Heavy Equipment Contractor Safety Manual

Heavy Equipment Contractor Safety Programs

The safety programs needed by a heavy equipment contractor depend on the equipment and work performed. A comprehensive manual may include programs covering:

• Heavy Equipment Safety
• Mobile Equipment Safety
• Equipment Inspection
• Excavation and Trenching Safety
• Traffic Control and Work Zone Safety
• Lockout/Tagout
• Overhead Power Line Safety
• Personal Protective Equipment
• Job Safety Analysis
• Forklift and Powered Industrial Truck Safety
• Crane and Rigging Safety
• Fall Protection
• Hazard Communication
• Hearing Conservation
• Silica Exposure Control
• Heat Stress Prevention
• Emergency Action Plan
• First Aid

Programs that do not apply to the company’s operations can be removed, while additional programs should be included when specialized equipment or work activities create additional hazards.

Heavy Equipment Safety

Heavy equipment should be operated only by employees who have received appropriate training and are authorized by the company to operate the equipment.

Operators should understand:

• Equipment controls
• Operating characteristics
• Manufacturer limitations
• Rated capacities
• Stability
• Attachments
• Blind spots
• Warning devices
• Inspection requirements
• Safe operating procedures

Operators should use equipment only for its intended purpose and within its operating limitations.

Operator Training and Authorization

Employees should not operate heavy equipment until they have demonstrated the knowledge and ability necessary to perform the assigned work safely.

Training should address the specific equipment and may include:

• Controls
• Startup and shutdown
• Equipment inspection
• Travel
• Steering
• Braking
• Attachments
• Load handling
• Slopes
• Stability
• Blind spots
• Ground personnel
• Emergency procedures

Additional instruction should be provided when an employee is assigned unfamiliar equipment or when equipment, attachments, conditions, or work methods change.

Pre-Operation Equipment Inspections

Heavy equipment should be inspected before operation as required by company procedures, applicable regulations, and manufacturer instructions.

Inspection items may include:

• Service brakes
• Parking brake
• Steering
• Tires
• Tracks
• Hydraulic systems
• Hoses
• Cylinders
• Attachments
• Lights
• Horn
• Backup alarm
• Cameras
• Mirrors
• Windows
• Seat belts
• Access systems
• Guards
• Fire extinguishers
• Fluid levels
• Leaks

Deficiencies affecting safe operation should be reported and corrected before the equipment is used when necessary.

Equipment Defects

Operators should not continue using equipment when a defect creates an unsafe condition.

Defective equipment should be:

• Removed from service when necessary.
• Tagged or otherwise identified when appropriate.
• Reported to the responsible supervisor.
• Repaired by qualified personnel.

Repairs should not create additional hazards or defeat manufacturer-installed safety systems.

Seat Belts

Operators should wear seat belts when equipment is equipped with them and their use is required.

Seat belts are particularly important when equipment has rollover protective structures because they help keep the operator within the protected zone during a rollover.

Seat belts should be maintained in usable condition.

Operators should not disable or modify them.

Rollover Protective Structures

Equipment equipped with rollover protective structures should be maintained so the protective system remains effective.

Employees should not drill, weld, cut, or otherwise modify rollover protective structures unless the modification is specifically permitted or appropriately engineered.

Operators should understand that ROPS protection depends on remaining inside the operator compartment and using the seat belt.

Falling Object Protection

Equipment exposed to falling materials may require appropriate overhead or falling-object protection.

Hazards may occur during:

• Demolition
• Excavation
• Loading
• Forestry-related work
• Material handling
• Work beneath highwalls
• Other operations involving falling objects

Operators should not use equipment in conditions exceeding the protection provided by the cab or protective structure.

Mounting and Dismounting Equipment

Employees should use designated steps, ladders, handholds, and access points when entering or leaving equipment.

Employees should:

• Maintain three points of contact.
• Face the equipment when climbing.
• Keep steps clean.
• Avoid carrying objects that interfere with climbing.
• Avoid jumping from equipment.

Damaged access systems should be repaired.

Blind Spots

Heavy equipment can have large areas around the machine that are not visible to the operator.

