equipment_rollover.ppt

Developed under an OSHA Susan B. Harwood Grant, #SH-19499-09-60-F-48, by
the Associated Builders and Contractors-Central Texas Chapter
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Equipment Rollover
Susan B. Harwood Grant Training Program

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Equipment Rollover
Susan B. Harwood Grant Training Program

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Disclaimer/Usage Notes
• Photos shown in this presentation may depict situations that
are not in compliance with applicable OSHA requirements.
• It is not the intent of the content developers to provide compliance-
based training in this presentation, or to train employees how to
operate the equipment depicted. The intent is more to address
hazard awareness in the construction industry, and to recognize the
overlapping hazards present in many construction workplaces.
• It should NOT be assumed that the suggestions, comments, or
recommendations contained herein constitute a thorough review of
the applicable standards, nor should discussion of “issues” or
“concerns” be construed as a prioritization of hazards or possible
controls. Where opinions (“best practices”) have been expressed, it
is important to remember that safety issues in general and
construction jobsites specifically will require a great deal of site- or
hazard-specificity – a “one size fits all” approach is not
recommended, nor will it likely be very effective.

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• No representation is made as to the thoroughness of the
presentation, nor to the exact methods of remediation to be taken. It
is understood that site conditions vary constantly, and that the
developers of this content cannot be held responsible for safety
problems they did not address or could not anticipate, nor those
which have been discussed herein or during physical presentation. It
is the responsibility of the employer, its subcontractors, and its
employees to comply with all pertinent rules and regulations in the
jurisdiction in which they work. Copies of all OSHA regulations are
available from your local OSHA office, and many pertinent
regulations and supporting documents have been provided with this
presentation in electronic or printed format. This presentation is
intended to discuss Federal Regulations only - your individual State
requirements may be more stringent.
• It is assumed that individuals using this presentation or content to
augment their training programs will be “qualified” to do so, and that
said presenters will be otherwise prepared to answer questions,
solve problems, and discuss issues with their audiences.

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• As a presenter, you should be prepared to discuss all of the potential
issues/concerns, or problems inherent in those photos with the
students

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Why Require Training?
• Operator training is required by:
– OSHA
– Manufacturers
– Clients
– Employers

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Why Is Training Needed?
• OSHA investigated two fatal
accidents in 2005 in southern
Colorado involving the rollover of
pneumatic rubber-tired
roller/compactors

8
Accident #1
• May 2005
• Employee was
fatally injured
while operating
a pneumatic
rubber-tired
roller

9
Accident #1
• Roller ran off the road and traveled
down a 22-degree embankment
• Rolled over 1½ times, stopped on its
top
• Operator was thrown from the
machine
–Fatally crushed between the machine
and ground

10
Accident #1
• Roller was originally equipped with a
ROPS and a seatbelt
–Both had been removed prior to the
accident

11
Accident #2
• August 2005
• Employee was
rolling material
into the gravel
using a
pneumatic
rubber-tired roller

12
Accident #2
• Roller ran off the road and down a 28-
degree embankment
• Compactor rolled onto its side and
came to a stop
• Operator was thrown from the
machine and fatally crushed
• Roller was not provided with a ROPS,
operator not wearing a seatbelt

13
Summary of Accidents
• In both cases,
–If the machine had been equipped with
a ROPS system, and
–If the operator had been wearing a
seatbelt,
The operator’s survival would have
increased significantly

14
Additional Accidents
• Between 2000 and 2006
• OSHA investigated over 50 rollover
incidents

15
5
0
19
14
1 1
6 6
0
2
4
6
8
10
12
14
16
18
20
ROPS/Seat
Belt
ROPS/No
Seat Belt
ROPS
Removed
No ROPS
Total Cases
Fatal Cases

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Roller Compactor Safety
• Always be aware that a rollover hazard
exists
• ROPS and seatbelts ALWAYS reduce the
risk of a fatality
• Highest hazard locations were roadway or
embankment edges

