Operating heavy equipment in a quarry is, simply put, not for the careless. Machine operators have to pay attention not only to their work and other equipment, but also to the site conditions around them. Failure to do so can have serious consequences.

A few sobering facts and statistics:

• From 2015 through 2019, falling or sliding material accounted for 9% of U.S. mine fatalities.¹
• Total sand and gravel operation fatalities in 2020 were 60% higher than in 2019.²
• The current tight market for skilled operator labor makes inexperience a contributing factor, but even experienced operators make mistakes.

Vibration is a Serious Hazard

One of the less obvious hazards faced by quarry equipment operators is whole-body vibration. The constant stress of extreme vibration takes a toll, especially for dozer operators working on rocky terrain. Other equipment, such as front-end loaders and excavators, can induce jarring and jolting events that cause similar cumulative problems.

The bad news is whole-body vibration can lead to musculoskeletal disorders of the spine. It can also increase fatigue, which contributes to accidents in the short term, along with diminished motor performance capacity over the long run.

It’s a widespread problem that can lead to debilitating spinal issues. Between 2012 and 2016, surface mines and quarries reported a total of 523 non-fatal, days-lost injuries and no-days-lost injuries related to the back, neck and head.3

So, what can be done to limit injuries and accidents among quarry equipment operators?

• Proper operating techniques can help. With good training, operators can learn how to work without inducing unnecessary shocks.
• Effective site management can help smooth out haul roads and work areas to reduce rough spots.
• Effective equipment design, such as sealed and shock-mounted cabs plus advanced seats, can mitigate some vibrational issues.
• Proper techniques for climbing on and off equipment can make a difference, too.

Get Out of the Cab

But what if operators could do their jobs without working aboard their equipment at all?

With today’s remote-control technologies, operators can run dozers, excavators and wheel loaders from a safe, comfortable location away from their machines. They’re not subject to vibration or cab noise levels. And in some cases, multiple camera views — or simply a different viewpoint from off the machine — can provide enhanced visibility for more efficient operation.

Cat^® Command Leads the Way

To see what’s possible in remote control technology today, Command technology from Caterpillar is a good place to start.

Cat^® Command was originally developed for mining applications, where the closed and controlled mine site environment offers fewer variables to contend with. The technology has now advanced to the point where it has proven viable for a wide range of quarry and construction applications.

Command technologies include two control configurations:

• Cat Command Console: A line-of-sight, stand-up system that employs a portable, over-the-shoulder controller. The operator works within view of the machine but up to 400 meters or 437 yards away. The controller itself provides complete machine and implement control, plus machine status information.
• Cat Command Station: A fixed system that can be operated from virtually anywhere, on or off the jobsite. This sit-down station replicates the control layout of the machine, with one or more video monitors providing all-around views. Located indoors, it provides the safest, most comfortable and most convenient operating environment possible.

Of the two configurations, the Command Console system has the greatest impact on jobsite safety. For example, when a need arises to rescue a machine from a precarious location, the remote console allows operators to maintain line of sight to the machine but work out of harm’s way. They also require no on-site communications infrastructure. Operators could, for example, clean up a rock fall beneath a potentially unstable highwall without risk of personal injury.

Both systems retain smooth and precise machine control as if operating from the cab, and they offer complete access to advanced machine features. Built-in safety mechanisms shut down the machine in case of power or communications loss.

Safer work. Easier recruitment.

Command Stations can be located wherever the workforce may be. Operators don't have to commute to a distant or hazardous jobsite. In the future, they may even be able to work from home.

Both Command systems reduce the chances for jobsite and long-term injuries. Plus, they make recruiting and retaining operators much easier. Heavy equipment operation becomes something akin to playing a video game rather than hours on a moving seat. That’s an attractive advantage for a younger generation of potential operators.

In fact, remote control equipment makes good business sense at every level. Production can restart immediately after blasting. You get decreased downtime from faster shift changes and operator relocation. Best of all, you get a healthier, more productive crew that can work at top efficiency all shift long.

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¹ https://mshau.com/the-5-most-common-mining-fatalities-probably-not-what-youd-think/

² https://arlweb.msha.gov/Accinj/Accinj.htm

³ https://www.pitandquarry.com/preventing-exposure-to-whole-body-vibration/