Blind spots vary according to:

• Equipment type
• Cab configuration
• Attachments
• Load
• Direction of travel
• Site conditions

Ground employees should stay out of equipment operating areas unless their work requires entry.

Employees approaching equipment should establish positive communication with the operator before entering a hazardous area.

Ground Personnel Safety

Ground employees are particularly vulnerable to struck-by and caught-between incidents.

Ground personnel should:

• Remain visible to operators.
• Stay outside equipment swing areas.
• Avoid blind spots.
• Maintain escape routes.
• Wear required high-visibility apparel.
• Avoid standing between equipment and fixed objects.
• Establish communication before approaching equipment.

Operators should stop when they lose track of employees whose location is important to safe operation.

Backing Safety

Backing should be minimized when practical.

Before backing, operators should:

• Check behind the equipment.
• Verify the travel path.
• Use mirrors and cameras.
• Check warning devices.
• Maintain appropriate speed.
• Use a spotter when necessary.

Employees should not walk or work directly behind backing equipment.

Backup Alarms and Warning Devices

Required backup alarms, horns, lights, cameras, and other warning devices should be maintained in working condition.

Operators should understand that warning devices do not eliminate the need to verify that the travel path is clear.

Excessive background noise can reduce the effectiveness of audible alarms.

Spotters

Spotters may be used when operators have restricted visibility or work near employees, structures, utilities, traffic, or other hazards.

Before work begins, the operator and spotter should agree on:

• Signals
• Communication methods
• Equipment movements
• Spotter position
• Stop signals

The spotter should remain visible to the operator and stay out of the equipment’s path and pinch points.

If communication is lost, equipment movement should stop until communication is restored.

Excavator Safety

Excavators create hazards associated with:

• Swing radius
• Blind spots
• Counterweights
• Buckets
• Attachments
• Excavation edges
• Underground utilities
• Overhead power lines
• Ground stability

Employees should remain outside the excavator’s swing and operating areas unless their presence is necessary and communication has been established with the operator.

Loader Safety

Loader operators should maintain control of the machine and keep loads stable.

Operators should:

• Travel with buckets appropriately positioned.
• Avoid overloading.
• Maintain visibility.
• Observe ground conditions.
• Avoid abrupt turns.
• Use caution on slopes.
• Keep employees clear of operating areas.

Raised loader arms should be appropriately blocked before employees work beneath them when required.

Bulldozer Safety

Bulldozer operators should evaluate slopes, edges, excavations, unstable ground, and visibility before beginning work.

Operators should avoid:

• Operating too close to unsupported edges.
• Traveling across unsafe slopes.
• Allowing employees near moving tracks or blades.
• Working beneath unstable material.

Blades should normally be lowered when equipment is parked.

Backhoe Safety

Backhoe operations combine hazards associated with excavation, swinging equipment, stabilizers, loaders, and underground utilities.

Operators should:

• Establish stable equipment positioning.
• Deploy stabilizers as required.
• Keep employees clear of swing areas.
• Evaluate excavation edges.
• Identify utilities.
• Maintain appropriate power-line clearances.

Employees should not work beneath raised buckets or attachments.

Skid Steer Safety

Skid steers and compact track loaders can create severe crush and caught-between hazards.

Operators should:

• Enter and exit using designated methods.
• Use seat belts and restraint systems.
• Keep protective structures in place.
• Maintain attachments in safe positions.
• Follow manufacturer procedures.
• Avoid bypassing interlocks.

Employees should not work beneath raised lift arms unless the required mechanical support device is installed.

Grader Safety

Motor graders may operate close to traffic, slopes, road edges, and other equipment.

Operators should evaluate:

• Blade position
• Traffic
• Visibility
• Road edges
• Ground conditions
• Other equipment
• Pedestrians

Operators should maintain safe speeds and remain aware of the extended blade.

Compactor and Roller Safety

Compactors and rollers may operate on slopes, near excavation edges, and close to ground employees.

Operators should:

• Observe manufacturer slope limitations.
• Wear seat belts.
• Maintain safe distances from edges.
• Control speed.
• Remain alert to pedestrians.
• Avoid unsafe turns on slopes.

