Minimising the Risk of Struck-By Incidents with Heavy Equipment

The forestry and logging industries heavily rely on a diverse fleet of specialized heavy equipment – from tree harvesters and forwarders to skidders and log loaders. In our 20 years of forestry operations and woodland management… While these machines are essential for efficient and sustainable timber extraction, they also pose significant risks to forestry workers. Struck-by incidents, where a worker is struck by a moving or falling object, are among the leading causes of serious injuries and fatalities in the forestry sector.

Mitigating these hazards requires a multi-faceted approach that encompasses operator training, worksite safety protocols, proper equipment maintenance, and the use of appropriate personal protective equipment (PPE). By implementing comprehensive safety measures, forestry contractors can minimise the risk of struck-by incidents and protect their most valuable asset – their workforce.

Heavy Equipment

Types of Heavy Equipment

Forestry operations typically involve a wide range of heavy equipment, each designed for specific tasks. Common machines include:

Tree Harvesters: Felling, delimbing, and bucking trees.
Forwarders: Transporting felled trees from the stump to the landing.
Skidders: Dragging or winching logs from the stump to the landing.
Log Loaders: Loading and unloading logs onto trucks or trailers.
Chippers/Grinders: Reducing branches, tops, and other woody biomass into small chips or mulch.
Excavators: Constructing and maintaining forest roads and landings.

Equipment Hazards

Each piece of heavy equipment poses unique struck-by risks, such as:

Tree Harvesters: Falling or flying debris during felling and processing operations.
Forwarders/Skidders: Swinging or rolling logs during transport.
Log Loaders: Falling or swinging loads during loading/unloading.
Chippers/Grinders: Ejected wood chips or other projectiles.
Excavators: Collisions with the machine or falling dirt/rock during roadwork.

Equipment Safety Features

Forestry equipment manufacturers have incorporated various safety features to mitigate struck-by hazards, including:

Rollover Protective Structures (ROPS): Safeguard the operator in the event of a machine rollover.
Falling Object Protective Structures (FOPS): Shield the operator from falling or flying objects.
Backup Cameras and Sensors: Improve visibility and awareness of surroundings.
Safety Interlocks: Prevent the operation of dangerous functions under unsafe conditions.
Guarding: Cover exposed moving parts and pinch points to prevent worker contact.

Struck-By Incidents

Causes of Struck-By Incidents

Struck-by incidents in the forestry industry can occur due to a variety of factors, including:

Lack of Operator Awareness: Operators failing to recognize the presence of ground personnel or their limited visibility around the machine.
Improper Equipment Use: Operating machines beyond their design capabilities or in an unsafe manner.
Inadequate Worksite Organization: Unclear zones for pedestrian movement and equipment operation.
Poor Maintenance and Inspection: Malfunctioning safety features or unaddressed equipment defects.
Environmental Conditions: Reduced visibility due to dust, fog, or poor lighting.

Consequences of Struck-By Incidents

Struck-by incidents can have severe consequences, including:

Serious Injuries: Crushing, laceration, and traumatic amputation injuries.
Fatalities: The second leading cause of fatalities in the forestry industry.
Productivity Losses: Downtime, workers’ compensation claims, and equipment damages.
Regulatory Penalties: Potential OSHA citations and fines for safety violations.

Preventing Struck-By Incidents

Effective prevention strategies for struck-by incidents in forestry operations include:

Comprehensive operator training and certification programs.
Clearly defined worksite safety protocols and traffic management plans.
Rigorous equipment maintenance and inspection procedures.
The use of appropriate personal protective equipment (PPE).
Effective communication and coordination between equipment operators and ground workers.

Risk Minimisation Strategies

Operator Training and Certification

Ensuring that all heavy equipment operators receive comprehensive training and maintain the necessary certifications is a critical step in reducing struck-by incidents. Training should cover:

Safe operating procedures for each machine.
Recognizing and mitigating blind spots and restricted visibility.
Proper loading, unloading, and material handling techniques.
Worksite communication and coordination protocols.
Emergency response and accident prevention measures.

Worksite Safety Protocols

Establishing and enforcing clear worksite safety protocols is essential for minimising struck-by risks. These protocols should include:

Designated pedestrian zones and equipment operation areas.
Defined traffic patterns and right-of-way rules.
Signage, barricades, and other visual cues to guide workers and equipment.
Procedures for safely approaching and interacting with operating machinery.
Disciplinary measures for non-compliance with safety standards.

Equipment Maintenance and Inspection

Regular maintenance and thorough inspections of heavy equipment are crucial for identifying and addressing potential struck-by hazards. Key maintenance tasks include:

Pre-use checks for proper functioning of safety features.
Scheduled preventive maintenance to address wear, tear, and defects.
Prompt repair or replacement of any malfunctioning components.
Documentation and communication of maintenance history and equipment status.

Legislation and Regulations

Occupational Safety Standards

Forestry operations might want to comply with various occupational safety regulations, including:

OSHA’s Logging Operations standard (29 CFR 1910.266), which outlines requirements for employee training, personal protective equipment, and machine guarding.
ANSI/ASSP A10.38 Basic Elements of an Employer’s Program to Provide a Safe and Healthy Work Environment, which covers safety program management, risk assessment, and incident investigation.