17
• When operating on uneven surfaces,
chances of a rollover increase
• Another hazard was runaway machines,
typically down slopes
• Evaluate roadways and work surfaces for
dangerous inclines/declines

18
ROPS
• A ROPS is a protective frame
mounted on the machine and extends
above the operator’s seat
• ROPS bear the weight of the machine
during a rollover event
• ROPS minimize the likelihood that the
machine will overturn completely

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ROPS
• A principle in ROPS design is to
restrict the overturn to 90 degrees
• ROPS must to be used in
combination with a seatbelt
• A ROPS only provides protection if
the operator remains in the seat

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• A number of hazards associated with
rollovers were pointed out, including:
– Working near road edge or embankment was
the most hazardous
– The second most hazardous were steep
slopes and roadway curves
– Problems with gear-shifting and brakes
resulted in runaways
Source: Compactor Overturns and Rollover Protective Structures

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• Compacting soil appeared to be more
hazardous than other operations
• Hazards included the soil edges and
soft soil pockets that could drop under
the weight of the unit.

22

23

24

25

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Compactor Roller Safety
• Loading and unloading machines onto
trailers posed a potential overturn hazard
• Hazards were caused by
– skidding on the ramps,
– using wood blocks or planks as ramps,
– or a machine that was too narrow to span
both sides of the ramp

27
What is this in the
background?

28

29

30

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Need for ROPS
• Studies show that if the machines involved
are equipped with ROPS, and if the
operators are wearing seatbelts, the
operator’s survival increases significantly

32
Regulations
• OSHA does not have a standard requiring
the use ROPS or seatbelts
• OSHA’s position is that the hazard of
equipment rollover is a “recognized
hazard” within the meaning of the General
Duty Clause of the OSH Act

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General Duty Clause
(a) Each employer --
(1) shall furnish to each of his employees
employment and a place of employment
which are free from recognized hazards
that are causing or are likely to cause
death or serious physical harm to his
employees;
(2) shall comply with occupational safety
and health standards promulgated under
this Act

34
General Duty Clause
(b) Each employee shall comply with
occupational safety and health standards
and all rules, regulations, and orders
issued pursuant to this Act which are
applicable to his own actions and conduct

35
Other Regulations
• 29 CFR 1926.20(b)(4), states “the
employer shall permit only those
employees qualified by training or
experience to operate equipment and
machinery.”

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Other Regulations
• 29 CFR 1926.21(b)(2), “Safety training
and education,” states further that “the
employer shall instruct each employee in
the recognition and avoidance of unsafe
conditions….”

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• Employers performing construction work
are required to ensure that their operators
are trained;
– To use the equipment properly and
– To understand how to recognize those
situations and conditions that pose a rollover
hazard

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• For example, operators need to
understand that:
– Soft edges can cause one side of the
equipment to sink and therefore may pose a
risk of rollover;
– Turning away from a slope with articulated
steering can destabilize the compactor;

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• Improperly inflated tires can destabilize
roller/compactors; and
• Rain or wet conditions can pose a hazard
during unloading and loading
• and can increase the possibility of
rollovers near embankments as soil
conditions become unstable

40
• Leaving a compactor vibrator engaged
while stationary has led to the settling of
soil on one side of the unit, allowing it to
overturn
• Articulation of a mobile unit with the
jackknife pointed toward an edge presents
a substantial overturn hazard

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• Remember to always think safety, the life
you save may be your own
• Always use ROPS and seat belts
• Now we will review as well as discuss
proper procedures for operating your
machine

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Safety is Important
• Three reasons Safety is important :
– Accidents can cause death or serious injuries,
or disability,
– Accidents can cost both you, and your
employer
– With proper training, and with Machine
Operators making it their responsibility to
work safely, accidents can be prevented

43
Safety Alerts
• The Safety Alert
Symbol is used to;
–Identify important
safety messages
–Alert you to the
possibility of
injury or death

