Overloaded equipment

Pre-Operation Safety

Equipment Inspection

• Walk around entire vehicle before operation
• Check fluid levels (fuel, oil, coolant, hydraulic)
• Inspect tires or tracks for damage and proper inflation
• Test service brakes, parking brakes, and steering
• Ensure all lights, signals, and alarms function
• Check mirrors for proper adjustment
• Inspect safety devices (seat belts, ROPS, etc.)
• Clear windows and mirrors for visibility

Operator Qualifications

• Proper training for specific equipment
• Valid license or certification if required
• Medical clearance if required
• Knowledge of equipment capabilities and limitations
• Familiarity with manufacturer's operating manual
• Understanding of site-specific hazards
• Regular refresher training
• Competency verification

Work Zone Planning

• Identify and mark utilities
• Establish traffic control patterns
• Designate equipment-only zones
• Create pedestrian-free zones
• Plan access and egress routes
• Post speed limits
• Identify hazards (power lines, excavations, etc.)
• Communicate plan to all workers

Safe Operation Practices

General Operating Rules

• Wear seat belt at all times when provided
• Never operate while impaired or fatigued
• No passengers unless equipment is designed for them
• Keep loads stable and within capacity
• Maintain safe speeds for conditions
• Lower all hydraulic attachments when not in use
• Never leave running equipment unattended
• Park on level ground when possible

Mounting and Dismounting

• Use three-point contact (two hands, one foot or two feet, one hand)
• Face the equipment when mounting/dismounting
• Never jump from equipment
• Use steps and handholds provided
• Check for slippery surfaces
• Never mount/dismount moving equipment
• Keep steps clear of mud and debris
• Use fall protection when required

Visibility and Communication

• Check blind spots before moving
• Use spotters when visibility is limited
• Maintain visual contact with workers on foot
• Use standardized hand signals
• Verify radio communication before depending on it
• Make eye contact before approaching equipment
• Use horns or alarms when starting movement
• Keep windows and mirrors clean

Working on Slopes

• Follow manufacturer's slope limitations
• Keep loads low when on slopes
• Travel straight up and down slopes when possible
• Turn on level ground when possible
• Use wheel chocks when parking on slopes
• Never work on slopes exceeding equipment's capability
• Be aware of changing conditions affecting stability
• Use appropriate ground engagement tools

Traffic Management and Control

Internal Traffic Control Plans

• Designate vehicle-only areas
• Create worker-free zones
• Establish one-way traffic patterns when possible
• Separate vehicles from workers on foot
• Provide pedestrian crossings at safe locations
• Use physical barriers when needed
• Clear signage for traffic patterns
• Regular review and updates

Flaggers and Spotters

• Proper training and certification
• High-visibility clothing (Class 2 or 3)
• Clear line of sight with operators
• Standard signals understood by all
• Safe position away from equipment
• Communication devices when needed
• Relief during extended operations
• Authority to stop operations for safety

Backing Procedures

• Back only when necessary
• Use spotters for limited visibility
• Check behind before backing
• Back slowly with horn or alarm
• Maintain visual contact with spotter
• Stop immediately if spotter is lost from view
• Use cameras or proximity detection when available
• No backing without clear visibility or assistance

Equipment-Specific Safety

Mobile Cranes

• Level outriggers on stable ground
• Inspect all rigging before lifts
• Check for overhead power lines
• Follow load chart restrictions
• Barricade swing radius
• Prohibit workers under suspended loads
• Use tag lines to control loads
• Conduct pre-lift meetings for critical lifts

Excavators and Backhoes

• Call for utility locations before digging
• Keep stability with proper positioning
• Know maximum reach limitations
• Watch for overhead hazards
• Maintain safe distance from excavation edges
• Never swing loads over workers
• Lower bucket when not in use
• Use outriggers when provided

Loaders and Bulldozers

• Carry loads low for stability
• Travel with load uphill
• Never use bucket for personnel lift
• Be aware of limitations on slopes
• Watch for underground utilities
• Maintain safe distance from edges
• Park with blade or bucket lowered
• Never allow riders in bucket

Dump Trucks

• Inspect bed hoist mechanism
• Stay clear of overhead power lines when dumping
• Check stability before raising bed
• Never work under raised bed without support
• Use backup alarms and spotters
• Ensure loads are balanced
• Cover loads when required
• Check tailgate latching before moving

