July/August 2004
Trucks and other industrial equipment can pose serious safety risks when backing up. This advice can help you understand and minimize the dangers.
Safely operating trucks and industrial equipment is challenging enough when you’re moving in a forward direction, but the task becomes even more difficult when backing up. That’s because the operator often has little or no view of what’s behind him. This can lead to serious or fatal injuries to any individual in the equipment’s path. It’s essential, therefore, for operators to know how to back up their trucks and industrial equipment safely.
Mirrors and Blind Spots
Safely backing up any truck or industrial machine starts with mirrors. A combination of two mirrors—a rectangular one and a round one—on both sides of the unit can give the operator a good view to the rear. On trucks, mounting an additional round mirror on the engine compartment can give the driver a combination of the views from both mirrors plus the added view of the side of the cab.
To be useful safety tools, mirrors must be clean and properly adjusted, and the operator should quickly scan all mirrors while backing up. In this way, mirrors can help operators spot road obstructions, smaller vehicles/equipment, and people.
The problem is that mirrors don’t enable the operator to see what’s directly behind the equipment. With trucks, the trailer or payload section blocks the driver’s rear view, while other types of equipment such as front-end loaders can have engine compartments that partially obstruct the rear view. The closer a pedestrian is to the back of a loader, the less of him or her will be visible to the operator. This unviewable area behind a truck or other machine is called the blind spot—and it is this spot that can prove deadly for anyone in it.
In one truck-related accident, a worker at a scrap recycling facility was walking across the yard, apparently unaware that a customer was backing up behind him. Though the truck had dual mirrors on both sides of the cab, the driver couldn’t see the worker walking in the truck’s blind spot. As a result, the worker was crushed and killed beneath the vehicle’s rear tires.
Another incident involved a front-end loader. In this case, a temporary employee was assigned to sort scrap at a recycling plant. He was warned not to wander from his sorting station because front-end loaders were operating in the area and their operators might not see him. On his first day, the employee was twice warned about wandering into the restricted area. On his second day, it is believed that the worker spotted a discarded toolbox in the restricted area. To retrieve it, he crossed behind a backing-up loader to a spot where the operator couldn’t see him. The employee was crushed beneath the loader’s rear tires and died later that day.
Another worker on his first day on the job was assigned to separate piles of scrap to be moved by a front-end loader. The worker crossed behind the backing loader, oblivious of its backup alarm. The operator couldn’t see that the worker had entered the machine’s blind spot. The worker was run over and killed by the backing loader.
Smaller scrap-handling machines such as skid-steers can also have blind spots, especially if an employee bends down or kneels behind the equipment. At one scrap operation, for example, a worker would manually sort corrugated while a skid-steer loader removed the sorted piles. One day, the loader was backing into the sorting area. From his seat, the operator could not see the sorter, who had bent down to grab some paper. The rear wheels of the loader pulled the worker beneath the machine, then the front wheels crushed the worker’s head, killing him instantly.
The best way to prevent blind-spot accidents is for the operator to check what’s in the blind spot before backing up. With trucks, the driver must get out of the cab and walk to the rear of the vehicle. There, the driver must check for three things:
1. Check the path the vehicle will be traveling, looking for both obstructions and defects in the path as well as when and where the path turns or slopes. When backing up on
a curved path, the driver should stop when the vehicle reaches the curve, then get out of the vehicle to view the path. Before leaving the cab, the driver should set the gears, apply the parking brake, and turn off the engine, taking the key with him.
2. Look for overhead obstructions, including checking for clearance of power lines, overhanging structures, and any building openings.
3. Check for movement of pedestrians and other vehicles. Ideally, the driver should advise others of his intent to back up as this will prevent people from moving inadvertently into the area.
When operating front-end loaders, the operator should similarly check that nothing is in the blind zone before backing up and verify that no one will be moving into it. If the operator has any doubts once he’s inside the cab, he can double-check by pulling the loader forward enough to determine if anyone is in the blind zone.
Technology can also help overcome the dangers of blind spots. For instance, video camera systems, which can have monitors mounted either on the dashboard or from the cab ceiling, can help drivers or operators see areas that mirrors might miss. In addition, wireless headsets on both the driver/operator and any employee assisting the driver/operator can improve backing-up safety.
