Accountability Starts With You SAMPLE · Did you know? Regulations specify that an operator must take a refresher course if any of the following apply: • The operator is observed

Copyright Safety Provisions, Inc.

The material presented within this course is for educational and training purposes only. All parties involved in the development, distribution and maintenance of this course shall be held harmless from any incident resulting from misuse of the content beyond the guidelines and purposes herein stated. Before you begin, you should understand that it is your responsibility to adhere to the laws and regulations presented within the following course and its corresponding materials. Likewise, it is your further responsibility to strictly follow any additional guidelines specific to your own workplace. Good luck & stay safe!

Note to Instructors: The first few slides in this presentation can be drawn upon as desired and used to initiate dialog as to the importance of safety training and operator responsibility. If you choose to skip these slides, the official presentation begins on slide 26.

Accountability Starts With You

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Anyone who operates heavy equipment must receive training prior to operating any machine on their own. As noted below, requirements for refresher training are also very specific.

Did you know?Regulations specify that an operator must takea refresher course if any of the following apply:

• The operator is observed operating the equipment in an unsafemanner (e.g., no seat belt, reckless driving, etc.)

• The operator is involved in an accident or a near miss• The operator received a poor evaluation for performance• The operator is required to use a different type of machine or

attachment• Workplace conditions have changed

Additionally, regulations state that it is the employer who is responsible to determine the frequency of refresher training.SAMPLE


Best practices and, in many cases, the standards also says that each operator must be re-evaluated every three years to see if they are still competent to operate the equipment. A so-called “free-pass” cannot be awarded based on experience, age, or time on the job. The extent of the evaluation is to be determined by the employer, but should include a written and practical examination that prove continued competency.

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Initial training, as well as any evaluations or refresher courses must be documented with the name of the person or persons who taught the class or conducted the evaluation. Although wallet cards are not always required as proof of training, many companies and worksites do require onsite proof that you have been trained. At the very least, in the case of an investigation, inspectors will want to see proof of proper and consistent training (in the way of training outlines, class lists, training goals, tests, certificates, etc.)

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Welcome to the Hard Hat Training Series!

Welcome to the Hard Hat Training Series! Today we will discuss the safe operations and maintenance of Road Compactors, also known as steam rollers, rollers, roller compactors, and soil compactors. SAMPLE


Used to compact and flatten both soil and asphalt, the compactor originated from the steam powered roller, earning the name steam roller, which originated in France in 1860. These rollers became popular, and were used to build roads around the world. Around the 1950’s these machines turned to diesel rather than steam for their power source. SAMPLE


Today, these machines are still essential in building roads and preparing sites for construction projects. These compactors vary in style, size, drum type, cab, and features. Because of this variety, this training might cover, or not cover, aspects of your compactor, making it even more important that you familiarize yourself with your compactor and its manualSAMPLE


Perhaps, as a child, you spent hours playing in the backyard with a miniature version. But these, of course, are not toys. The bigger the machine, the greater the potential for damage, and the greater the need for responsible operators. With that in mind, the goal today is to focus on general safety principles and provide information that will increase your knowledge, make you a better operator, and keep you and those around you safe.

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To explain the safety principles in this presentation, we will take a look at the functionality and components of compactors. We’ll also show you why it’s important to conduct a thorough inspection at the beginning of each shift before operating the compactors.SAMPLE


We will look at machine stability and the importance of careful operations to prevent common rollover accidents with compactors.

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We’ll emphasize the importance of planning each job, as well as the importance of knowing your machine and the area you will be working in. Understanding your machine, as well as the area you are working, in is imperative.

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And finally, we will touch on some of the more common hazards associated with compactors and discuss how to recognize, avoid, or minimize them.

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By the time you complete this training with both the written and practical exams, you should be better prepared to safely operate a compactor. You will be familiar with the equipment used by your company, have an increased knowledge of how to set up and safely operate it, and be able to recognize and avoid the most common hazards associated with their use.

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These are some of the main standards concerning loaders and earth-moving operations. Many areas have additional standards, as do some industries. It is your responsibility to know all federal, provincial, local and any company rules that apply to your machine and jobsite.

CAN/CSA-B352.0-09: ROPS, FOPS (General Equipment)

CAN/CSA-M12117-05: Eartj-Moving Machinery (TOPS) for Compact Excavators

CAN/CSA-M3471-05: Earth-Moving Machinery – ROPS, Laboratory Tests, Performance Requirements

Can.CSA-M3450-03: Earth-Moving Machinery – braking Systems of Rubber-Tired Machines – Systems and Performance Requirements and Test Procedures

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• Received training by a qualified person.• Read and understood the manufacturer's operating

instructions and safety rules as found in the operator’s manual.

• Read and understood all decals, warning labels, and capacity plates on the machine and attachments.

• Performed a thorough pre-shift inspection each day prior to operating the machine.

Equipment operators also share in the responsibility to ensure that they and their co-workers have:

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Anatomy & Components

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In this section, we will look at the basic anatomy and major components of compactors and give a general description of each of them. We’ll also go over things you should look for while performing a pre-shift inspection. Your operator’s manual should have a more detailed list. SAMPLE


Because there are multiple different compactors, some aspects of your compactor might not be covered in this training. Likewise, this training might cover features that do not apply to your compactor. For this reason, it is essential that you familiarize yourself with your compactor and thoroughly read the operator’s manual. SAMPLE


When inspecting a compactor’s structural integrity and functionality, pre-shift inspections are generally broken down into two groups: “Key Off” and “Key On” checks. In other words, inspections that are done with the engine off or on, respectively. However, for the purpose of organizing this presentation, we will address off and on checks simultaneously, working from the inside of the compactor outward.

