Construction sites are inherently dangerous, especially when heavy equipment is involved. According to OSHA, equipment-related accidents account for a significant portion of fatalities and injuries. Drawing from real OSHA-investigated case studies, here are 10 essential tips to enhance safety—each backed by a specific incident to highlight the risks and reinforce best practices.
1. Conduct Thorough Pre-Operational Inspections
Always inspect equipment for mechanical issues, structural integrity, and proper functioning before use. This includes checking brakes, hydraulics, and stability features to prevent malfunctions. Documenting these inspections can help track maintenance trends and ensure compliance with safety standards over time.
Supported by OSHA case: In a 2016 crane collapse in New York City, a Liebherr crawler crane fell during lowering in high winds due to inadequate pre-checks and planning, killing one motorist and injuring others.
2. Ensure Proper Operator Training and Certification
Operators must receive comprehensive training on specific equipment, including handling, limitations, and emergency procedures, with certifications renewed as required. Regular refresher courses can adapt to new equipment models or site-specific hazards, further reducing accident risks.
Supported by OSHA case: A fatal forklift accident at a Georgia battery plant in 2025 involved an untrained operator whose mishandling led to a worker’s death, prompting an OSHA investigation into training deficiencies.
3. Maintain Safe Distances from Operating Machinery
Establish and enforce exclusion zones around equipment to prevent struck-by incidents, using barriers or spotters when necessary. Clear signage and communication protocols within these zones can alert workers and prevent unauthorized entry.
Supported by OSHA case: In a 2022 crane boom collapse near Beaumont, TX, two brothers were killed when the boom fell on their truck, highlighting the need for clear zones during operations.
4. Secure All Loads and Attachments Properly
Use appropriate locking mechanisms, pins, and straps to ensure loads and attachments like buckets don’t detach unexpectedly. Double-checking attachments before each lift or operation adds an extra layer of security against equipment failure.
Supported by OSHA case: A pipefitter was killed in a California trench when an excavator bucket detached from a quick coupler and struck him, due to missing safety pins.
5. Never Leave Equipment Running Unattended
Shut off engines and engage parking brakes when exiting machinery to avoid unintended movement. Implementing a buddy system or remote monitoring can provide additional oversight in busy or remote sites.
Supported by OSHA case: A 59-year-old worker in Virginia was run over and killed in 2023 by an unoccupied bulldozer that rolled downhill after being left idling.
6. Use Rollover Protective Structures (ROPS) and Seatbelts
Equip machinery with ROPS and mandate seatbelt use to protect operators during tip-overs. Routine checks to ensure ROPS are undamaged and seatbelts are functional can prevent severe injuries in uneven terrain.
Supported by OSHA case: A bulldozer operator was ejected and asphyxiated under the ROPS in a 2023 Florida beach site flip-over after hitting a rut, exacerbated by not wearing a seatbelt.
7. Avoid Operating Near Power Lines or Hazards
Maintain at least 10 feet clearance from overhead power lines and survey sites for underground utilities. Collaborating with utility companies for pre-site marking can identify hidden dangers early in the planning phase.
Supported by OSHA case: From 1984-1994 data, cranes were involved in 108 fatal electrical injuries, often from contact with power lines during construction.
8. Implement Lockout/Tagout Procedures
De-energize and lock out equipment during maintenance to prevent accidental startup. Training all team members on these procedures ensures everyone understands their role in maintaining a safe work environment.
Supported by OSHA case: An employee was crushed between the lift arms and cab of a CAT 966 Wheel Loader in 2018 while cleaning asphalt, due to failure to lock out during close-proximity work.
9. Prohibit Riding on Forks or Platforms
Never allow workers to stand or ride on elevated forks or makeshift platforms, as falls can be fatal. Providing approved man baskets or lifts for elevated work offers a safer alternative to improvised methods.
Supported by OSHA case: A worker fell from a platform on a forklift and was pinned between the mast and frame, resulting in death from improper elevation practices.
10. Operate at Safe Speeds and on Stable Ground
Adjust speed to conditions and ensure ground is level and firm to prevent rollovers or loss of control. Conducting soil tests or using ground mats in soft areas can stabilize operations and minimize instability risks.
Supported by OSHA case: A front-end loader operator died in 1996 after the machine fell into an excavation, crushing him, due to unstable edge and lack of ROPS.