An Alarming Situation
Backup alarms are a common safety feature on trucks and other equipment in scrap processing facilities. While backup alarms are required on equipment used in the construction industry, neither OSHA nor the Department of Transportation requires backup alarms on commercial or industrial vehicles used in general industry. Though not required, backup alarms that are installed in general industry vehicles must be kept in good working order.
Though backup alarms are definitely useful safety devices, don’t assume that they will automatically prevent backing-up accidents. One problem is that employees can tune out and ignore backup alarms in operations where equipment is constantly backing up and alarms are constantly sounding. Also, the background noise in some facilities can be so loud that it drowns out the sound of the backup alarms, preventing people from hearing the warning.
In one accident, a scrap plant worker had his back turned to a truck that was backing toward him. The sound from the truck’s backup alarm was 43 decibels, while the sound in the surrounding workplace was close to 80 decibels. The worker did not hear the alarm until the truck was inches from him. The truck struck the worker, who fell beneath the rear wheels and was crushed to death.
To be effective, backup alarms must first be in good working order, meaning that they must sound whenever a vehicle is moving in reverse. Also, such alarms must be loud enough to be heard above the other noises in the plant. One way to address that problem is to install backup alarms that increase in sound as the background sound increases. Backing-up strobe lights can provide additional warning that can be helpful at night or in dark environments. Another type of backup alarm only sounds when an object is detected in the path of the backing vehicle or equipment. If the object moves or is removed, the backup alarm stops.
Generally, backup alarms are designed to protect people on the ground, though special sensors can be installed in both the rear and side of the vehicle to help the operator. These sensors send out radar-like signals that check for any potential obstruction in the equipment’s path. The signals bounce back to a monitor in the cab that interprets the signals and provides the driver with the appropriate warning information.
People and Machinery
Any time that pedestrians—employees or other individuals on foot—are moving or working in close proximity to moving trucks or equipment, there’s the potential for accidents. One problem is that such pedestrians can become accustomed to operating alongside the machinery. This can lead to complacency, with individuals not paying attention to the equipment or taking unnecessary or foolish risks.
At one recycling warehouse, a truck was dumping scrap paper in the unloading zone when a worker decided to run behind the vehicle. The driver was maneuvering the truck back and forth to dislodge the scrap load. The worker slipped on scrap paper, fell, and was unable to get up before the vehicle rammed into him. The worker bled to death beneath a pile of corrugated.
Pedestrian accidents in scrap recycling operations have also occurred between operators of various types of mobile equipment. For instance, an operator of a hydraulic excavator at a scrap plant had stopped the unit to get out and check on the connections to the attached lifting magnet. This placed him squarely in the blind spot of a backing-up truck. The truck ended up crushing his head against the boom of the excavator.
Another accident occurred when one truck attempted to back up to another to transfer scrap. The operator of one truck waited at the rear of his vehicle while the other operator backed his vehicle closer. The operator of the backing-up vehicle stopped and got out of the cab without setting the parking brake. His vehicle drifted backward several feet before the driver could stop it. This pinned the other driver between the two vehicles. The injured driver died a short time later.
In another incident, a truck driver had just completed a delivery of scrap and was securing the trailer’s tarp cover. At the same time, the driver of another vehicle was backing into the same area. While the backing-up driver looked into his left mirror, the other driver disappeared from view in the right mirror. The rear corner of the moving truck then pinned the driver against his own vehicle, crushing his head and killing him instantly.
Other pedestrian-related accidents in scrap operations involve spotters—those individuals who direct the movement of trucks and other machinery in the plant. While spotters can provide a valuable service, their close proximity to moving equipment places them in danger.
One scrapyard owner, for example, would often stand in his yard, directing the simultaneous movement of several loaders and trucks. His goal was to keep all the vehicles moving quickly to improve efficiency. One day, he was directing delivery trucks while three loaders zipped between them. One loader driver did not see the owner and backed into him. The owner died later from internal trauma.
Another recycling facility used a spotter to direct the movement of loaders and delivery trucks. One loader operator waited for a truck to leave before backing up. He checked both mirrors, looking for the spotter who had been in the area moments before. When he did not see the spotter, the operator backed up his loader using his mirrors. After moving several feet, he felt two bumps. He stopped the loader to check what he had backed over. It was the spotter. The spotter had crossed beyond the visible range of the mirrors before the operator glanced into them. He was directly behind the loader in its blind spot when the operator backed up.
To protect themselves from such backing-up accidents, spotters should follow these safety points:
• Always wear a vest or clothing of a highly visible color, which will improve the machinery operator’s ability to see the spotter. In contrast, dark or neutral clothing can make the spotter more difficult to see.
