Part 7
Heavy equipment accidents
Cranes, excavators, forklifts, dozers and loaders power projects, but contact with moving equipment remains a top killer. From 2018–2022, the U.S. recorded 3,600+ fatalities from contact with objects/equipment. Forklift incidents alone were linked to 67 deaths (2023) and ~24,960 serious (DART) cases in 2021–22. Typical outcomes are crush injuries, amputations and head trauma, with lone-working scenarios amplifying severity through delayed rescue.
Example cases:
Tower crane collapse
Pins were removed during disassembly against procedure; gusts toppled the weakened crane leading to 4 fatalities. Findings: procedural violations, weather ignored, no qualified supervisor.
Forklift maintenance solo
A worker changing a forklift hydraulic line was crushed when forks/cage fell. Local DA/TV report notes he was working alone and had no immediate aid or emergency control.
Excavator repair while working alone
A 36-year-old heavy-equipment mechanic died from mechanical asphyxia while installing a swing drive on an excavator. He had been left working alone at the site. Investigators highlighted inadequate blocking/energy isolation and the lack of a second person during the repair.
Mitigation strategies:
Competence first: Certified operators (cranes/forklifts) and trained spotters; brief ground crews on blind spots, exclusion zones, signals; close supervision for new/infrequent operators.
Plan the worksite: Traffic management with physical separation of people/plant, one-way routes, speed limits, banksmen/flaggers in tight areas, adequate lighting; documented JHAs and lift plans.
Engineer out the harm: Maintain per manufacturer schedule; pre-shift checks; lockout/tagout for service; ROPS + seat belts; cameras/360° vision, proximity detection and collision-avoidance, telematics and fatigue monitoring; crane wind-speed limits/anti-collision.
Enforce supervision & procedures: Competent person on site; insist on spotters for reversing/swinging plant; never bypass guards or pins; stop-work authority when conditions (weather/ground) breach limits.
Control fatigue: Shift design, rest breaks, and no lone night operations on critical plant where alertness is paramount.
Protect lone workers: Define what cannot be done solo (e.g., high-risk lifts, under-equipment maintenance); scheduled check-ins; GPS/SOS/man-down devices; radios/satellite comms; buddy rules for servicing under raised loads.
