Heavy Equipment Safety in Quarries: Best Practices

Quarries aren’t like other jobsites. You’ve got massive machines, moving rock, and crews on foot all working in the same space. But that mix comes with risk. Crushers, conveyors, and haul trucks can put your crew in danger. The best way to protect people and protect production is to build safety into your daily routines.

Tools like equipment safety checklists and site safety audits help ensure that everyone goes home safe at the end of each shift.

Aggregate work poses some unique challenges, as it involves additional potential hazards from the use of machinery such as crushers, conveyors, and mobile plants, as well as the danger from blasting zones. These specialized dangers require unique protocols and controls to ensure worker safety. This article will provide you with best practices for the use of heavy machinery in quarries, so you can ensure that everyone stays safe on your site.

Daily Equipment Safety Checks

Machines don’t take care of themselves. A daily inspection is the fastest way to catch problems before they turn into breakdowns. One way to document these safety inspections and ensure that they are done consistently is to use a checklist. Each piece of equipment will have a unique safety checklist (check with the manufacturer); however, there are some common items that should be inspected on all equipment.

Detailed daily equipment checklist for crushers, conveyors, and loaders

• Overall: Check for any damage, cracks, or unusual wear.
• Fluids: Look for signs of leaks under the machine.
• Parts: Ensure all bolts, pins, and fasteners are secure.
• Operations: Check for any unusual noises or vibrations.
• Fuel and DEF: Ensure proper fuel and DEF levels.
• Cleanliness: Check for excessive dust or debris that could pose a hazard.
• Tires/Tracks/Undercarriage: Check for wear, damage, and proper inflation.
• Engine: Inspect for leaks, proper fluid levels (oil, coolant), and overall condition.
• Hydraulics: Check for leaks, hose damage, and proper fluid levels.
• Brakes: Ensure proper function and responsiveness, if applicable.
• Lights/Gauges: Verify functionality.
• Safety: Check alarms, horns, fire extinguishers, and seat belts, if applicable.
• Controls: Verify all controls are working correctly.
• Guards/Shields: Ensure they are in place and properly secured.
• Welding: If applicable, check for proper ventilation and safety precautions.
• Compressed Gas: Check for leaks, proper storage, and ventilation.

Equipment-specific checks

• Crushers: Check jaw plates, bearings, toggle plate, eccentric shaft, and hydraulics. Pro tip: The way your crusher is configured, from liner choice to feed size, also impacts performance and long-term safety. For more on setups that work, see our crushing equipment guide.
• Cranes: Inspect hoist, brakes, and other operational components.
• Drills: Check for proper drill function and alignment.
• Haul Trucks: Inspect tires, brakes, lights, and dump mechanisms.

Machine Risk Assessment

Before operating a new piece of equipment, it’s imperative to assess the potential risks to operators and surrounding workers. A machine risk assessment can be used to determine whether additional safety measures should be employed or if the risk isn’t significant enough to warrant action. These assessments can also be used after an incident or near miss to determine if further measures should be implemented.

How to conduct a machine risk assessment

A machine risk assessment involves identifying potential hazards associated with a machine, analyzing the related risks, and implementing control measures to mitigate those risks. When working with machines in the aggregate industry, pay particular attention to the machine’s moving parts and pinch points, as well as any confined spaces.

Here's a detailed 12-step process for machine risk assessment and mitigation:

1. Identify the machine or process that needs safeguarding.
2. Collect information about the machine or process, including capacity, lifecycle, design drawings, system descriptions, previous incidents, and a list of workers exposed to the risks.
3. Gather feedback from maintenance staff, affected workers and operators, safety professionals, etc.
4. Observe the machine in use.
5. Identify potentially hazardous areas or tasks.
6. Assign a risk level to each area/task.
7. Evaluate each risk level to determine if further action is needed.
8. Create a risk reduction system of protective measures to help reduce each risk to an acceptable level. Measures include:
   1. Hazard elimination or substitution
   2. Engineering controls (modifications to the process)
   3. Awareness means (signage, audible alarms)
   4. Administrative controls (procedures and training)
   5. Personal protective equipment (PPE)
9. Estimate system costs.
10. Properly install or implement safeguards.
11. Conduct a follow-up risk assessment.
12. Document assessment outcomes.

Safe work practices and situational hazards

Quarries are high-risk environments due to the amount of equipment, vehicles, and pedestrian traffic in the same area. Your crew relies on each other, and worker safety depends on safe work practices. Your team must be trained on how to use each piece of equipment properly and demonstrate their understanding and ability to apply these practices.

How to safely use machinery in quarries

Operating machinery in quarries can be particularly hazardous due to the environment and the constantly changing nature of the site. Here are some best practices for equipment operation in a quarry:

• Wear high-visibility clothing in compliance with the Mine Safety and Health Administration (MSHA), along with appropriate PPE, including a hard hat/helmet, safety glasses, hearing protection, reinforced safety boots, and gloves.
• Only operate machinery if you have the proper training and certifications.
• Maintain a safe travel distance between machines, especially when visibility is poor.
• Watch out for bench and highwall hazards, and other obstacles.
• Use spotters to guide equipment when in tight spaces or if visibility is limited.
• Don’t bypass safety guards, switches, or interlocks.
• Obey posted speed limits and warning signs.
• Never operate machinery if you are tired or impaired by alcohol, drugs, or other medications.