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These are some of the main interior components of a compacter. Of course, control types, names, and locations will vary by brand and type:

• Temperature Control Panel• Gauge Panel• Steering • Main Switch Panel• F-N-R lever (Travel Lever) • Emergency Brake • Vibration controls and switches • Engine Speed selector • Front Windshield Latch• Right Door Release Lever• Seat• Horn

Operator’s Station

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Always use a checklist specific to your compactor to guide you through any pre-operation checks. This list is often provided by the manufacturer or your employer. Maintenance schedules located on the machine should also be strictly followed.

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Being familiar with the compactor begins with the operator’s manual. The operator’s manual is required to be on the machine at all times, and everyone who operates it should be familiar with it, especially the safe operations portion of it. As mentioned, this manual also has guides for inspection and maintenance.

Operator’s Manual

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While it may seem like a small thing, if you find the operator’s manual to be illegible or missing, replace it immediately. Too often, operators are found operating machines without knowing where the manual is, or having never read it at all. This is especially true for all attachments, since they also come with their own manuals. These manuals should be read, understood, and kept on the attachment at all times.

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Inside the machine, the simplest place to start inspecting is the floor. Make sure that the floor is clear of any garbage, tools, or other objects. These can interfere with the operator or controls of the compactor.

Operators Cab and Seat

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The seat should also be inspected. While it may seem unimportant, it’s a device designed to keep you safe. This is true on many levels, especially relating to ergonomics and the health of your back muscles and spine. As soon as you are seated, your seat should be properly adjusted. If the seat is damaged in any way, take the time to fix it.SAMPLE


The seat belt can save your life, and because of this you should always wear it. Make sure it locks and unlocks correctly and that there are no tears in the fabric that could prevent it from protecting you in the case of a tip over. Often, serious injuries occur that could have been prevented had the operator been wearing his seatbelt.

Safety Devices and Seat Belt

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Excessive rust should also be addressed if it keeps the belt from locking and unlocking with ease. On some older machines, there may not be a seat belt. In this case, you should consult the manufacturer. Many companies have seat belt kits that should be installed on older machines.

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Another safety system that may be found in the cab is the fire extinguisher. If the machine comes equipped with an extinguisher . At the very least, extinguishers should be visually inspected monthly. They should also be tested and subjected to a maintenance check annually. Also, be aware that they do expire or can become inoperable with time. As the saying goes: when in doubt, change it out.

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Manufacturers also require that certain warning labels and informational decals be located inside the cab. These are not just for show or a one-time reference, but have everything to do with safe operations. Keep them clean and replace them if they are missing or become illegible or damaged.

Interior Cab Decals

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Once the cab has been looked over and determined to be in good condition, it’s time to test the controls. With the parking brake on and travel lever in neutral, start the engine and let the engine heat up to operating temperature. Go through each function of the compactor to make sure the controls do what they are supposed to do.

Controls

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Check every control, lever, button, and switch. Make sure they operate smoothly through all functions, that they do not stick, are not damaged, and that there are no delays in movement. Pay attention to the gauges and dials, too.

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More specifically, in a flat, safe area test the forward and backward movement of the compactor, as well as its turning and stopping capabilities. Any delay or malfunction should be addressed immediately so it doesn’t lead to an accident. Make sure that it is safe for both the machine and for the surrounding area before testing the vibrating system. SAMPLE


The parking brake should be applied whenever you are leaving the machine. The location of the parking brake varies by machine. The operator’s manual will tell you where the parking brake is located on your machine and how to activate it. Apply the parking break whenever leaving the machine .

Parking Brake

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The reverse signal alarm and beacon light should also be tested. The alarm will sound when the reverse gear is engaged. If your particular machine did not come with them, consider having an approved after-market alarm installed. They can be vital in preventing a worker or pedestrian from being run over.

Backup Alarm

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Similarly, the horn is one of the most important safety devices you have to alert pedestrians and other workers of your presence. It should be tested each day and used throughout a shift.

Horn

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Even the heat and cold air should be checked, and any saturated interior filters should be replaced. It’s common to see a lot of operators tough it out in hot, cold, or dusty conditions; however, research shows that in such conditions, a worker’s ability to operate efficiently is impaired. Doing so can also quickly lead to heat stroke, hypothermia, respiratory complications, or other illnesses.

Air, Heat, and Others

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If interior mirrors are present be sure that they are clean and positioned correctly. Each mirror serves a purpose and can be the means of protecting you and those around you.

Interior Mirrors

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The windows (both inside and outside) should also be kept clean and free from damage to maintain maximum visibility at all times during operations. Test the wipers and the defrost heater, and repair any cracks or chips immediately.

Glass

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Once you are done inspecting the interior of the compactor, you must also check the exterior for proper labeling, structural integrity, and operational components.

Exterior

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There are many components on compactors that make them function. These will vary on each compactor. It is important that you are familiar with this machine to be efficient as well as safe. We have outlined common components that need to be checked before every shift.

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First, before any exterior inspection, make sure you are wearing the proper Personal Protective Equipment (PPE) for the job, especially gloves and eye protection when you will be checking fluids and hoses for leaks. Since most hydraulic hoses are under high pressure, a leak the size of a pinhole can inject fluid under your skin, leading to poisoning, infection, and even death.

