HEAVY EQUIPMENT

SAFETY
Opening & Background

TRAINING RULE
 Phone on silent mode (if there is an urgent call
take it outside)

 If you need a break or explanation don’t hesitate

to stop us

 Try to stay always focus on your safety and the

safety of your buddy.
TRAINING GOALS

I – Identify hazards on heavy equipments

 dbfd

ll. - Know the dangers associated with

the used of heavy equipments

lll. – know and learn the heavy equipment

safety requirements
WHAT IS THE MEANING OF HEAVY EQUIPMENT?
• Heavy equipment refers to sturdy machines and vehicles designed to
handle demanding construction tasks. They're used every day to power
the construction industry and finish construction projects on time and
within budget.
WHAT ARE THE HAZARDS OF HEAVY EQUIPMENT?

• MOVING PARTS AND CRUSH HAZARDS

Heavy equipment often consists of large moving parts such as rotating
blades, tracks, and conveyor belts, which can pose a significant crush
hazard. Operators and workers must be cautious and maintain a safe
distance from these moving parts to avoid accidents.

• FALLING OBJECTS AND STRIKING HAZARDS

Improperly secured loads or unstable materials being lifted by heavy
equipment can result in falling objects that pose a striking hazard.
Operators and workers should wear appropriate personal protective
equipment (PPE) and maintain a safe distance from the equipment during
lifting and loading operations.

• ELECTROCUTION HAZARDS
Heavy equipment relies on electrical systems to function properly.
Operators should be aware of the risks associated with working near
power lines, underground cables, or electrical installations. Insulated tools
and proper training can help mitigate the risk of electrocution.
WHAT ARE THE HAZARDS OF HEAVY EQUIPMENT?

• NOISE AND VIBRATION HAZARDS

Working with heavy equipment often involves prolonged
exposure to high levels of noise and vibrations, which can
lead to hearing loss, musculoskeletal disorders, and
fatigue. Wearing hearing protection and taking regular
breaks can mitigate these hazards.

• FIRE AND EXPLOSION HAZARDS

Heavy equipment that operates with flammable fuels,
hydraulic fluids, or lubricants poses a risk of fire or
explosion. Routine inspections, proper storage of
flammable substances, and adherence to safety protocols
help prevent these incidents.

• PINCH HAZARDS
Heavy equipment may have mechanisms or parts that can
pinch body parts if operators or workers come into contact
with them. Awareness and adherence to safety protocols
can prevent such accidents.
WHAT ARE THE HAZARDS OF HEAVY EQUIPMENT?

• VISIBILITY HAZARDS
Limited visibility from the operator’s cabin can lead to accidents.
The use of mirrors and additional safety devices, along with
proper positioning and signaling, improves visibility and reduces
the risk of collisions.

• LACK OF TRAINING AND INADEQUATE MAINTENANCE

Insufficient operator training and inadequate maintenance of
heavy equipment contribute to safety hazards. Comprehensive
training programs and regular inspections and maintenance
routines are essential to ensure safe equipment operation.

• OPERATOR AND TRAINING 3RD PARTY CERTIFICATION

Comprehensive training programs should be provided to
operators to ensure they possess the necessary skills and
knowledge to operate the equipment safely. Certification
programs validate an operator’s competency, and ongoing
training keeps them updated on safety practices.
WHAT ARE THE HAZARDS OF HEAVY EQUIPMENT?
• EQUIPMENT INSPECTION AND MAINTENANCE
Regular inspections and maintenance routines help identify and address
potential issues with heavy equipment. Operators should conduct pre-
shift inspections to check for any signs of wear, damage, or malfunction.
Timely repairs and maintenance tasks should be carried out by qualified
technicians

• SAFETY CERTIFICATE VALIDITY

Heavy equipment should have a safety certificate issued by an equipment
inspector or safety personnel. The validity period of the certificate may
vary depending on client requirements. In live plants such as oil and gas
facilities, safety certificates are mandatory to ensure equipment safety.
For example, the safety certificate validity for KNPC (Kuwait National
Petroleum Company) is usually three months, but it may differ depending
on the client

• PERSONAL PROTECTIVE EQUIPMENT

Operators and workers must wear appropriate PPE when working with
heavy equipment. This includes items such as hard hats, high-visibility
vests, safety glasses, gloves, and steel-toed boots. PPE serves as a
barrier between the operator and potential hazards, reducing the risk of
injuries
WHAT ARE THE HAZARDS OF HEAVY EQUIPMENT?
• CLEAR COMMUNICATION AND SIGNALING
Effective communication is crucial when working with heavy equipment.
Operators should have clear signals and communication protocols
established with ground personnel to ensure safe maneuvering and
operations. Visual and audible warnings enhance safety on the worksite.