Aerial Lifts

• Inspect before each use
• Check for overhead hazards
• Use fall protection properly attached
• Stay within load capacity
• Do not climb on guardrails
• Maintain firm footing on platform
• Set outriggers on stable surface
• Never move lift while elevated (unless designed for it)

Maintenance and Repair Safety

Lockout/Tagout Procedures

• Shut off engine
• Remove key and secure it
• Place transmission in park or neutral
• Set brakes and block wheels
• Release hydraulic pressure
• Lower or secure all raised components
• Lock out energy sources
• Test by attempting to operate controls

Safe Jacking and Blocking

• Use only rated jacks for equipment
• Place on solid, level surface
• Use jack points specified by manufacturer
• Install blocking/jack stands before working underneath
• Never substitute concrete blocks for proper stands
• Secure equipment against movement
• Consider multiple points of failure
• Use wheel chocks in addition to brakes

Tire and Track Maintenance

• Follow manufacturer procedures
• Use safety cage for tire inflation
• Stand aside during inflation
• Use proper tools for track tension
• Secure rims properly
• Inspect for damage before inflation
• Never hammer on inflated tire or rim
• Be aware of stored energy in tracks

Refueling Safety

• Shut off engine
• No smoking or open flames
• Ground and bond containers
• Avoid spills and clean immediately if they occur
• Use proper dispensing equipment
• Never use gasoline for cleaning
• Be aware of hot surfaces
• Know locations of fire extinguishers

Emergency Procedures

Equipment Fires

• Stop in safe location if possible
• Shut off engine
• Exit equipment immediately
• Attempt to extinguish only if safe
• Use appropriate extinguisher
• Call for emergency assistance
• Keep others away from the area
• Report incident to supervisor

Rollovers

• Stay inside cab with seatbelt fastened
• Hold firmly to steering wheel
• Brace yourself
• Do not jump from rolling equipment
• Shut off engine when motion stops
• Exit carefully when stable
• Assess injuries
• Secure area and report incident

Utility Strikes

• Stop operation immediately
• Stay on equipment if electrical contact
• Warn others to stay clear
• Call emergency services
• Contact utility company
• Do not touch equipment and ground simultaneously
• Jump clear with feet together if fire forces evacuation
• Document the incident

Struck-By or Caught-In Incidents

• Stop all operations immediately
• Call for emergency medical assistance
• Do not move the victim unless in imminent danger
• Provide first aid if trained
• Secure the scene for investigation
• Preserve evidence
• Document all aspects of the incident
• Report to supervisor and safety personnel

Special Work Environments

Night Operations

• Adequate lighting for work areas
• Reflective clothing for all workers
• Enhanced communication systems
• Additional warning lights on equipment
• Reduced speed of operations
• More frequent breaks for operators
• Enhanced traffic control
• Careful planning of operations

Congested Sites

• Detailed traffic management plan
• Physical barriers between operations
• Dedicated spotters
• Enhanced communication
• Coordination between contractors
• Limited equipment movement times
• Designated pedestrian routes
• Regular safety coordination meetings

Public Traffic Interfaces

• Traffic control devices per MUTCD
• Barriers separating work from traffic
• Reduced speeds in work zones
• Warning signs and flaggers
• Reflective clothing for workers
• Escape routes for workers
• Buffer zones between traffic and work
• Regular inspection of traffic control

Trenching Operations

• Equipment kept back from trench edges
• Soil placed minimum 2 feet from edge
• Spotters for equipment near trenches
• Vibration concerns for trench stability
• Equipment crossing points reinforced
• Limited access points for equipment
• Separate worker access points
• Regular inspection of trench conditions

Training and Qualification

Required Training Elements

• Equipment-specific operation
• Pre-operation inspection
• Recognition of hazards
• Safe operating procedures
• Load handling and stability
• Communication protocols
• Emergency procedures
• Applicable regulations

Refresher and Update Training

• After incidents or near misses
• When new equipment is introduced
• When conditions change significantly
• At regular intervals (annually recommended)
• When operator performance indicates need
• After extended absence from operation
• When regulations change
• Based on company policy

Documentation Requirements

• Initial qualification training
• Equipment-specific training
• Evaluation of competency
• Refresher training
• Pre-operation inspections
• Maintenance records
• Incident reports
• License or certification verification