Equipment should not be operated on unstable ground that could contribute to rollover.

Scraper Safety

Scrapers can expose employees to large blind spots, high operating speeds, and interaction with other earthmoving equipment.

Operators should:

• Follow established haul routes.
• Maintain separation.
• Observe right-of-way rules.
• Control speed.
• Avoid unsafe slopes and edges.
• Maintain communication when working with push equipment.

Ground personnel should remain clear of scraper operating areas.

Haul Trucks

Haul and articulated trucks should be operated according to site traffic procedures and equipment limitations.

Operators should:

• Inspect equipment.
• Wear seat belts.
• Observe speed limits.
• Maintain safe following distances.
• Control equipment on grades.
• Verify dump locations.
• Avoid operating with raised beds except as necessary for dumping.

Drivers should understand that raised beds can contact overhead structures and power lines.

Dumping Operations

Dumping should occur on ground capable of supporting the equipment.

Operators should evaluate:

• Ground stability
• Slope
• Edge conditions
• Overhead hazards
• Material conditions
• Equipment positioning

Truck beds should not be raised when the vehicle is excessively tilted or unstable.

Employees should remain clear of dumping areas.

Equipment Stability

Equipment stability can be affected by:

• Slopes
• Soft ground
• Excavation edges
• Loads
• Raised attachments
• Speed
• Turning
• Equipment configuration

Operators should understand how attachments and loads affect the machine’s center of gravity.

Equipment should be operated within manufacturer limitations.

Working on Slopes

Before operating on slopes, employees should evaluate:

• Slope angle
• Soil
• Surface conditions
• Moisture
• Equipment limitations
• Travel direction
• Attachments
• Loads

Operators should avoid sudden turns, abrupt braking, or other movements that can reduce stability.

Manufacturer slope limitations should be followed.

Working Near Edges

Heavy equipment operating near excavations, trenches, embankments, retaining walls, pits, or other drop-offs can overturn if the edge fails.

Equipment should remain sufficiently far from edges based on:

• Ground conditions
• Excavation depth
• Soil stability
• Equipment weight
• Vibration
• Weather

Protective systems, berms, stop logs, spotters, or other controls may be appropriate depending on the work.

Excavation and Trenching

Heavy equipment contractors frequently perform excavation and trenching operations.

Work should address:

• Underground utilities
• Soil conditions
• Protective systems
• Competent-person inspections
• Spoil placement
• Equipment near edges
• Access and egress
• Water accumulation
• Hazardous atmospheres
• Falling loads

Employees should not work beneath suspended excavation loads.

Underground Utilities

Before excavation begins, underground utilities should be identified and located as required.

Potential utilities include:

• Electrical
• Gas
• Water
• Sewer
• Communications
• Process piping

Excavation methods should be adjusted when approaching known utility locations.

Employees should understand procedures for damaged or exposed utilities.

Overhead Power Lines

Heavy equipment can contact overhead electrical lines with booms, buckets, raised truck beds, attachments, loads, or other equipment components.

Before work begins:

• Identify overhead lines.
• Determine required clearances.
• Evaluate equipment movement.
• Establish boundaries.
• Use spotters when appropriate.
• Coordinate de-energization or other protection when required.

Power lines should be treated as energized unless their status has been appropriately established.

Traffic Control and Work Zones

Heavy equipment contractors often operate near public roads, construction traffic, and other vehicles.

Work-zone planning may include:

• Signs
• Cones
• Barricades
• Channelizing devices
• Flaggers
• Spotters
• High-visibility apparel
• Equipment routes
• Pedestrian controls

Employees should be protected from both public traffic and construction vehicles.

Internal Traffic Control

Construction sites should establish predictable routes for equipment, trucks, employee vehicles, and pedestrians when practical.

Internal traffic-control planning may address:

• One-way routes
• Speed limits
• Equipment crossings
• Loading areas
• Backing zones
• Parking
• Pedestrian routes
• Restricted areas

Separating employees on foot from moving equipment is one of the most effective ways to reduce struck-by hazards.