Compliance Requirements

Forestry contractors might want to double-check that that their operations, equipment, and personnel meet the applicable safety standards. This includes:

Providing the necessary training and PPE for workers.
Implementing comprehensive maintenance and inspection programs.
Documenting safety-related activities and maintaining compliance records.

Enforcement and Penalties

Failure to comply with occupational safety regulations can result in significant penalties, including:

OSHA citations and fines for identified safety violations.
Increased workers’ compensation costs and liability risks.
Potential legal action and reputational damage for the company.

Personal Protective Equipment (PPE)

Hard Hats and Protective Clothing

Forestry workers might want to wear appropriate PPE, such as:

Hard Hats: To protect against falling or flying objects.
High-Visibility Vests/Clothing: To enhance worker visibility and awareness.
Protective Footwear: Steel-toed boots with slip-resistant soles.
Gloves: To prevent cuts, abrasions, and pinch-point injuries.

Visibility and Communication Devices

Additional PPE can improve worker visibility and communication, such as:

Flashing Lights or Reflective Strips: To alert operators of ground personnel.
Two-Way Radios or Wireless Headsets: For clear and immediate communication.

Proper Use and Maintenance of PPE

Forestry workers might want to be trained on the proper use, care, and maintenance of their PPE to double-check that its continued effectiveness in protecting them from struck-by hazards.

Worksite Design and Layout

Designated Pedestrian Zones

Clearly defining and segregating pedestrian walkways and equipment operation areas is crucial for minimising struck-by risks. This may involve:

Marked Pathways: Designated walking routes for ground workers.
Restricted Zones: Areas off-limits to pedestrians during equipment operation.
Barricades and Signage: Visual cues to guide workers and equipment.

Equipment Movement Patterns

Establishing and communicating predetermined equipment movement patterns can help ground workers anticipate and avoid potential struck-by hazards. This includes:

Traffic Flow Plans: Unidirectional or designated travel routes for equipment.
Equipment Staging Areas: Designated locations for loading, unloading, and parking.
Coordination Protocols: Procedures for safely navigating shared work areas.

Signage and Traffic Control

Effective signage and traffic control measures are essential for guiding both workers and equipment operators, such as:

Warning Signs: Alerting workers to potential struck-by hazards.
Directional Markers: Indicating equipment movement patterns and pedestrian routes.
Flaggers or Spotters: Providing real-time guidance and communication during high-risk operations.

Operator Awareness and Communication

Blind Spots and Restricted Visibility

Forestry equipment often has significant blind spots and areas of restricted visibility, presenting a significant struck-by risk. Operators might want to be trained to:

Identify Blind Spots: Understand the limitations of their machine’s line of sight.
Conduct Walkarounds: Thoroughly inspect the work area before starting or moving the equipment.
Use Mirrors and Cameras: Leverage available visibility-enhancement technologies.

Verbal and Non-Verbal Cues

Clear communication between equipment operators and ground workers is essential for preventing struck-by incidents. This includes:

Hand Signals: Standardised hand gestures to indicate equipment movement or worker positioning.
Radio Communication: Coordinating activities and providing real-time updates.
Visual Aids: Flags, lights, or other cues to draw the operator’s attention.

Coordinating with Ground Workers

Operators might want to actively coordinate with ground personnel to double-check that everyone’s safety. This may involve:

Pre-Work Briefings: Discussing the day’s activities and safety protocols.
Designated Spotters: Ground workers who guide the operator during high-risk manoeuvres.
Stop Work Authority: Empowering all workers to halt operations if they observe unsafe conditions.

Maintenance and Inspection Procedures

Pre-Use Equipment Checks

Operators should conduct thorough pre-use inspections to double-check that the proper functioning of all safety features, including:

Guarding: Verifying that all moving parts are properly shielded.
Lighting and Visibility Aids: Ensuring backup cameras, mirrors, and work lights are in good condition.
Audible Alarms: Testing the operation of backup alarms and other warning devices.

Regular Preventive Maintenance

Forestry contractors should implement a comprehensive preventive maintenance program to address potential struck-by hazards, such as:

Scheduled Servicing: Replacing worn components, lubricating moving parts, and cleaning the equipment.
Safety Feature Inspections: Verifying the proper functioning of ROPS, FOPS, and other safety systems.
Documentation and Tracking: Maintaining detailed maintenance records and equipment histories.

Identifying and Addressing Defects

Any identified defects or malfunctioning safety features might want to be promptly addressed to mitigate struck-by risks. This includes:

Removing Equipment from Service: Tagging and isolating unsafe machinery until repairs are completed.
Communicating Defects: Ensuring that all operators and maintenance personnel are aware of the issue.
Implementing Temporary Controls: Using barricades, signage, or spotters to manage the hazard until a permanent fix is made.

By implementing these comprehensive strategies, forestry contractors can significantly reduce the risk of struck-by incidents and protect the safety and well-being of their most valuable asset – their workforce. For more information on sustainable forestry practices, visit Forestry Contracting.

Example: Mixed-Species Reforestation Project 2023