Working around mobile plant is a high-risk activity in many industries, including construction, mining, civil works, and logistics. Mobile plant includes a wide range of equipment, such as forklifts, excavators, skid steer loaders, tipping trucks, and other machinery that moves around a worksite. Despite their usefulness, mobile plant presents serious hazards to workers when appropriate controls and exclusion zones are not in place.
This article explores the key risks and safety measures for working around mobile plant, referencing Australian legislation and guidance provided by Safe Work Australia. Whether you’re a health and safety officer, site manager, or a worker on the ground, understanding and enforcing safe working distances and controls is essential to prevent injuries and fatalities.
The Hazards of Working Around Mobile Plant
Every year, serious incidents and fatalities occur due to unsafe interactions between people and mobile plant. According to Safe Work Australia, being hit by moving plant is one of the leading causes of death in the construction and manufacturing industries.
Some of the major risks include:
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Blind spots – Operators may not be able to see people walking or working near the machine.
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Unexpected movement – Mobile plant can suddenly move, tip, or reverse.
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Communication failures – Misunderstandings between spotters, drivers, and workers.
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Lack of physical barriers – No separation between plant and people.
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Complacency – Familiarity can breed unsafe shortcuts.
Read our article, Hazards When Working With Moving Plant.
Legal Duties under Australian WHS Legislation
The Work Health and Safety (WHS) Act and WHS Regulations in Australia require that all PCBUs (Persons Conducting a Business or Undertaking) must manage the risks associated with mobile plant. This includes:
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Identifying hazards related to mobile plant.
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Assessing the risks to workers and other people.
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Implementing control measures (including exclusion zones).
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Ensuring workers are trained and supervised.
According to Safe Work Australia’s model Code of Practice, effective control measures should follow the hierarchy of controls: elimination, substitution, engineering controls, administrative controls, and personal protective equipment (PPE).
Safe Distances When Working Around Mobile Plant
One of the most important administrative controls when working around mobile plant is maintaining safe exclusion zones. These are pre-defined distances that people must stay away from operating plant unless certain controls are in place (e.g., a physical barrier or spotter).
Examples of Recommended Safe Working Distances:
| Mobile Plant Type | Recommended Minimum Distance |
|---|---|
| Tipping Trucks | 10 metres |
| Skid Steer Loaders | 3 metres |
| Forklifts | 4 metres |
| Excavators | 5 metres (or more depending on swing radius) |
| Backhoes | 5 metres |
| Mobile Cranes | As determined by lift plan and load radius |
These distances are general recommendations and may need to be increased depending on site-specific factors such as terrain, visibility, and type of activity.
According to Safe Work Australia’s General Guide for Working Around Mobile Plant, PCBUs should assess each type of plant and establish site-specific safe distances. Spotters, signage, barriers, and exclusion zones should be in place and clearly communicated to all workers.
See our courses on Traffic Management, People and Plant on a Construction Site, Blind Spots and Vision Shadows, Access Egress Barrier Selection, Forklift Operation, Mobile Cranes, Excavations, Road and Bridge Construction and Road Construction.
Planning Safe Interactions Between People and Mobile Plant
Proper planning and communication are essential for preventing incidents. Here are some key strategies:
1. Site Layout and Traffic Management Plans
Develop a traffic management plan that includes:
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Separate pathways for vehicles and pedestrians.
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Designated exclusion zones.
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Signage and warning systems.
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One-way traffic systems (where possible).
2. Pre-Start Meetings and Communication
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Conduct toolbox talks daily to remind workers of exclusion zones and high-risk areas.
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Use two-way radios or spotters to communicate clearly during high-risk tasks.
3. Use of Technology and Engineering Controls
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Fit plant with reversing alarms, cameras, and proximity detection systems.
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Use physical barriers or fencing to separate work zones.
4. Training and Competency
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All operators must be licensed and trained in the safe operation of their machinery.
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Workers on foot should be trained to understand mobile plant blind spots and exclusion zones.
5. Supervision and Monitoring
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Supervisors must monitor adherence to safe work procedures.
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Conduct regular safety inspections and adjust controls as needed.
Case Example: Civil Construction Site
On a large infrastructure site in NSW, a subcontractor was struck by a reversing dump truck. Investigation found that exclusion zones were not properly enforced and the pedestrian was walking in a designated plant operating area. Since then, the company introduced a 10-metre exclusion zone around all tipping trucks, with spotters required whenever trucks reverse.
This example reinforces the need for strict enforcement of safe working distances and worker awareness.
Safe Work Australia Guidance
Safe Work Australia provides detailed materials on working around mobile plant, including:
- General Guide for Working Around Mobile Plant
- General Guide for Workplace Traffic Management
- Managing Risks of Plant in the Workplace Code of Practice
These documents offer practical advice on risk assessment, exclusion zones, operator competency, and workplace layout.
They highlight that safe systems of work must be documented, communicated, and reviewed regularly to ensure ongoing protection.
Key Takeaways for Safety Professionals
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Always assess the risks before allowing workers near mobile plant.
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Implement clear exclusion zones – 10 metres for tipping trucks, 3-5 metres for smaller machines.
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Communicate these distances visually and verbally on site.
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Train all workers on the risks of working around mobile plant.
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Refer to Safe Work Australia’s guides to align your site with best practice and legal compliance.
Visit the TIS Training website to view the catalogue of courses that support your training, ensuring your people understand exclusion zones and effective communication when working around mobile plant.
Final Thoughts
Working around mobile plant doesn’t have to be dangerous – but it does require proactive planning, clear communication, and consistent supervision. By establishing safe distances, educating workers, and implementing effective control measures, workplaces can significantly reduce the risk of injury or fatality.
Staying compliant with Australian WHS legislation and adopting Safe Work Australia’s guidance is not only a legal requirement – it’s also essential for keeping workers safe and your organisation protected.