Equipment Interaction

Multiple pieces of equipment may operate simultaneously in limited areas.

Operators should maintain appropriate separation and communication.

Planning should consider:

• Blind spots
• Swing areas
• Travel paths
• Right-of-way
• Loading operations
• Excavation work
• Ground employees

Operators should not assume another equipment operator knows their intended movement.

Loading Trucks

Excavators and loaders used to load trucks should operate from stable locations.

Truck drivers should follow established procedures for:

• Positioning
• Remaining in or leaving the cab
• Communication
• Load completion
• Pulling away

Employees should remain clear of areas where material could fall from the bucket or truck.

Loading and Unloading Heavy Equipment

Transporting heavy equipment creates hazards during loading, securement, and unloading.

Before loading or unloading:

• Select stable ground.
• Inspect ramps.
• Align the trailer.
• Control traffic.
• Verify equipment capacity.
• Maintain a clear area.

Operators should travel slowly and avoid abrupt steering or braking while on ramps.

Equipment Transportation

Equipment transported on trailers should be properly positioned and secured.

Transport planning should consider:

• Equipment weight
• Trailer capacity
• Load distribution
• Height
• Width
• Attachments
• Securement
• Route restrictions

Employees responsible for securement should inspect chains, binders, straps, and attachment points.

Attachments

Heavy equipment may use buckets, breakers, forks, grapples, augers, compactors, couplers, and other attachments.

Before using an attachment:

• Verify compatibility.
• Inspect connections.
• Confirm secure engagement.
• Understand operating limitations.
• Evaluate changes in capacity and stability.

Employees should remain clear while attachments are being connected or disconnected.

Quick Couplers

Quick-coupler systems should be inspected and used according to manufacturer requirements.

Operators should verify that attachments are properly engaged before use.

When appropriate, the operator should perform a connection check before beginning work.

Ground employees should stay clear while attachments are being connected, tested, or changed.

Fork Attachments and Material Handling

Equipment fitted with forks should be operated within the capacity and limitations of the equipment and attachment.

Operators should:

• Keep loads stable.
• Maintain visibility.
• Avoid exceeding capacity.
• Keep employees clear.
• Use appropriate load-handling methods.

Improvised lifting arrangements should not be used.

Suspended Loads

Some heavy equipment may be designed or approved for certain lifting operations.

When equipment is used to handle suspended loads, the company should follow applicable manufacturer instructions and regulatory requirements.

Planning should address:

• Equipment capacity
• Approved lifting points
• Rigging
• Load weight
• Load control
• Employee positioning

Employees should remain clear of suspended loads.

Cranes and Rigging

Heavy equipment contractors may use cranes and rigging to place pipe, structures, equipment, trench boxes, and other materials.

Lift planning should address:

• Load weight
• Equipment capacity
• Rigging
• Ground conditions
• Power lines
• Load path
• Signal persons
• Employee positioning

Rigging equipment should be inspected and appropriate for the intended load.

Material Handling

Mechanical assistance should be used when practical for heavy or awkward materials.

Employees should avoid:

• Pinch points
• Suspended loads
• Unstable materials
• Placing hands beneath loads
• Working between equipment and fixed objects

Pipe and other round materials should be stored or restrained to prevent rolling.

Pinch Points and Caught-Between Hazards

Heavy equipment contains numerous crush and pinch points.

Hazardous areas may include:

• Articulation points
• Tracks
• Wheels
• Attachments
• Hydraulic components
• Swing areas
• Hitches
• Equipment and structures

Employees should never position themselves where unexpected equipment movement could trap them.

Equipment Maintenance

Only appropriately trained and authorized employees should perform equipment maintenance.

Before servicing, employees should evaluate:

• Electrical energy
• Hydraulic pressure
• Pneumatic pressure
• Gravity
• Moving components
• Raised attachments
• Hot surfaces
• Stored energy

Equipment should be placed in a safe condition before maintenance begins.

Lockout/Tagout and Hazardous Energy

Heavy equipment maintenance may require hazardous-energy control.