• Meet with the driver to review the path to be followed and the directional signals that will be used. Use bold hand movements or visual aids such as hand-held SLOW/STOP signs to provide clear signals and prevent confusion.
• Stand alone while directing the vehicle. The presence of others with the spotter can confuse the backing driver.
• Stand in an area that affords visibility of all equipment moving in the area and gives the equipment operator an easy view of the spotter.
• Check the path the vehicle will follow, looking for potential obstructions or problems both behind and to the sides of the backing-up equipment. The spotter should also make sure he has a direct escape path away from the moving equipment at all times.
• Be positioned in direct sight of the operator’s mirrors and attempt to maintain eye contact with the operator via these mirrors throughout the backing-up process.
• Stop the backing-up process whenever the spotter needs to reposition himself.
The operator, meanwhile, must back up at a slow speed to be able to react quickly to the spotter’s signals. In particular, the operator and the spotter should be aware of downward inclines that could increase the equipment’s stopping distance once the brakes are applied.
The driver must also constantly scan between both mirrors, making sure the spotter is visible at all times. This is important because the spotter can sometimes inadvertently drift behind the backing equipment, or the backing equipment can slowly move toward the spotter. Whenever the operator doesn’t see the spotter in the center of the mirror, he must immediately stop the equipment and reposition the spotter.
Maintaining for Safety
Proper maintenance can also play an important role in backing-up safety, as the following incident illustrates:
A spotter was directing a truck’s movement while another employee was backing a front-end loader down an incline. When the loader operator saw the spotter through his side windshield, he slammed his foot on the brakes, but the loader wouldn’t stop. Though the operator pumped repeatedly on the brakes, the loader still wouldn’t stop. Instead, it accelerated down toward the spotter, running over and crushing him. An OSHA inspection found that the brakes on the loader hadn’t been properly maintained, even though employees reported seeing large puddles of fluid under the equipment. Proper maintenance and a container of brake fluid could have saved the spotter’s life.
To prevent such accidents, truck drivers and equipment operators should inspect their units before operating them. In the cab, while moving the equipment in reverse, check to make sure it stops when the brake pedal is depressed. Check that the parking brake functions properly. While doing this, have another employee verify that the backup and brake lights are working. In addition, have them check for the proper sounding of the backup alarm, if installed. Make sure the mirrors are clean and properly adjusted. These and other inspection items should be noted on an inspection report. Any item that would make the equipment unsafe to operate should be reported to the appropriate supervisor.
As a final note, all operators must wear their seat belts
or other protective restraints during operations, and they should report any problems they discover while operating the equipment.
Following the above recommendations can help any truck driver or equipment operator back up safely rather than into danger.
Backing-Up Basics
Here are some preventive safety points that can improve backing-up safety in scrap recycling operations:
• Make sure all rearview mirrors on equipment are clean and properly adjusted.
• Verify that the braking systems and warning devices are functioning properly on all equipment.
• Check the path your equipment will travel before starting to back up, looking for any potential problems regarding obstructions, other equipment, and people.
• Understand blind spots and the various options to ensure that nothing gets in a piece of equipment’s blind spot while backing up.
• Teach all employees about blind spots and train them to not put themselves in that spot, even for a moment.
• Spotters should wear high-visibility protective gear and always be in direct sight of the backing-up operator. Spotters should also use clear directional signals that have been reviewed with the operator, while the operator must move slowly enough to properly react to these signals.
• Be aware of inclines that could increase the stopping distance of backing-up equipment.
• Always inspect your equipment before using it, and immediately report any problems.
New ReMA Video Covers Backing-Up Safety
Backing Up Safely is the latest addition to ISRI’s Working Safe & Smart video series. The 24-minute VHS video examines the dangers posed by backing-up trucks and industrial equipment, illustrating these dangers with accounts and graphic images of real backing-up accidents in scrap recycling operations. The video also provides safety tips to help scrap recyclers minimize the risk of backing-up injuries or fatalities in their operations.
Backing Up Safely was produced in February 2004, and a complimentary copy was sent to all ReMA members in May.
To order additional copies of this video—or any other ReMA safety resources—call 202/737-1770 or visit the association’s online Bookstore at www.isri.org. •
Trucks and other industrial equipment can pose serious safety risks when backing up. This advice can help you understand and minimize the dangers.