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Now, just like the operator’s manual and warning labels inside the machine, there’s information on the outside that also needs to be in place and can help you be a better operator. More specifically, you should know where to find the model number and be aware of the operating weight of the compactor.

Capacity and Labels

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The manufacturer also requires certain warning labels to be on the compactor. The operator’s manual should have a list of the required decals and labels. These labels also need to be in a legible condition. If they’re not or if they are missing, replace them immediately.

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The frame is the foundation of the machine. These are designed to be resilient but should be checked for cracks or deformities during your exterior checks. Make sure that you report and wear on the frame and have necessary repairs done before operating the compactor.

Frame

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In order to be able to turn, many compactors have an articulation joint, usually between the operators control center and the front drum. This joint should be inspected for any wear, cracks, or other damage that might compromise its integrity. The articulation joint should never be stood on, or used as a step by the operator or other workers.

Articulation Joint and Lock

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These joints are able to be locked in place by the articulation lock. This lock should be applied whenever transporting, lifting, or performing the maintenance on the machine. Operators should make sure that the articulation lock is not in place before operating the compactor as this will prevent it from turning.

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Generally speaking, the body of the compactor itself should be visually inspected for any damage or signs of deterioration. More specifically, whether old or new, inspect the chassis and body for loose fasteners or bolts, damage to the body and its working components, excessive rust, structural cracks, or any broken welds.

Body

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It is common to see compactors equipped with a Role Over Protection System (ROPS), these structures prevent the compactor from rolling over incase of an accident. Coupled with a functioning seatbelt, the ROPS is highly effective in preventing serious accidents and fatalities in cases of rollover. These should be inspected daily for any structural compromises to the structure

Protective Structures

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On that note, do not, under any circumstances, modify structural members by welding on additional parts, drilling holes, cutting, or grinding. This will affect the integrity of the ROPS and they will need to be replaced.

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While you’re inspecting the ROPS, take time to look at the lights. It is common to see lights that have been broken, removed, or are misaligned. But all lights must be operational. This is especially important when working at night or in the morning, under cover, or on foggy or overcast days. Brake and reverse lights should also be checked and fixed or replaced if necessary.

Lights

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If your compactor has tires, they should be part of your daily inspection. Traditionally, off the lot, they are filled with air. Never fill a tire with anything that has not been approved by the manufacturer. If there are any questions about what can or cannot fill a tire, check your owner’s manual or contact the manufacturer.

Tires

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No matter the tire type, you should inspect them for missing lug nuts, bent rims, worn down tread (no less than 50% is the general rule), improper inflation, and leaks. Excessive rust should also be addressed. Note that an underinflated, worn out, or uneven tires can seriously affect the stability of your compactor. SAMPLE


Be aware that structural cracks are commonly found on and around the bolts and lug nuts. This is because of the day-to-day wear and tear they undergo. Extreme temperatures can take a toll, as well. Make sure the bolts and rims are void of any dangerous cracks or other damage. Never paint over them, as this could hide further signs of imminent failure.

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Because of the rough terrain on which compactors operate, it is common to see gouges in the tread. This is generally nothing to be too concerned about unless, of course, those gouges are extreme and can lead to bigger problems. Carefully check the tread and sidewalls, and replace the tire if you deem it is going to be a problem.

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Take the time to clean out the tire tread if mud, snow, or other debris becomes embedded between the grooves. These can reduce traction and decrease the compactor’s stability.

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Don’t forget to check the tire’s side that is closest to the machine and where it connects to the body. Too often we see operators checking the side facing out while ignoring the inner side of the tires. These can become damaged just as easily and they need to be inspected and cleaned often.

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There are numerous types of compactors. These are typically defined by the drums that are being used. There are multiple types of drums all with different uses. We will briefly describe the more common types of compactors and the drums that they use.

Drums

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The most common type is the smooth wheel drum. These can have one or two drums depending on the compactor. These are often equipped with oscillating equipment that are within the drums. These cause the drums to vibrate which in turn make the compactor more effective at reducing air pockets in whatever material is being compacted.

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Sheep foot rollers have hexagonal patterned protrusions that penetrate the soil. Similar to these are tamping rollers, which have bigger lugs, and are often equipped with four compacting wheels rather than one or two long drums.

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Pneumatic tired rollers use rubber wheels on axles to compact the ground. Compaction can be controlled by inflation of these tires. Because these use tires, however, special care needs to be taken to make sure that each tire is in good, working condition, and that they are inflated to the desired tire pressure before each shift.

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No matter the type of drum is on your compactor, it is vital that you do a visual inspection on your drum every day before your shift. Make sure that there are no cracks, deformities, or other compromising wear on the machine.

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Scrapers are placed near the top of the drum and are there to scrap off dirt and debris that might be on the drum. These maintain the compactors conditions and ensures a job quality for the compaction.

Scrapers

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Compactors can have two blades for each drum. Make sure that each blade is checked, and switched out when needed. Adjustments may need to be made on the blade. Consult the owner’s manual on how to make these adjustments and how much space should measure between blade and drum.

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Compactors are also equipped with a spraying system, designed to wet down the drum to prevent it from picking up materials while operating. This helps create a smooth compacted surface on whatever project is being worked on.

Water Sprayer and Pump

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Spray nozzles should be checked before operating. These can get clogged with dust and debris from the project being worked on. Likewise, hoses or other connections that supply water to the spray also need to be checked for wear or tear.