Employees should:

• Shut down equipment.
• Isolate energy when required.
• Relieve stored pressure.
• Lower or block attachments.
• Prevent movement.
• Verify controls before beginning work.

Normal controls such as ignition switches should not be relied upon when additional energy isolation is necessary to protect employees.

Blocking Raised Equipment

Employees should not work beneath raised equipment, beds, buckets, blades, arms, or attachments unless they are adequately supported or blocked.

Hydraulic systems alone should not be relied upon to support equipment during maintenance.

Manufacturer-provided support devices should be used when applicable.

Hydraulic Systems

Hydraulic systems can contain high pressure even after equipment has been shut down.

Employees should:

• Relieve pressure before disconnecting components.
• Inspect hoses and fittings.
• Keep body parts away from suspected leaks.
• Use appropriate methods to locate leaks.
• Replace damaged components.

High-pressure fluid injection injuries require immediate medical attention.

Tire and Wheel Safety

Large equipment tires and wheel assemblies can contain tremendous stored energy.

Only trained employees should perform specialized tire and wheel servicing.

Employees should follow appropriate procedures for:

• Inflation
• Deflation
• Wheel removal
• Multi-piece rims
• Damaged tires
• Tire fires

Employees should remain outside hazardous trajectories during inflation and servicing.

Fueling

Fueling operations should control fire, spill, and equipment-movement hazards.

Employees should:

• Shut down equipment when required.
• Control ignition sources.
• Avoid smoking.
• Use approved fueling equipment.
• Avoid overfilling.
• Clean up spills promptly.

Fuel caps should be replaced before equipment returns to operation.

Battery Safety

Equipment batteries may expose employees to electrical energy, corrosive electrolyte, and explosive gases.

Employees should use appropriate PPE and tools when servicing batteries.

Charging and jump-starting procedures should follow equipment manufacturer requirements.

Ignition sources should be controlled around batteries where flammable gases may accumulate.

Fire Prevention

Heavy equipment can develop fires involving fuel, hydraulic fluid, electrical systems, engines, or accumulated combustible material.

Operators should inspect equipment for:

• Leaks
• Damaged wiring
• Excessive debris
• Overheated components

Fire extinguishers should be provided and maintained when required.

Employees should know how to safely shut down and evacuate equipment during a fire.

Personal Protective Equipment

PPE should be selected according to the hazards of the work.

Common heavy equipment PPE may include:

• Hard hats
• Safety glasses
• Work gloves
• Safety-toe footwear
• High-visibility apparel
• Hearing protection
• Respiratory protection
• Fall protection

Specialized maintenance or construction activities may require additional PPE.

High-Visibility Apparel

Employees working around moving equipment and vehicles should wear high-visibility apparel when required or appropriate to the exposure.

Garments should be maintained so employees remain readily visible.

High-visibility apparel does not replace the need for traffic control, communication, or separation from equipment.

Hearing Conservation

Heavy equipment, demolition, compactors, breakers, and other construction activities can create hazardous noise.

Employee exposures should be evaluated and appropriate controls implemented.

Employees should use hearing protection when required and participate in applicable hearing-conservation activities.

Silica Exposure

Excavation, grading, demolition, roadwork, concrete breaking, and other heavy-equipment activities may generate respirable crystalline silica.

Controls may include:

• Water
• Dust suppression
• Enclosed cabs
• Cab filtration
• Work practices
• Respiratory protection

Employees should understand applicable silica hazards and controls.

Hazard Communication

Heavy equipment contractors may use fuels, lubricants, hydraulic fluids, coolants, solvents, paints, cleaners, and other hazardous chemicals.

The Hazard Communication Program should address:

• Labels
• Safety Data Sheets
• Employee training
• Chemical storage
• Protective measures

Employees should review hazards before using unfamiliar products.

Dust and Visibility

Dust can reduce visibility and create respiratory hazards.

Dust-control measures may include:

• Water trucks
• Wet methods
• Road maintenance
• Reduced speeds
• Enclosed cabs
• Ventilation or filtration

Operations should be modified when dust prevents operators or ground employees from safely seeing equipment, traffic, or work areas.