Best practices to avoid being struck by heavy equipment

Whether you’re a pedestrian or an equipment operator, it’s important to pay attention to what’s going on around you to avoid being struck by equipment. Here are some best practices to keep workers safe:

• Develop a formal traffic plan that designates vehicle and pedestrian areas and sets speed limits. Everyone on site, including visitors, should receive training on the plan.
• Install convex mirrors at blind corners and intersections to improve visibility.
• Post warning signs and speed limits. Make sure signs are visible in low-light conditions.
• Use spotters or signal persons when necessary.
• Make eye contact with operators before approaching or crossing the path of a piece of equipment.

Working around blind spots, using spotters and signals

In quarry operations, working around large mobile equipment presents serious risks due to limited visibility and blind spots. The Mine Safety and Health Administration (MSHA) emphasizes the importance of communication protocols, spotters, and site-specific safety practices to prevent accidents.

Spotters and Communication

When operating in tight spaces, low visibility, or near haul roads and crushers, spotters should be used to guide equipment operators. Spotters and operators should meet before operations begin to:

• Inspect the area
• Determine the best position for the spotter to maximize visibility
• Agree on site-specific hand signal

The spotter should maintain eye contact with the operator and stay within designated safe zones, typically visible in the operator’s mirrors. Operators must follow the spotter’s directions, stop if unsure, and operate equipment slowly and cautiously.

Key Principles for MSHA-Compliant Signaling

Clear communication: Signals must be easily understood by the operator.

Response confirmation: Operators should only act on signals they fully understand.

Consistency: Signals should be standardized across the site and reinforced through training.

MSHA does not mandate a universal set of hand signals for all mining equipment. Instead, signals should be standardized at the site level and tailored to the specific equipment and tasks. While crane and hoisting signals are commonly referenced, they are not required for general quarry operations.

Site Safety Audits

Site safety audits help ensure that your protocols are up to date with current conditions and are addressing all the hazards present on a site. They differ from an MSHA inspection in many ways.

Quarry site safety audit vs. MSHA inspection

A site safety audit is self-performed to assess the overall effectiveness of a company's safety program, identifying weaknesses and areas for improvement. It’s usually performed by internal personnel, such as a safety committee or safety professional, and involves reviewing the company’s safety policies, training, equipment, and practices. It’s a proactive approach to help prevent accidents and maintain compliance, enabling management to identify areas for improvement.

On the other hand, an MSHA inspection verifies compliance with specific safety regulations and standards and may investigate potential hazards or violations. A compliance officer performs the inspection, which can focus on a particular area or be a comprehensive review of the entire worksite. Inspections can be triggered by a complaint, random selection, or as part of a scheduled inspection. Outcomes include identifying and addressing potential hazards, issuing citations, and imposing fines for non-compliance.

How to prepare for a site safety audit

A site safety audit begins with planning and research, followed by conducting site inspections, reviewing documentation, developing an action plan, and making changes as needed.

The following are the steps in performing a site safety audit:

1. Define the scope of the audit and its objectives.
2. Assemble a team, potentially including internal personnel and/or external consultants.
3. Review company policies and procedures, employee training, and applicable standards, creating a checklist to guide the audit.
4. Conduct a site inspection, observe work practices, test safety equipment, and interview workers.
5. Compile and document the audit findings.
6. Develop an action plan for corrective actions, prioritizing risks.
7. Implement corrective actions and follow-up to ensure they are effective

What to do if an inspector shows up

If an MSHA inspector shows up, it’s important that you cooperate without volunteering information. Everyone on location should know what to do:

• Verify the inspector’s credentials, then notify relevant personnel (supervisor, safety officer, etc.) and cooperate with the inspection.
• Do not obstruct the inspection, but do not volunteer information or admit fault.
• Document everything, including the inspector's observations and any photos taken.
• Address minor violations immediately, if possible, and consult with legal counsel to understand your rights and obligations

Signage & Communication

Employers must inform workers about potential hazards on the site. This can often be best achieved using safety signage. Clearly communicating about the type of hazards present and how workers can address them will help ensure a safe site.

Importance of clear site safety signs

Clear safety signage informs everyone of potential hazards as they navigate through the site. Often, hazards are not readily apparent, putting visitors and new employees at risk. Safety signs perform several functions, including:

• Communicating essential information about site conditions or protocols.
• Reducing accidents.
• Ensuring regulatory compliance.
• Providing a visual warning system, alerting workers and visitors to potential hazards.
• Guiding visitors and workers safely through the site.
• Indicating the location of safety equipment.