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The wetting system is supplied by a water tank located on the machine. Check the manual to know where to fill yours. You should constantly monitor the water levels in your machine and refill when necessary. Never run the pump without water. This will damage the pump.

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Lastly make sure that you drain the tank after your shift during cold weather conditions. Water freezing in the pipes and hoses can cause damage and compromise the wetting system.

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Engine CheckThe engine is the central factor for your compactor. Without it, no part of the machine will work. If you take care of it, it will extend the life of your machine and ensure the quality work is performed.

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Because engines will vary depending on manufacturer and model, strictly follow the schedule for maintenance as dictated by the manufacturer in the operator’s manual. This schedule is also often posted on a decal on the back of the engine cover. SAMPLE


Generally speaking, the fluids levels in your compactor should be checked each day before your shift. If your machine needs more oil, coolant, or hydraulic oil, fill it. Make sure that you do not run on low levels as this will cause damage to the machine. Consult your owner’s manual on what fluid will work in your machine. Use only approved fluids.

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More specifically, check the oil levels and make sure the oil is not excessively dirty. Replace it at least as often as suggested in the manual and sooner if needed. Only add the proper type and amount of oil. Do not add more than needed.

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Typically drums and vibrators will need refills on gear oil. Consult your owner’s manual to know what type and weight of oil to use. Use only approved fluids for your machine.

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Also check the fans, belts, batteries, filters, electric wires, and intake hoses. Replace and maintain them as instructed. SAMPLE


Fuel levels and fuel filters should also be checked, especially if the compactor has been idle for an extended period of time. Make sure you are familiar with the gas type your machine requires and that you know how to refuel it safely.

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Take caution when checking hydraulic lines. These have highly pressurized fluid, which, if injected into the skin, can cause severe injury. Whenever checking lines, use a piece of cardboard and run it behind the lines to look for leaks. This will protect you from potential injury and allow you to see if there are any holes in the lines.

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The importance of properly and routinely inspecting and maintaining your compactor cannot be overstated. Not only will it affect work efficiency, it can affect the safety of all involved. For this reason, if at any time you notice something wrong, immediately record it and report it to your supervisor. Then lock out and tag out the machine if it is unsafe to operate. Never use a machine that is in need of repair.

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Most compactors are not equipped to use attachments, however, tamping rollers will often have a blade, similar to that of a dozer. Like any machine, these need to be inspected daily to make sure they are in operating condition. Make sure to consult your owner’s manual for daily, weekly, and monthly maintenance that needs to be performed on these, or any other attachment that is equipped on your compactor.

Attachments

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Stability

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One of the key factors to pay attention to when operating a compactor is the stability of the machine. Several factors come into play with stability, including slope, dynamic conditions, and ground conditions. The size, build, and weight of the compactor you are operating also comes into play.

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Ground conditions, speed, sudden turning and stopping, wind, and the slope traveled—all of these things can introduce additional forces onto the machine that will make it less stable and increase the potential for tip over.

Dynamic Conditions “An object in motion will continue in motion unless acted upon by an equal or greater force.” -Sir Isaac Newton

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Ground conditions are another key factor when planning for compactor stability, more specifically the slope of the landscape and ground conditions of the worksite.

Ground Conditions

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If compactors use an articulation system to turn, the center of gravity shifts while turning. This increases the risk of rollover whenever making turns. Avoid making sharp turns or turning at high speeds, especially around loose or wet soil.

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Slopes and embankments are the leading causes in accidents among compactors. When possible, avoid working around slopes. Manufacturers will tell you what grade of slope your compactor can handle. Make sure that any slopes being worked on do not exceed the rated capacity of your machine.

Slopes

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Whenever working on a slope, always approach it at a 90 degree angle to the edge so that you are going straight up or down. Never drive diagonal to the edge. Approach slopes slowly. Do not attempt to turn or change the speed of the compactor while ascending or descending a slop. SAMPLE


Compacting areas around embankments are particularly hazardous. If the ground is loose, it may give way under the compactor, potentially causing a rollover. When possible it’s best to avoid the risk and not use rollers near embankments at all.

Embankments

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When compacting close to an embankment make sure that the center of gravity of the machine is on solid, compacted ground. As a general rule of thumb, making sure that a minimum of 2/3 of the drum width is on flat, solid ground can help prevent rollovers around embankments.

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In case of rollover, the ROPS on your compactor will help prevent the compactor from rolling multiple times. It is absolutely essential that you maintain the integrity of your machine’s ROPS, and that you always wear your seatbelt when operating the compactors.

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If for some reason your compactor begins to tip, do not attempt to unlatch the safety restraints to jump from the cab. Sometimes, operators think they would have enough time to clear the machine when it starts to tip, but many workers have been crushed while trying. Instead, brace your body and ride it out. The safety restraints can save your life.

Did you know?Even if your equipment is equipped with a ROPS system, it will not protect you from a rollover with out using your seat belt. In fact, it is not uncommon for

operators caught in a rollover without their seat belt to be injured by the very ROPS system designed to protect them. OSHA investigated compactor accidents. Seven out of seven accidents with out a ROPS system resulted in fatalities of the operator. In 19 accidents with machines equipped with ROPS but the operator was not wearing a seatbelt, 14 resulted in fatalities. With 5 accidents where operators wore seatbelts, and the machines was equipped with ROPS, all operators survived. In order to be fully protected in case of rollover, operators must wear their seatbelt and the machine needs to be equipped with an ROPS system. SAMPLE


Operations

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In this portion of the training, we will go over some safe operation guidelines. Compactor safety can be broken down into two main categories:

• Familiarity with your machine

• Familiarity with your work site

The more you know about what is going on and why, the more prepared you will be. Over the next few slides, we will repeat previously-discussed safety principles in order to reiterate their importance. They are common-sense standards offered as a reminder, and you should follow them with exactness.

