Part 7
Heavy equipment accidents
Cranes, excavators, forklifts, dozers and loaders power projects, but contact with moving equipment remains a top killer. In the UK in 2024/35 there were 124 work-related fatalities: 18 from being struck by a moving object, 17 from being trapped by something collapsing/overturning,14 from being struck by a moving vehicle, and 13 from contact with moving machinery. Typical outcomes are crush injuries, amputations and head trauma, with lone-working scenarios amplifying severity through delayed rescue.
Example cases:
Forklift overturn
A forklift truck overturned, killing a 35-year-old operator. HSE’s prosecution found inadequate control of forklift operations. The employer was fined £500,000 in 2023. The case underlines the need for proper training, supervision and safe traffic systems around lift trucks.
Excavator blind spot
A ground worker was struck and killed by a 16-tonne excavator bucket after entering swing radius. Reports note no exclusion zone, limited visibility, and inadequate supervision.
Pedestrian vs. reversing plant
A new starter was hit from behind and run over by an excavator; HSE found no segregation and no safe traffic system in place.
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.