Best practices for sign placement

Safety signs must be placed in an appropriate location, or those who need them won’t be able to see them. Here are some best practices for safety sign placement around haul roads, high walls, and crushers:

• Follow all federal, state, and local regulations regarding sign usage, including MSHA guidelines.
• Strategically place signs in high-traffic areas, ensuring visibility, clear sightlines, and proper lighting.
• Signs should be mounted at eye level, as close to the point of the hazard as possible, and away from obstructions like equipment or foliage.
• Use high-contrast colors for maximum readability.
• Move or remove signs as conditions change.
• Maintain signs regularly to ensure visibility and readability.

Weather & Environmental Conditions

When conditions change, safety has to come first. Protocols and procedures for working in inclement weather should also be a part of any safety program. Working outdoors often exposes workers to more risks than working inside a building.

Is it safe to operate heavy equipment in lightning?

It is not safe to operate heavy equipment during a lightning storm. Equipment can attract lightning strikes, and the resulting electrical discharge can cause serious injury or death to the operator, as well as damage to the equipment.

When lightning is near, all operations should be shut down and workers should seek shelter.

Site shutdowns for lightning

Both MSHA and the National Oceanic and Atmospheric Administration (NOAA) recommend that work stop outdoors when thunderstorms are near (if you can hear thunder, they are close). Lightning is a significant occupational hazard for workers who are outdoors.

Here are other recommended lightning safety measures:

• Seek shelter in fully enclosed buildings with electrical wiring and plumbing.
• If a building is not available, seek shelter in a hard-topped metal vehicle with rolled-up windows.
• Do not use corded phones, except in an emergency. Cell phones can be used safely.
• Avoid touching metal.
• Avoid open spaces.
• Have a policy for working in inclement weather before a storm comes.

Other weather conditions

Besides storms, other weather conditions can pose a safety threat to workers outdoors, including extreme heat and cold, fog, and rain. Here are suggestions for working safely in inclement weather:

• In heat:
  • Drink plenty of water or sports drinks before, during, and after work.
  • Wear sun protection, such as hats, sunglasses, sunscreen, long-sleeved shirts, and long pants.
  • Take frequent breaks in the shade to cool down.
• In cold:
  • Dress in layers.
  • Wear insulated gloves and waterproof boots.
  • Take breaks to warm up and drink warm beverages.
• In fog:
  • Wear high-visibility clothing, including vests, jackets, etc.
  • Wear anti-fog safety glasses or use wipes or coatings to keep lenses clear.
  • Listen carefully for the sound of approaching vehicles or equipment.
  • Dress warmly.
• In rain:
  • Wear appropriate PPE, including waterproof jackets and pants, non-slip footwear, slip-proof gloves, and eye protection. Ensure PPE is properly fitted and does not interfere with movement.
  • Move slowly to avoid slipping.

Personal Protective Equipment & Operator Training

The best crews are trained up and geared up. PPE protects the individual. Training protects the whole team.

Employers are responsible for providing the proper personal protective equipment (PPE) and training their workers on how to wear and use it effectively. They also must provide proper training for equipment operators to ensure they know how to use each piece of equipment appropriately and safely.

PPE for quarry work

While not an exhaustive list, here are some suggestions for PPE for quarry work:

• Hard hats/helmets
• Protective footwear, such as steel-reinforced boots
• Eye and face protection
• Respirators or dust masks
• Hearing protection, earplugs or earmuffs
• High-visibility clothing
• Gloves
• Fall protection, safety harnesses or lanyards
• Seat belts

As each site has different hazards, employers must provide the appropriate PPE to address the hazards present on their specific site.

How to maintain operator certifications

Equipment operators must maintain current training and certifications for each piece of equipment they use.

• Make sure operators receive up-to-date training on the specific model of equipment they will be using.
• Track certification expiration dates, if applicable.
• Document all training and evaluations.

Legal Compliance & Continuous Improvement

It’s essential to comply with all MSHA requirements for equipment safety, as failure to do so can result in accidents, citations, or fines. You’ll also need to document your safety practices and training, in case of a safety audit or site inspection.

Safety regulations vary depending on the type of worksite and the governing authority. For example, quarry operations are regulated by the MSHA, while construction sites fall under the Occupational Safety and Health Administration (OSHA). Other federal or state-level programs may also apply, depending on your location and industry. Always verify which standards are relevant to your operation and consult a qualified safety professional to ensure full compliance.

Encourage a culture of safety

Establishing a culture of safety goes beyond the mandatory requirements. It’s a shared commitment between workers and employers that emphasizes the importance of safety over other goals. Everyone, from leadership down, participates in promoting and maintaining a safe work environment.

Use checklists, audits, and training logs to stay prepared

To ensure you’re ready for potential site inspections or safety audits, maintain proper documentation that demonstrates how your safety program operates. Keep detailed records, including checklists and training logs, in a central location so you can produce them when asked. Conduct regular safety audits to ensure your documentation is accurate and up to date.

Regularly update site safety checklists

Checking boxes isn’t enough. A real safety program grows with your site, your crew, and your equipment. As conditions change on work sites, make sure you update your safety checklists accordingly.

Aggregate Equipment Support and Training

We’ve been supporting New England quarries for over 35 years. The team at Thompson Equipment is ready to help you and your people with expert advice, equipment rentals, service, inspection support, parts, and training. Reach out today to learn more about our services.