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It has been said that “anyone can drive a compactor, but few know how to operate one.” Like any vehicle, what separates the drivers from the true operators is an understanding of and adherence to safe operating principles. Having a license to drive a car can help you as you learn to operate a compactor, but it does not qualify you. Only experience, training, and a respect for the rules can make you a safe operator.

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Many operators have driven compactors for several years. Experience has made them accomplished and well-practiced. This is good because they are efficient, but it can also be bad in that experience, at times, can give way to bad habits.

Know Your Machine

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So often, we do not stop to consider whether or not something is safe – because it’s the way we’ve always done it without incident. If you continue to operate unsafely out of habit, though, it is only a matter of time before an accident of some kind occurs. The following slides will touch on principles that are commonly ignored in the name of experience.

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First and foremost, you must receive training specific to the machine and job type. Remember, the controls and handling can differ widely from brand to brand, so in some cases you may need additional training specific to each machine. In addition to classroom training and a written exam, regulations require compactor operators to be observed operating the machine before they can be considered certified or qualified.

Training

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Again, read and be familiar with your company policy and the operator’s manual for your compactor. The manual has specific information you need regarding safe operations, maintenance, pre-shift inspections, and capacity and warning labels.

Operator’s Manual

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Conduct a thorough pre-shift inspection. These inspections and any completed maintenance should be properly recorded. SAMPLE


Aside from pre-operation checks and training, safe operations start with entering the machine safely. It may seem ridiculous, but injuries from incorrectly entering the machine can and do happen all of the time. This is especially true for operations where mud and weather conditions can make for slippery conditions.

Mounting, Dismounting

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Here are some things to consider when entering the machine:

• Use the three-point contact method • Never use the controls for steps or

handholds• Keep the handles and steps free from

grease and grime • Be careful when the conditions are muddy,

wet, or icy (one slip is all it takes)• Slowly and carefully rotate your body and

ease backward into the cab/seat• Position yourself comfortably to avoid

injury or inadvertently hitting controls• Adjust the seat and fasten your seatbelt

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When exiting follow the same precautions. Whenever exiting your machine, make sure that you are properly parked, with the brake applied, and that the machine is turned off. Never leave a compactor while it is running.SAMPLE


Compaction of the material is accomplished by the massive weight of the machine. As the compactor rolls over the ground material, the weight from the drums forces air out, resulting in a compacted material.

Compaction

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Move slow while compacting. A slow roll will facilitate a good compaction and will you maintain control of the compactor. Moving slow is especially important when using a vibration system.

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Different drums are better designed to handle different materials, including asphalt, gravel, sand, and soil. When selecting your compactor make sure that you select one that is designed to handle the specific job and material you need.

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Likewise some drums are not designed to compact certain materials. Make sure to consult your owner’s manual on your machine to know whether or not your compactor can handle the specific job and ground material. Using a compactor on materials that it is not designed for can cause damage to the machine.

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Vibrations created by the compactor will shift the material and reduce the air trapped inside. These systems can be very effective in getting a better compaction of ground materials with less time. However, special care needs to be taken with them as well.

Vibration

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Do not activate the vibration system while on hard or cured concrete or ground that has been frozen over. Using vibration can cause damage to the machine’s bearings, as well as other parts of the compactor.

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Make sure to shut off vibrations when the machine is not rolling. Immediately shut off vibrations if the machine is stuck in soil or mud while in the operation.

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Finally, make sure that it is safe to use the vibratory function in the area you are in. Vibrations can damage nearby buildings or underground supply ends. If there is any indication that it may cause damage, do not use the vibratory function.

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Before operating a compactor, make sure you are familiar with the position of the controls and what each one does. They should be properly labeled and legible. Keep hands, floors, and controls free from water, grease, and mud to ensure non-slip control.

Steering and Controls

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Slope WorkWhenever performing slope work you run a risk of tip over. To minimize this risk always approach a slope at a 90 degree angle. Never attempt to turn while on a slop.

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Other Precautions Whenever you start up your machine, make sure the area is clear of workers and pedestrians. Before starting the machine, sound the horn and allow time for everyone to leave the area.

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Whether you are going forward or backward, if it is day or night, you should always have a clear view of your surroundings, and you should let everyone in the area know you are there. Use accessory lights, warning signs, audible warnings such as horns, and signals to keep everyone aware and safe.

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Another topic that we just cannot emphasize enough is giving rides. Compactors, like most heavy equipment, are meant for onlyone person inside. Do not try to put multiple people in the cab at once, and certainly do not let someone hang onto the side as you travel from one point to another. While two of the above photos are of a backhoe and not a compactor, they illustrate theprinciple of not riding on the side of the machine. Unfortunately, this happens much more often than it should.

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Lastly, while it should go without saying, never allow children to operate the machine. Outside of family-owned farms, labor laws dictate that “a youth 16 or 17 years old may perform any non-hazardous job.” Operating heavy equipment does not qualify as “non-hazardous.” The law goes on to clarify that operators must be 18 years of age to drive heavy equipment.

