Quarry traffic is something entirely different and more dangerous than your average city rush hour.

A fully loaded haul truck, such as a Cat^® 777, could crush a pickup without slowing down — and unless it’s equipped with camera and proximity sensors, it has blind spots that can easily hide other equipment, vehicles and ground personnel.

Machine operators, site employees and visitors all need to be vigilant about where they are in relation to moving equipment. And it’s vital that everyone knows the rules of the road and site traffic patterns. Here are some tips that can help:

• Ensure all traffic and directional signs are well maintained and facing the proper direction.
• Set strict traffic and right-of-way rules and train all employee on traffic flow patterns.
• Don't be afraid to reverse the traffic direction from normal road traffic if it produces better visibility around berms, landforms and other obstacles.

2. Watch the Terrain

Quarries are dynamic environments. As excavation progresses, haul roads shift around, highwalls and berms change, and water flows can become unpredictable.

Everyone on the site needs to know how to spot faults on highwalls, rutting on benches, loose ground and other hazards. As site conditions change, communication is vital. Ensure the next shift knows about potential hazards that may not have been there the day before.

Some other site management tips:

• Haul road berms should always be at least half the wheel height of the largest piece of equipment on the site.
• Position shovels and articulated trucks so the cabs swing away from the bench face when loading.
• Bench edges can unexpectedly give out underfoot. Stay well back from the edge as faults can extend deep into the bench.
• Keep an eye out for sliding hazards in wet conditions, especially on haul road slopes and around ponds.

3. Keep Your Distance

One way quarry traffic does resemble driving on any other road is the need to maintain a safe distance between moving equipment, especially in rough weather. It doesn't take much rain or snow to make a haul road slippery, especially on slopes. Add limited visibility, and increased following distances become an absolute must. Operators need extra room to react in case of slips or sudden braking.

• The safe travel distance for heavy equipment is double the required stopping distance.
• Stopping distance will vary depending on slope, load and underfoot conditions.

It’s also important to maintain safe distances from highwalls. Falling material is a constant danger. Changing environmental conditions, blast damage, vibration from truck traffic and root growth can all compromise a wall.

• Equipment and personnel should stay at least 2/3 of the highwall height away from the base of the wall.
• For example, under a 100-foot wall, people and equipment should stay 65 or more feet away.

4. Educate Your Crew

The most important piece of safety equipment on any machine is the operator sitting in the cab. All operators, especially new ones, need to understand the safety equipment, technologies and capabilities of their machines. Plus, they need work together to keep track of machine, vehicle and foot traffic in their working environment. Simply making eye contact with other operators and personnel can help everyone stay alert, productive and safe.

5. Conduct a Safety Site Evaluation

Some equipment OEMs offer worksite safety assessments that can provide a valuable outside perspective. For example, Caterpillar offers a Safety Site Evaluation that provides a complete evaluation of your safety management system.

During the evaluation, an expert looks at the full range of safety practices on your site — including tools and equipment, PPE, employee knowledge of safety policies, hazard identification, safety communication, housekeeping and orderliness, and emergency procedures. Everything is adapted to the characteristics of your site and the unique challenges your operation may face every day.

At the end of the evaluation, you’ll receive a comprehensive, prioritized report detailing what you're doing right, along with any areas where improvements are needed and recommendations on how best to implement them. Ask your local Cat dealer for a Safety Site Evaluation — it’s one of the many Site Evaluations offered to help improve your operation’s safety and efficiency.

Safety Pays

Whether you choose to have an outside assessment done or want to manage site safety on your own, promoting an ongoing 24/7 culture of safety on your quarry site is essential. It will help your people work more confidently and efficiently while reducing the potential for costly accidents and injuries. Getting everyone home safely every day is well worth the effort.