• TRAINED SIGNALMAN AND FLAGMAN???

When operating heavy equipment, having a trained signalman with proper
signaling flags is crucial. Clear and effective communication between the
operator and the signalman helps ensure safe equipment maneuvering
and prevents accidents

• BLIND SPOT PREVENTION

Equipment cabins should be designed to minimize blind spots. Adequate
mirrors and additional safety devices improve visibility and reduce the risk
of accidents caused by limited visibility.

• APPROVED SPARK ARREST

In environments with flammable materials or in live plants like refineries,
the installation of approved spark arrest devices, marked with USDA
marking, should be mandatory. These devices prevent sparks from the
equipment that could potentially ignite flammable substances
WHAT ARE THE HAZARDS OF HEAVY EQUIPMENT?
• FIRE EXTINGUISHER
Heavy equipment should be equipped with fire extinguishers to respond
promptly to fire incidents. The number of fire extinguishers required may
vary based on client requirements and local regulations

• PROPER ATTIRE MIRRORS

Operators should refrain from wearing loose clothing that may get
entangled with the equipment’s control levers. Additionally, the use of
rearview and side-view mirrors helps improve visibility and awareness of
the equipment’s surroundings

• SEAT BELT USAGE

Operators should always wear seat belts while operating heavy
equipment. Seat belts help protect operators in the event of sudden
stops, collisions, or equipment overturning.

• THREE POINT RULE FOR MOUNTING AND DISMOUNTING

The three-point rule should be followed when mounting or dismounting
heavy equipment. This means having three points of contact with the
equipment (e.g., two hands and one foot or two feet and one hand) to
maintain stability and prevent falls.
WHAT ARE THE HAZARDS OF HEAVY EQUIPMENT?
• REFUELING SAFETY
When refueling heavy equipment at the site, it is crucial to switch off the engine
and ensure no hot work is being conducted within a specific radius. Bonding and
grounding should be done before refueling to prevent static electricity buildup. A
separate permit should be obtained for equipment refueling

• HOT WORK PERMIT

In live plants like refineries, a hot work permit should be obtained before
performing any hot work activities near or on heavy equipment. This permit
ensures that necessary precautions are taken to prevent fire or explosion
hazards.

• SAFE LOADING AND UNLOADING

When loading and unloading materials or objects, operators should follow safe
procedures to prevent injuries. This includes using appropriate equipment and
techniques, securing the load properly, and ensuring that the equipment is on
stable ground

• AVOID UNEXPECTED START UP

Operators should never leave heavy equipment unattended without properly
securing it. Unexpected start-up can occur if someone inadvertently activates the
equipment, leading to accidents or injuries. Operators should engage the parking
brake, lower attachments, and turn off the engine before leaving the equipment.
WHAT ARE THE HAZARDS OF HEAVY EQUIPMENT?
• KNOWLEDGE AND OBEYING LOAD LIMITS
Each piece of heavy equipment has specific load limits that should be strictly
adhered to. Operators should be knowledgeable about these limits and avoid
exceeding them. Overloading equipment can compromise its stability and lead to
accidents.

• RECONIZING PHYSICAL AND EMOTIONAL LIMITS

Operators should be aware of their physical and emotional limits when operating
heavy equipment. Fatigue, stress, and distractions can impair judgment and
increase the risk of accidents. It is important to take breaks, manage stress, and
stay focused while operating heavy equipment.

• CREATING BUFFER ZONES

Creating buffer zones around heavy equipment can help prevent unauthorized
personnel from entering hazardous areas. Clear signage and physical barriers
should be used to mark these zones and restrict access.