44
Safety Alerts
• Follow the
instructions in the
safety message to
prevent injury to
yourself or others

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Manufacturer’s Manual
• States that you must be qualified and
authorized to operate the machine
• YOU must
– understand the manufacturers instructions
– be trained
– demonstrate the actual operation of the
machine
– know the safety rules and regulations

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Signal Words
• DANGER - indicates an imminently
hazardous situation that will result in death
or serious injury
• WARNING –indicates a potentially
hazardous situation which could result in
death or serious injury
• CAUTION –indicates a potentially
hazardous situation that may result in
minor or moderate injury

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A Word to the Operator
Remember that Safety is up to YOU, only
YOU can prevent serious injury or
death

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Follow a Safety Program
• Protect yourself by wearing the
appropriate PPE
– Hard hats, safety glasses, hearing protection
• WARNING! – Do not wear loose fitting or
dangling clothes
• Be Careful
– Encourage those around you to act safely

49
Safe Operation
• Drugs or alcohol use can change your
alertness or coordination
• Consult with your medical advisor if you
are taking prescription or over-the-counter
medication
– Ensure you can safely operate the machine
– Check the label for warnings against
operating machinery

50
Know the Safety Rules
• Your employer on the job site will have
rules on the proper operation of equipment
• Check with your supervisor or safety
coordinator to learn the rules for your job
site

51
Safety Rules for Compactors
• Know how to operate the Machine, and
the characteristics of the machine
• Never modify or remove part of the
machine
• Always fasten your seat belt
• Keep other workers out of the work area

52
• Lower the blade and all other hydraulic
attachments (if equipped) to ground.
–Know the proper shut down procedure
for your specific machine as this can
vary from different types and models of
machines
–Remove your key to keep unauthorized
people from operating the machine

53
Job Site Traffic
• You must know the rules covering traffic at
your job site,
• Understand what the signs, flag signals,
and markings mean,
• Know what hand, horn, whistle, siren or
bell signals mean
• Use your lights, turn signals, flashers and
horn

54
Know Your Equipment
• Know how to operate the equipment on
your machine
• Know the purpose of the controls, gauges,
and indicators
• Speed range, braking and steering
characteristics
• Know the turning radius, and operating
clearances

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Know Your Equipment
• Rain, snow, ice, loose dirt or gravel, soft
ground all change the operating
capabilities of your machine
• Study the DANGER, WARNING and
CAUTION signs and decals on your
machine

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Operator’s Manual
• Study and know the manufacturer’s
operations manual before starting the
machine
• If there is no manual with the machine –
Get One
• Ask your supervisor to explain anything
that you do not understand

57
Operator’s Manual
• If your machine is equipped with other
devices,
– Read the manufacturer’s operating and safety
manuals that apply to that equipment
BEFORE you use the device

58
Preparation for Use
• Check the safety equipment
– Seat Belt/Operator Restraints
– Lights
– Safety Signs/Decals
– Horn
– Back-Up Alarm
– Mirrors
– First Aid Kit
– Fire Extinguisher

59
Preparation for Use
–Falling Object Protective Structure
(FOPS)
–Roll-Over Protective Structure (ROPS)
WARNING – NEVER remove a FOPS or ROPS
structure except for service

60
Preparation for Use
• Check the machine each day before use
– Check for broken, missing or damaged parts
– Have necessary repairs made before using
– Check Pneumatic tires (if so equipped) for
cuts, bulges and correct pressure
– Replace badly worn or damaged tires

61
Preparation for Use
• Check the machine each day before use
– Check the service and parking brakes
– Perform all maintenance procedures
– Check the hydraulic system
– Fix any leaks

62
Preparation for Use
• WARNING – Diesel fuel or hydraulic fluid
under pressure can penetrate the skin or
eyes and cause serious injury
– Never use your hand to find leaks
– Wear a face shield or goggles
– Use a board or cardboard to find leaks

63
Preparation for Use
• Check the cooling system
WARNING – Allow the radiator to cool
before checking the level

64
Preparation for Use
• Before operating check that the steering
frame lock on articulated machines has
been removed
WARNING – An articulated machine cannot
be steered with a steering frame lock in
place

65
Preparation for Use
• If you find an item that needs repair during
your daily inspection
• report it to your supervisor and tag the
machine on the start switch or other
location where it will be noticed.
• You should never operate a machine that
isn’t in safe working condition.