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Now back to the seat belts for a minute: is it really required to wear them? This is a question we hear often enough—usually when wearing a seat belt is considered a burden by the worker, when someone is trying to justify not wearing one, or when they are using an older machine that did not originally come with seat belts.

Seatbelts

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In answer to the question, there is not always a specific standard that requires the use or installation of seat belts for compactors. But that doesn’t mean you don’t need to wear one. In fact, it is the responsibility of each employer to furnish to each of his employees a place of employment free from any recognized hazards that are causing or are likely to cause death or serious physical harm.

That means the employer needs to take measures to prevent injuries in the case of a common accident—like a tip over. In that case, wearing a seat belt is one of the primary ways to protect an operator.

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For all intents and purposes, we teach that operators are required to wear their seat belts whenever they are in the seat. The only possible exception would be in cases where wearing one might prove more hazardous, such as working over or next to water. Even then, it is up to the employer to determine what and when those exceptions, if any, occur.

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Personal protective equipment (PPE) is designed to keep you safe in a variety of situations, but sometimes people find it restrictive. The question always arises: do I have to wear a hard hat when operating? Do I need to wear gloves, safety goggles, or a mask?

Personal Protective Equipment

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Like seatbelts, there are some grey areas regarding when a worker needs to wear a hard hat and when they do not. Much of the responsibility falls on the employer to create rules, and the employees to follow them. What we do know is that some regulations state, “each affected employee shall wear protective helmets when working in areas where there is a potential for injury to the head from falling objects.” “Affected employees” is defined as any “employees who are exposed to the hazards.” With the information we have discussed, you have enough information to make the decision on your own.

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As far as gloves and protective ear and eye wear go, the same principles apply. As mentioned in the anatomy section, you should wear gloves when doing pre-shift inspections, especially when handling batteries and checking hydraulic hoses. compactors can be loud, making hearing protection a good idea. If the machine or area you are working around is loud, hearing protection could be required anyway. As for eye protection, it is required any time there is a potential for danger to the eyes.

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Just as important as knowing your compactor, you need to be familiar with the worksite where you will be operating. As stated earlier, regulations require refresher training if a condition in the workplace changes in a manner that could affect safe operation of the machine.

Know Your Worksite

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In addition to significant changes in the work place, there are several other things you need to constantly be aware of no matter the work site:

• Pedestrians and Workers• Traffic• Communication• Slopes and Ramps• Safe Parking• Other Site Hazards

We will briefly discuss each of these as we lead into the final section on hazards.

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First and foremost, if you are working in an area with high foot or vehicle traffic, you should set up barricades, convex mirrors, warning signs, and other precautions. Wind, people, and traffic can easily upset signs or barricades, so it important that you maintain these throughout the day so that no unauthorized bystanders or workers enter the danger zone. SAMPLE


On that note, pedestrians have the right-of-way, but that does not mean that they are always right, nor are they necessarily aware of your presence. On busy worksites, it is common for workers or pedestrians to be solely focused on what they are doing. There is no room for assumption; if they assume you can see them but you can’t, or if you assume they are aware of you and your intentions but they aren’t, then that is a recipe for disaster. Ultimately, it is your responsibility to be aware of all people on foot.

Pedestrians

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Always establish eye contact with pedestrians or with operators of other vehicles. Make sure they are aware of your intent. If they continue while you are in the process of maneuvering, signal for them to stop. Then, wave them on when you are finished, or when you have stopped and are ready for them to proceed. Wait until they are safely out of the way before continuing.

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Backing up can be especially dangerous in compactors. Some larger compactors have seats that are able to pivot and look backward, allowing the operator to easily look behind them while reversing. No matter the compactor, always look behind you and honk the horn while backing up. If your compactor has a back-up horn make sure that it is working before operating the compactor. Whenever you are backing up do so slowly to avoid accidents and injuries.

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Pedestrians aside, pay close attention to other surroundings, especially if your job is near vehicular traffic of parking lots. In this case it is crucial that the worksite is marked off. Compactors should not be driven on public roads.

Traffic

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Whether trailing another piece of heavy equipment or a car on a main roadway, always keep a distance of at least three vehicle lengths. Be as familiar as you can with their intended path, and with any potential obstacles that might cause them or you to stop abruptly. When you do have to stop, try to avoid doing so suddenly, as the dynamic force imposed upon the machine can affect its stability and cause a tip over.SAMPLE


Remember, when approaching another operator in any type of machine, loaded units normally have right-of-way over empty units, so yield to them first.

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When working near by or directly on a public roadway, use flaggers, high-visibility clothing, and barricades to alert oncoming traffic of your presence. Place flaggers and cones far enough ahead so drivers will have enough time to slow down. Every year, several workers are injured and even killed by oncoming traffic.

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When the time comes to park the compactor, do so in an appropriate location. Never park in an area that would block fire lanes, emergency equipment, or access to stairways, entrances, or exits. Park on level ground when possible. If you must park on an incline, park at a right angle to the slope, set the parking brake, and block the wheels and drums. When parking on a road, use cones with a sufficient buffer to warn oncoming traffic.

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Typically, you do not want to compact the ground when it is too wet as it will reduce stability and affects the quality of compaction.

Other Site Considerations

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Construction sites have many in-ground hazards. Potholes, debris, tools, stub-ups, bumps, and ledges can all cause immediate instability and tip over. If there’s a chance they can lead to an accident, mark them off.