Heat Stress

Heavy equipment employees may work outdoors for extended periods in high temperatures.

Heat-stress procedures may include:

• Drinking water
• Rest
• Shade
• Acclimatization
• Work scheduling
• Employee monitoring

Operators should recognize that air-conditioned cabs do not eliminate heat exposure during inspections, maintenance, or ground work.

Cold Stress

Cold conditions can affect employees, equipment, ground stability, and walking surfaces.

Controls may include:

• Appropriate clothing
• Warming opportunities
• Protection from wind and moisture
• Snow and ice removal
• Employee monitoring

Cold-weather inspections should consider frozen components, reduced traction, and changing ground conditions.

Severe Weather

Heavy equipment operations may be affected by:

• Lightning
• Heavy rain
• High winds
• Snow
• Ice
• Flooding
• Reduced visibility

Supervisors and operators should evaluate whether conditions allow work to continue safely.

Weather can change slope stability, excavation conditions, haul roads, and equipment traction.

Housekeeping

Equipment cabs, access points, work areas, and maintenance locations should be kept reasonably clean.

Employees should control:

• Mud
• Oil
• Grease
• Tools
• Trash
• Loose materials
• Cords and hoses

Steps and handholds should be kept free of conditions that could cause slips or falls.

Job Safety Analysis

A Job Safety Analysis (JSA) can help identify hazards before heavy equipment operations begin.

JSAs may be appropriate for:

• Excavator operation
• Loader operation
• Bulldozer operation
• Grading
• Backhoe operation
• Skid steer operation
• Compaction
• Equipment loading and unloading
• Excavation
• Utility work
• Equipment maintenance
• Working near power lines
• Work adjacent to traffic
• Lifting operations
• Non-routine equipment work

The JSA should identify the steps of the task, associated hazards, and controls necessary to perform the work safely.

Emergency Procedures

Heavy equipment contractors should plan for foreseeable emergencies, including:

• Equipment rollovers
• Utility strikes
• Electrical contact
• Fires
• Excavation incidents
• Equipment collisions
• Hydraulic failures
• Employee injuries
• Severe weather

Employees should know how to stop operations, secure the area, summon assistance, and communicate the location and nature of the emergency.

Heavy Equipment Contractor Safety Training

Employees should receive training appropriate to their assigned duties and equipment.

Training may include:

• Equipment operation
• Equipment inspections
• Seat belts
• Blind spots
• Backing
• Spotters
• Ground personnel safety
• Excavation
• Overhead power lines
• Traffic control
• Loading and unloading
• Attachments
• Hazardous energy
• PPE
• Emergency procedures

Training should be documented as applicable.

Additional training should be provided when equipment, attachments, work methods, jobsite conditions, or employee responsibilities change.

Building a Heavy Equipment Contractor Safety Manual

A Heavy Equipment Contractor Safety Manual should be customized to the contractor’s actual equipment and operations rather than relying solely on a generic construction safety manual or individual Heavy Equipment Safety Program.

An excavation and grading contractor operating excavators, loaders, bulldozers, compactors, and haul trucks may require a different combination of programs than a paving contractor, utility contractor, demolition company, mining contractor, or civil contractor.

Companies operating multiple types of heavy equipment may also need supporting programs for excavation and trenching, traffic control, cranes and rigging, forklifts, silica exposure, hazardous energy, electrical hazards, overhead power lines, equipment transportation, and maintenance.

The manual should reflect the company’s equipment fleet, attachments, operators, ground employees, projects, maintenance activities, customer requirements, and work environments.

The completed safety manual should provide practical procedures employees and supervisors can use while supporting OSHA compliance, employee training, operator authorization, pre-job planning, JSAs, equipment inspections, incident investigations, customer requirements, and the company’s overall safety-management system.

Customized Heavy Equipment Contractor Safety Manuals

Get a Heavy Equipment Contractor Safety Manual customized for your excavators, loaders, bulldozers, graders, backhoes, skid steers, compactors, scrapers, haul trucks, attachments, excavation operations, equipment transportation, maintenance activities, and other heavy equipment hazards.