66
Preparation for Use
• Clean up the machine
– Windshields
– Mirrors
– All lights
– Steps and hand holds
• Remove personal items from the operators
area

67
Preparation for Use
• Use caution when fueling
– Never overfill or spill fuel
– Ground the fuel nozzle to the filler neck
– Use the correct fuel
WARNING – Never fill when the engine is
running, and never smoke while fueling
up.

68
Preparation for Use
• Know the work area:
– Inspect the Conditions of area you will be
working for conditions that could be
dangerous:
– Drop-offs or other obstacles
– Holes, obstructions, mud or ice
– Heavy traffic
– Thick dust, smoke or fog

69
Preparation for Use
• When operating inside a building know
your clearances
– Overhead
– Doorways
– Aisles
– Weight limitations of floors and ramps

70
Preparation for Use
• For Landfill Compactors:
• Perform frequent checks for wire or other
material wound around the axles and
remove them as soon as possible,
• Travel with the blade in the low position
and,
• Make sure you maintain good visibility by
keeping windows free of materials that
could interfere with visibility.

71
Preparation for Use
• While operating Machine:
– Approach intersections with caution
– Observe speed limits and traffic signs
– Know your stopping distance
– Avoid panic stops and sharp turns

72
Preparation for Use
• While operating Machine:
– Stop and clear all railroad crossings
– Never park in traffic areas
– Use appropriate lights at night
– Pull off the road and set up barricades when
parking at night

73
Preparation for Use
• If the machine will be driven over the road
– Use hand signals or turn signals when turning

74
Starting Safely
• Mount the loader safely:
– When you get on or off the machine:
• Maintain 3 point contact with the steps and
hand holds
• Face the machine
• Never jump on or off the machine

75
Starting Safely
• Mount the Roller Compactor safely:
– When you get on or off the machine:
• Never attempt to mount/dismount a moving
machine
• Do not use the steering wheel or any
control lever as a hand hold

76
Starting Safely
• Warn personnel before starting:
– Before starting, walk completely around the
machine
• Make sure no one is under the machine
servicing it, or close to it
• Let other workers know you are starting the
machine

77
Starting Safely
WARNING – Start the machine from
the operators seat only
Never by-pass neutral-start circuits by
jumping the starter terminals
The machine may start in gear and
injure or kill you or someone else if
started in gear

78
Starting Safely
• Know the starting procedure for your
machine:
–Sit in the seat and adjust it so you can
operate all controls properly
–Fasten the seat belt
–Engage the parking brake, put controls
in neutral

79
Starting Safely
• Know the starting procedure for
your machine:
–Familiarize yourself with warning
devices, gauges and operating
controls
–Clear the area of all persons
–Start the engine

80
Starting Safely
WARNING – Exhaust fumes can kill
• Be positive there is adequate ventilation
while operating

81
Starting Safely
• Jumper cables
– Follow instructions on proper use of jumper
cables
– Operator must remain in seat to control
machine
– Jump starting is a two-person operation

82
Starting Safely
• Ether Starting Fluid
– Ether is highly flammable and explosive
– Read the instructions on the container and in
the manufacturer’s manual.
– Do NOT use ether if the machine has a pre-
heater

83
Starting Safely
• After Starting the Engine
– Observe gauges, instruments and warning
lights
– Run an operating check
• Do not use a machine that is not in proper
operating condition
• It is the OPERATOR’S RESPONSIBILITY
to check the condition of the machine