• IDENTIFYING AND MARKING DANGER ZONES

Identifying and marking danger zones around heavy equipment is essential to
alert operators, workers, and pedestrians to potential hazards. This includes
areas where the equipment has limited visibility or where specific operations
pose a higher risk
WHAT ARE THE HAZARDS OF HEAVY EQUIPMENT?
WORK ZONE MANAGEMENT
Proper planning and management of work zones are essential to prevent
accidents involving heavy equipment. Designated pathways, barriers, and
signage should be in place to guide the movement of equipment and personnel.
Traffic control measures minimize the risk of collisions or incidents involving
pedestrians and other vehicles

• EXCAVATION SAFETY
Maintaining a safe distance from the edge of an excavation is essential to
prevent cave-ins and protect workers from being buried. This distance should be
strictly maintained during excavation operations

• BOOM SAFETY
To prevent accidents, operators should never allow anyone underneath the boom
of heavy equipment. This precaution helps avoid potential injuries caused by
falling objects or accidental movements of the boom

• AIR COMPRESSOR SAFETY

For air compressors, it is essential to have a hydro test certificate for the air
receiving drum if the certificate’s validity exceeds five years as per KNPC (this
tule can be differ client to client). Weep lash arrest devices for air compressor
hoses, along with proper couplings, should be in place to prevent hose lashings
and potential hazards
WHAT ARE THE HAZARDS OF HEAVY EQUIPMENT?
COMPACTOR SAFETY
For compactors, it is important to ensure that the on/off switch functions properly
and that there are no leakages. Employees operating compactors should wear
ear muffs to protect against excessive noise exposure

• DE-ENERGIZING ENERGY RESOURCES

Whenever possible, operators should de-energize energy sources, such as
electrical or hydraulic systems, when performing maintenance or repair tasks.
This helps prevent accidental activations and ensures the safety of operators and
maintenance personnel
 BLIND SPOTS OF EACH EQUIPMENT

EQUIPMENT BLIND AREA DIAGRAM

PROVISION OF SPOTTER/BANKSMAN/FLAGMAN
What is the important role of the spotter?
• A spotter serves as an extra set of eyes for drivers, equipment
operators and individual workers on the site. Besides making sure that
a truck that's backing up doesn't run into anything or anyone, spotters
pay attention to cranes and other equipment operating under or near
overhead power lines.
COMMON HEAVY EQUIPMENT ACCIDENTS IN THE CONSTRUCTION SITE
PERFORMING TASK WITHOUT SPOTTER/BANKSMAN
PROVISION OF SPOTTER/BANKSMAN/FLAGMAN
What is the banksman procedure?
During the operation the banksman will:

• Managing traffic flow to avoid excess queueing.

• Directing movement of vehicles and loads on a work site using standard hand signals
and/or verbal code.
• Understanding the risks on a site (such as blind spots) and how to manage them.
• Recommending and laying out safe on-site traffic systems to ensure the safe
movement of vehicles.

Increase level of communication on site

• A two-way radio is a useful method of communication on site with heavy machinery,

as are procedures and habits around visual communication like ensuring you make
eye contact before moving or giving a simple all-clear hand signal (more on that
later). Supervisors can also improve the communication with operators by introducing
a toolbox talk about the need for constant communication before the beginning of
each shift and directly addressing problems they’ve witnessed on site.
WHAT ARE THE 12 STANDARD OF BANKSMAN HAND SIGNAL?

1. EMERGENCY STOP - both arms point upwards with the palms facing
towards

2. START - attention start of command both arms are extended horizontally

with the palms facing towards

3. STOP - interruption End of movement the right arm points upwards with the
palm facing towards.
4. END - end of operation, both arms are clasped at chest height

5. RAISE - the right arm points upwards with the palms facing forward and
slowly makes a circle

6. LOWER - the right arm points downwards with the palm facing inwards and
slowly makes a circle
7. VERTICAL CLEARANCE - the hands indicate the relevant distance

8. HORIZONTAL CLEARANCE - the hands indicate the relevant distance

9. MOVE FORWARDS - both arms are bent with the palms facing upwards
and the forearms make slow movements towards the body
10. MOVE BACKWARDS - both arms are bent with the palms facing
downwards and the forearms make a slow movements away from the body

11. RIGHT - to the signal man’s, the right arm is extended more or less
horizontally with the palm facing downwards and slowly make a small
movements to the right

12. LEFT - to the signalman’s, the left arm is extended more or less
horizontally with the palm facing downwards and slowly make a small
movements to the left
Any Question?
ALWAYS REMEMBER!

NO JOB IS SO URGENT THAT WE

CANNOT TAKE THE TIME TO DO
IT SAFELY.
BE SAFE ALWAYS

REMEMBER IF IN DOUBT ASK