Workplace Transport Statistics
Workplace transport incidents remain one of the leading causes of death and serious injury on construction sites. Understanding the scale of the problem is the first step to prevention.
HSE Statistics
- Around 50 workers are killed each year by vehicles in UK workplaces
- Construction accounts for approximately 25% of these deaths
- Being struck by moving vehicles is a leading cause of fatal accidents
- Reversing vehicles are involved in around 25% of workplace transport deaths
Common Accident Types
- Pedestrians struck by moving plant or vehicles
- Workers crushed during reversing operations
- Plant overturning on slopes or soft ground
- Operators falling from plant
- Striking overhead power lines
- Underground service strikes
Key Regulations
Several sets of regulations govern the use of vehicles and plant on construction sites:
PUWER 1998
The Provision and Use of Work Equipment Regulations require that:
- Equipment is suitable for its intended use
- Equipment is properly maintained
- Users receive adequate training and information
- Equipment has appropriate guards and safety devices
Workplace (Health, Safety and Welfare) Regulations 1992
Requires traffic routes to be suitable, organised for safe pedestrian and vehicle movement, and routes to be clearly indicated where necessary.
CDM 2015
Requires traffic routes and pedestrian segregation to be planned and managed. The construction phase plan must address site traffic management.
LOLER 1998
Applies to plant used for lifting operations (cranes, telehandlers, excavators with lifting attachments). Requires thorough examination and lift planning.
Site Layout Planning
Effective site layout is fundamental to vehicle safety. A well-planned site minimises the interaction between vehicles and pedestrians, the primary cause of transport accidents.
Site Layout Considerations
Segregation is Key
Where possible, pedestrians and vehicles should be completely separated. Physical barriers (not just painted lines) provide the best protection. If complete segregation is not possible, strict management controls are essential.
Traffic Management Plans
A Traffic Management Plan (TMP) documents how vehicle and pedestrian movements will be safely managed throughout the project. It should be part of the construction phase plan.
TMP Contents
- Site Plan
Showing vehicle routes, pedestrian routes, crossings, parking, and work areas
- Vehicle Types
What vehicles will be used, their size, frequency, and purpose
- Speed Limits
Appropriate limits for different areas (typically 5-15 mph on site)
- Segregation Measures
Physical barriers, walkways, crossing points
- Reversing Controls
How reversing will be minimised and managed
- Delivery Management
Scheduling, unloading areas, and procedures
- Signage Requirements
Location and type of signs needed
- Banksmen Arrangements
When and where banksmen are required
Common Plant Types and Hazards
Excavators
360-degree slew creates crush zones around the machine. Blind spots are significant.
Controls: Exclusion zones, CCTV/radar, banksmen, stop/start protocols
Dumpers
High speed capability, poor rear visibility, rollover risk on slopes.
Controls: Speed limits, ROPS/FOPS, exclusion from pedestrians, no riders
Telehandlers
Versatile but complex. Stability varies with load and boom position.
Controls: Load charts, competent operators, ground conditions, no overreach
Delivery Vehicles
Drivers unfamiliar with site. May need to reverse. Pedestrian interaction risk.
Controls: Induction, escorts, designated delivery areas, banksmen
Rollers and Compaction Plant
Very poor visibility. Crush risk. Workers may need to be close for compaction checks.
Controls: Exclusion zones, stop work for checks, hi-vis, communication
Operator Competence
Only competent, trained operators should use construction plant. In the UK, competence is typically demonstrated through recognised card schemes.
Competence Card Schemes
Construction Plant Competence Scheme
Industry standard for plant operators. Red trained operator card (2 years), blue competent operator card (5 years). Covers 60+ plant categories.
National Plant Operators Registration Scheme
Alternative scheme accepted on most sites. Traditional and construction card options.
Construction Skills Certification Scheme
General site competence. Plant operators should hold CPCS/NPORS plus CSCS.
Familiarisation
Even competent operators need familiarisation with specific machines. Controls, safety systems, and operating characteristics vary between models. Operators should receive machine-specific familiarisation before use.
Pedestrian Safety
Pedestrians are the most vulnerable to vehicle-related injuries. Protecting pedestrians requires a combination of physical segregation, management controls, and worker awareness.
Physical Controls
- Dedicated pedestrian walkways
- Physical barriers (not tape)
- Controlled crossing points
- Exclusion zones around plant
- Safe refuges in vehicle areas
- Clear signage
Management Controls
- Stop/start protocols
- Banksmen for reversing
- Delivery scheduling
- Communication systems
- Hi-vis clothing requirements
- Supervision and enforcement
Exclusion Zones
Establish exclusion zones around operating plant where pedestrians must not enter while the plant is working. The size depends on the plant type and operation. For 360° excavators, a minimum of machine reach plus 5 metres is typical.
Vehicle and Plant Checks
Regular checks are essential to ensure plant is safe to use. PUWER requires equipment to be maintained in safe working order.
Inspection Regime
Pre-Use Checks by Operator
Before each shift: fluid levels, tyre condition, lights, mirrors, alarms, controls, guards, seatbelts, hydraulic leaks
Supervisor/Fitter Inspection
More detailed check including structural condition, safety systems, wear items, documentation
Planned Maintenance
Per manufacturer's schedule. Servicing by competent fitters. Records maintained.
Thorough Examination
For lifting equipment: 12 monthly for general lifting, 6 monthly for lifting people or accessories
Daily Check Items
Reversing Operations
Reversing is one of the most dangerous vehicle operations. Around 25% of all workplace transport deaths involve reversing vehicles.
The Hierarchy for Managing Reversing
Eliminate Reversing
One-way systems, drive-through unloading, turning areas
Separate from Pedestrians
Physical barriers, exclusion zones, time segregation
Use Technology
CCTV, reversing cameras, radar, proximity sensors
Use Banksmen
As last resort where other measures not reasonably practicable
Banksmen
Banksmen should only be used as a last resort, not as the primary control. If used, they must be trained, use standard signals, remain visible to the operator at all times, and never stand in the path of reversing vehicles. Driver and banksman must agree signals before starting.
Frequently Asked Questions
What card do plant operators need?
In the UK, CPCS (Construction Plant Competence Scheme) is the most widely recognised. NPORS is also accepted on most sites. The card must be valid, in date, and match the plant category being operated.
Who is responsible for plant safety?
The employer has overall responsibility under PUWER. This includes ensuring equipment is suitable, maintained, and operated by competent people. For hired plant, responsibilities should be clearly defined in the hire contract.
Do delivery drivers need site induction?
Yes. Anyone entering the site, including delivery drivers, should receive a brief safety induction covering site rules, traffic routes, and hazards. A driver's briefing sheet at the gate is common practice.
What site speed limit should we set?
Most construction sites operate 10-15 mph limits for vehicles, lower (5 mph) in congested areas or near pedestrians. The appropriate limit depends on site conditions, vehicle types, and pedestrian presence.
Are reversing alarms enough?
No. Reversing alarms are useful but not sufficient on their own. They become "background noise" on busy sites. They should be part of a wider package including elimination, segregation, and visibility aids.
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