84
Starting Safely
• Test the Controls
– Make sure the machine is operating correctly
– Put machine in neutral, test the engine speed
control
– Operate each control lever for proper function

85
Starting Safely
– Operate the shift controls to ensure forward,
neutral and reverse operate correctly
– Check the parking and service brake systems
– Test steering while moving slowly

86
Starting Safely
WARNING – Be certain you can control
both speed and direction before moving
the machine

87
Working Safely
• Stay in the operator’s seat at all times
• Keep your seat belt fastened when you drive or
operate the Roller Compactor
• Be in control of your machine at all times
• Assure yourself that the work area is clear of
other persons
• Look and listen for malfunctions
• Stop if a malfunction is detected
• Do not use the machine as a ram

88
Working Safely
• Never allow an untrained or unqualified
person to operate your machine
WARNING – Your Roller Compactor is a
one-person machine, NEVER permit
riders

89
Working Safely
• If operating Machine on road make sure
you use appropriate warning signs and
emblems “Slow moving vehicle”
• Look before you back up, and make sure
backup horn is working properly
• Know the pinch points and rotating parts
on the machine

90
Working Safely
• Traveling on the job site
– Take it slow and easy
– Watch out for congested areas
– Give the right-of-way to loaded machines
– Maintain a safe distance from other machines
– Pass cautiously

91
Working Safely
• Don’t obstruct your vision when traveling
• Operate slow enough to have complete
control at all times
• Travel slowly on rough, slippery ground or
hillsides
• Avoid operating your machine too close to
an overhang, deep ditch, or hole
• Always use service and parking brakes
carefully

92
Working Safely
• Stay in gear when traveling downhill,
never shift into neutral
• Maintain engine RPM to provide steering
and braking
• Use the same gear traveling down that
you would use travel up a hill
• Follow manufacturer’s manuals on brake
use

93
Working Safely
• Extreme caution should be used when
working along the top of a bank or slope
• Keep away from the edge
• Always look back when backing up
• Be extremely alert in hazardous areas
• Always be alert for low branches and dead
trees

94
Working Safely
• Before entering buildings, underpasses,
tunnels or bunkers check for hazards or
obstructions
• Check clearance height
• Avoid turning on an incline
• Use extreme caution and make the turn
wide and SLOW

95
Working Safely
• When in dust, smoke, or fog use extreme
caution
• Keep speed to a minimum when visibility
is poor

96
Working Safely
• Keep the work area flat and level if
possible
• Be aware of potential caving edges and,
• Always travel slowly over rough terrain or
avoid it and go around it

97
Working Safely
WARNING – Never enter or allow anyone
else to enter the Roller Compactor swing
pivot area,
• Death or serious injury can result
• Always make sure you follow the
manufacturer’s recommendations before
you operate the Roller Compactor

98
Working Safely
WARNING – Never operate the controls
from the ground
• Severe injury or death can result
• Always operate the Roller Compactor from
the correct operating position

99
Working Safely
• When operating your Machine on the road:
– Know your stopping distance at whatever
speed you’re going
– NEVER turn corners at high speeds
– Always look in all directions before you travel
forward or reverse

100
Working Safely
• Never operate Machine when extremely
tired:
– Your response time will be slower
– Your judgment will be impaired
– Remember Safety is your responsibility

101
Working Safely
Be Aware of :
• Trenches that may be to close to your
Vibratory Compactor, as it could cause a
collapse
• Buildings and Light Poles that might be to
close to where your Vibratory Compactor
is operating as damage may occur
• Always be sure workmen and others are
far enough away to avoid injury

102
Working Safely
WARNING – Always remember that
regardless of how heavy or stable your
machine may feel or appear to you, there
is always a chance of a rollover when
working on steep slopes
Always wear your seatbelt and make sure
your ROPS is on your machine

103
Working Safely
• Towing over-the-road is not recommended
• If your machine must be towed on the job
site
– Use a rigid tow bar (not a chain or rope)
– Never allow anyone to ride on towed machine