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Utility lines and boxes are another potential site hazard. Power lines, cable boxes, gas lines, fire hydrants, or other utilities are all cause for caution. As we will discuss, there are prescribed distances you should observe when operating near live lines. SAMPLE


When traveling on side streets, be on the lookout for grates, manhole covers, or other utility coverings. Never drive over them unless they have been previously inspected and deemed strong enough to hold the compactor’s weight.

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Above all, ensure the path of travel is clear of loose objects or debris, especially in any “keep clear” zones. Remove these obstacles if possible.

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Lastly, plan for the appropriate lighting, especially if you will be working in early morning hours or at night. Do not drive in the dark unless the compactor is equipped with operable lights. Using a truck’s headlights as the main source of light will not be sufficient, and poor lighting can affect visibility and lead to an accident.

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No matter the industry, the need to travel up and over ramps or dock boards is almost a given, especially if you will be stowing the compactor for travel between sites. Safety on trailers is not a given, though.

Ramps, Trailers

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Make sure to use a heavy-duty truck or trailer for transport. The flooring should be load rated and able to sufficiently carry your compactor. Check the floor for cleanliness and damage. If it appears excessively weak or is showing signs of imminent failure, don’t chance it. The trailer must also have any signs and lights required by law. Chock the trailer wheels before stowing the compactor.

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When you do travel up and down the ramps and onto trailers, make sure you do so in line with any slope limits provided by the manufacturer. Then travel slowly, keeping the centerline of the machine over the centerline of the trailer. Use a spotter to ensure you don’t get too close to the edge. Be especially careful when doing this in wet or snowy conditions.

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Avoid making turns while going up the ramp. Generally, if you are off-center, its best to back up in a straight line, gain a better alignment with the trailer, and attempt to go up the ramp again.

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Once on, set the parking brake. Both ramp and compactor should have designated tie down points on the front and back. Always connect to these anchor points. These components are not rated to handle it. All straps or chains must be directed outward from the machine and tightened. Straps must also be sufficiently load rated.

Photo courtesy of McDowell Heavy Equipment

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Many compactors can be lifted by cranes on to the trailer. If using this method, check the capacity rating for the crane and hoist to make sure it can lift the compactor. You also need to make sure that the compactor is designed to be lifted via crane.

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Look at the operator’s manual on for lift points on the compactor. Only use these designated lifting points to lift the machine. Make sure that these points are in good condition without wear or tear that might compromise their integrity. Use all lifting points to maintain balance. Make sure to lock the articulation joint whenever performing a lift.

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Common Hazards

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If any out-of-the-ordinary conditions exist, you should take extra care when planning for them. Make sure everyone involved or near the site is aware of the plan, any potential hazards, and what to do in case of an emergency. Many of the hazards we will discuss lead to accidents, injury, and even death, because what should have been deemed a critical lift was largely treated as any other lift and not planned for appropriately.

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Statistics have shown that there are certain inherent dangers associated with compactor operations, even during normal working conditions. A compactor can be a very dangerous piece of equipment and most of the injuries and deaths are due to several basic hazards. We will discuss some of the more common hazards associated with compactor operations and show you how to recognize, avoid, or minimize them.SAMPLE


Public records of accidents involving graders are kept by many organizations. After looking through many of them, we have determined most incidents that involve a grader can be divided into these categories:

• Rollover• Struck by Machine • Performing maintenance• Distraction• Fatigue

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The following investigated accident profiles are real. In some cases, two or three similar accidents have been combined for the purpose of illustrating key safety principles. They will show just how quickly things can go wrong when a roller compactor is used incorrectly and safety procedures are ignored.SAMPLE


Rollover is the most common accident involving compactors, and the most deadly. These accidents usually are the result of • Working near edges• Turning on slopes• Muddy or uneven ground• Backing up

Can you think of any other causes? Consider the following accident.

Rollover

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Accident Profile #1: Employee #1 was operating a 10,000-lb roller/compacter, packing soil to form a road. He was operating close to the edge of the road where the soil was very loosely compacted. He was killed when the soil gave way, the machine tipped over, and he was pinned under the roll-over protection system. He had not been wearing his seat belt. What went wrong?SAMPLE


Working next to an embankment is always dangerous especially when the soil is loose. In general it’s best to avoid work around embankments, as rollovers are more likely to occur. When you have to work near them, make sure to keep 2/3 of the compactor on firm ground.

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Second the operator was not wearing his seatbelt. Had he worn the seatbelt he would have been secured to his seat and the ROPS on the compactor would have kept him from being crushed. Instead, he was ejected out of the machine and killed by the ROPS that was designed to protect him. SAMPLE


Accident Profile #2: Employee #1 was loading a roller onto a flatbed trailer by driving it up the ramp. When he was loading the roller, it tipped over the side of the trailer. Employee #1 jumped off of the roller but the roller fell on

top of him. Employee #1 died from his injuries. what went wrong?

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Employee #1 should have had a better alignment before driving up the trailer. Also having a spotter may have allowed him to avoid the tip over. Never try to make corrections to the roller while on the ramp or trailer.

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It cannot be emphasized enough: Always wear your seatbelt. Even though he was on a trailer, the roller’s ROPS and seatbelt would have protected him from being crushed under the weight of the compactor.