104
Loading and Unloading
• If the machine is equipped with a ROPS,
you must wear the seat belt or restraint
when loading or unloading the machine
• Follow the procedures recommended by
the machine manufacturer for loading and
unloading

105
• Several precautions are applicable to all
machines
– Know the correct loading and unloading
procedure
– Load and unload on a level surface
– Block the transport vehicle so it cannot move

106
• Several precautions are applicable to
all machines:
– Never load or unload the machine by yourself
– Keep all people not involved in the loading or
unloading process clear
– The ramp and trailer must provide adequate
traction for loading or unloading machine

107
machines:
– Use ramps of adequate size and strength,
– Proper ramp angle and height
– Keep the trailer bed and ramps clear of mud,
oil, ice, snow and other slippery materials

108
machines:
– On articulated machines, attach the steering
frame lock after loading, remove before
unloading
– Chain and block machine securely for
transport
– Keep everyone clear of the area

109
• Know the overall height and width of the
transporter and Roller Compactor
combined to avoid overhead and narrow
obstructions

110
• Whenever you park the machine:
– Park away from road and traffic,
– Park on level, stable ground whenever
possible
– When it is not possible to park on level ground
park the machine at right angles to the slope
– Block your machine in both directions, and
apply parking brakes

111
Park Safely
• Safe Shutdown of the machine
– Stop the machine – use the service brake
– Lower attachments to the ground
– Shift controls to neutral/park and lock
– Engage parking brake

112
Park Safely
• Idle engine to cool down
• Stop engine
• Cycle all hydraulic controls
• Remove the key, and
• Shut off the master switch

113
Park Safely
• Safe Shutdown of the machine:
– Maintain three point contact when leaving the
machine
– NEVER jump off the machine
– Be careful of slippery conditions
– Block wheels if on a slope or incline

114
Maintenance
• Do not perform any work on a machine
unless you are authorized and qualified to
do so
• Attach a DO NOT OPERATE tag to the
switch if maintenance is needed
• Remove the key if the engine should not
be started

115
Maintenance
• Never work on the machine with the
engine running
• Exhaust fumes are hazardous to your
health, if necessary to run the engine in an
enclosed area use an exhaust pipe
extension or have proper ventilation.

116
Maintenance
• Be careful of fluids under pressure
– Use a piece of cardboard or wood to find
leaks
– Never use your bare hand
– Wear a face shield or safety goggles
• If fluid is injected into any part of your
body, go to a doctor for treatment
immediately

117
Maintenance
• Stop the engine while refueling
• Don’t smoke while refueling
• Don’t smoke when using starting ether
• Lead acid batteries can be explosive
– Keep arcs, sparks and flames away

118
Maintenance
• Special tools and procedures are required
for tire repair
– Call a repair service
• Maintain correct tire pressure
– Do not over-inflate
• Do not operate equipment if
– Tires are cut or damaged
– Lug bolts are missing

119
Test Your Knowledge
• Do you understand
– Your safety program
– The machine manuals
– Proper clothing and PPE
– The machine controls, warnings and devices

120
Test Your Knowledge
• How to inspect, mount and start your
machine
• How to check for proper operation
• Your work area and any special hazards
• Proper operating procedures

121
Test Your Knowledge
• Do you understand
– Proper parking, shutdown and dismounting
– Proper maintenance procedures
– Proper unloading and loading procedures
– The conditions where you should not operate
your machine

122
Conclusion
It is impossible for this course to cover every
hazardous situation you may encounter.
Your knowledge of the safety precautions
from this course and adherence to the
basic rules of safety will help you use good
judgment in all situations.
Safety is your business and
responsibility

123
Questions?
• Answers to additional questions can be
found in the following source materials
– 29 CFR 1926 Construction Regulations
– AEM Roller/Compactor Safety Manual

equipment_rollover.ppt

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