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Struck-by is the most common accident involving compactors, and the most deadly. These accidents usually are the result of • Distractions• Poor visibility• Backing up


Struck-by

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Accident Profile #3: Employee #1 was standing in front of a compactor while performing minor maintenance activities. A two-drum asphalt roller compactor struck the employee from behind. The coworker operating the compactor was preparing to park the roller compactor and lost control while transitioning from the asphalt road surface to the shoulder. The coworker was unable to regain control of the roller compactor and ran into Employee #1 while he was standing in front of the other roller compactor. The employee was pinned between the two rollers and was crushed. Employee #1 was transported to an area hospital, where he was pronounced dead What went wrong?SAMPLE


First off, both employees were not aware of their surroundings. Employee number #1 should have not allowed himself to be distracted while working on a construction site with heavy machine traffic. Employee #2 should have slowed down during the transition between asphalt and the shoulder. SAMPLE


Employee #2 should have sounded his horn and made others aware of him while parking. Its important that you are not only aware of your surroundings but that others are also aware of you. Make sure you can always see where you are going and that those in the vicinity are a safe distance from you and your machine.

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Machine maintenance can be dangerous. Only trained, qualified persons should ever perform maintenance on a roller. Those performing maintenance will need to be trained on • Lock out, Tag out• Hydraulic Lines • Proper Safety Procedures


Maintenance

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Accident Profile #4: Employee #1 was attempting to repair the engine a pavement roller that would not start. The hood was up on the roller and Employee #1 was busy working under the hood. The pavement roller engine apparently started accidently and lurched forward. Employee #1, who was standing directly in front of the roller, got his foot caught by the front drum of the pavement roller. The machine rolled over him, crushing and killing him What went wrong?SAMPLE


Before performing any maintenance the machine should be in park and the break must be set. For added safety, check the drums and wheels before performing maintenance. Also, stay clear of the machine whenever it is starting. Had the worker stood near the side of the machine instead of the front, he likely wouldn’t have gotten caught in its path. SAMPLE


Before performing maintenance on a compactor, make sure to lock the articulation joint and lockout the machine. Always consult the operator’s manual for additional information and procedures concerning maintenance safety. SAMPLE


It is extremely important that you relieve the pressure before performing any work on the hydraulic system. Always use cardboard instead of your hands to look for leaks on the back side of hydraulic lines. SAMPLE


Compaction work is slow and repetitive, which makes it really easy to get distracted during operations. Though it may seem ok, it only takes a moment from a seemingly safe operation to take a tragic turn. Distractions can result from • Cell Phone Use• Oblivious to Surroundings • Lack of Focus • Stress• Medications


Distraction

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Accident Profile #5: Employee #1, a laborer, was working on a paving construction project at an airport. He was on taxiway F, which had just been paved, and he was run over and killed by a rubber-tired asphalt roller that was backing up on the runway. The roller operator stated that he had not seen the worker on the taxiway. The roller's back-up alarm was not functioning at the time of the accident. What went wrong?SAMPLE


The obvious problem here is that the back up alarm wasn’t functioning. Had Employee #1 been able to hear an alarm he might have been aware of the compactor and avoided injury. Employee #2, the operator, should have also sounded his horn before backing, especially given that the alarm was not functioning.

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More so, had the operator been more aware, than maybe he would have seen employee #1 and avoided the fatal accident. Likewise, if Employee #2 was more aware of what was going around him he might have avoided the danger. SAMPLE


Fatigue is a common distraction that may not always lead to injury, but does often reduce efficiency. Fatigue can result from working too many hours, lack of sleep, hunger, or monotonous, repetitive work. When an operator shows signs of fatigue, he should be relieved to get rest or exercise to refresh his alertness.

Fatigue

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Dress appropriately for the weather to prevent stress on your body. Both cold and hot temperatures can drain the body of its energy, especially if sleep and diet have been neglected.

Weather: Heat and Cold

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Stress can also become a major distraction. Operators under emotional stress may not be able to stay focused. If you’re feeling extremely angry or upset, it would be wise to wait to operate until emotional stability is restored.

Emotions/Physical Health

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Likewise, if you are suffering from health problems that affect your machine operating ability then you should not be allowed on a machine. Even cold medicine can compromise your alertness. If you are taking prescription or over-the-counter drugs, you should obtain medical advice on whether it is okay to operate machinery.

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Conclusion

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Compactors, like all heavy equipment, require caution and discretion to operate safely. Improper training, poor operation, failure to perform preventive maintenance, and failure to inspect can lead to tragic consequences.

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Accidents can happen on any given day and at any work site. There are so many things and situations that can cause injury or even death on the job. While we cannot go over them all here, it is important you take the time to analyze the potential hazards each job, site, or machine present.

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Safety is the responsibility of everyone involved in compactor operations—from operators to maintenance personnel. You can help ensure safe operation by knowing and following all safe work practices and safety regulations that are applicable to your workplace. When in doubt, during any phase of an operation, take the time to stop and consult your operator’s manuals, company rules, co-workers, or safety supervisor. Time is money, true, but a mistake made to save time can cost money and lives. Good luck and stay safe! SAMPLE


All rights reserved. The Hard Hat Training Series is a registered trademark of Safety Provisions, Inc.

No parts of this training may be reproduced in any form, electronically or mechanically. Purchasers are allowed to print out the materials for classroom use (i.e. student manuals, exam, answer keys, etc.). Purchasers do have permission to modify the training program for specific training needs. The presentation or any portion of it, however, may not be resold, posted online, lent out, used to create another course, or the like.

Safety Provisions, Inc. | (360) 930-9247 | [email protected] | hardhattraining.comSAMPLE

Documents

Accountability Starts With You SAMPLE · Did you know? Regulations specify that an operator must take a refresher course if any of the following apply: • The operator is observed