Best Practices for Loading Activities
Safe loading practices are a crucial part of quarry operations and play a large role in protecting employees, equipment, and production. Loading areas are often busy, dynamic environments where heavy equipment operates in close proximity. Without proper controls and clear communication, the risk of incidents increases significantly.
The following guidelines outline key practices to help ensure a secure, efficient, and well-managed quarry loading operation.
Equipment Readiness and Safe Operation
Equipment inspections are the first step in safe quarry operations. All mobile equipment should be inspected at the beginning of each shift, including:
- Backup Alarms: Must be in good working order to alert nearby personnel when equipment is reversing.
- Lights: Ensure all headlights, brake lights, and warning lights are functioning to maintain visibility in all conditions.
- Brakes: Check service and emergency brakes to ensure they operate correctly and can safely stop loaded equipment.
- Steering: Verify smooth and responsive steering to prevent loss of control during operation.
- Mirrors: Confirm all mirrors are clean, undamaged, and properly adjusted to give operators full visibility around the vehicle.
Operators must use safe mounting and dismounting practices. Three points of contact should always be maintained when entering or exiting equipment to help prevent slips, trips, and falls, which are a common source of injury in quarry operations.
Communication and Equipment Movement
Clear communication is essential anytime equipment is in operation. Operators should sound a warning horn before starting or moving equipment and use different signals to distinguish between moving forward and reversing.
Continuous communication between the load operator and truck driver is also critical. This may include:
- Radios
- Standardized hand signals
- Other approved communication methods
For most loading operations, truck drivers should remain in the cab while being loaded, unless site-specific procedures require otherwise.
Designated Loading Areas and Edge Protection
Loading operations should only take place in designated loading zones located on stable, compacted surfaces capable of supporting heavy equipment and trucks. This helps control traffic flow and reduce incidents.
Berms or other physical barriers must be installed wherever there is a risk of over-edge dumping or reversing hazards. These barriers should be at least mid-axle height of the largest self-propelled vehicle that travels the roadway. Properly constructed berms provide a visual and physical safeguard, particularly near highwalls, stockpiles, or drop-offs.
Protecting Personnel in Active Work Zones
All personnel must wear appropriate personal protective equipment at all times. This includes:
- Hard hats when outside the cab
- High-visibility apparel
- Safety-toed footwear
Consistent PPE use improves visibility and helps reduce potential injuries. Ground personnel must always remain visible to equipment operators, and unauthorized individuals must be kept clear of loading areas. Restricting access to work zones helps prevent injuries from equipment.
Preventing Overloading and Equipment Instability
Equipment and haul trucks should never be overloaded. Operators must adhere to manufacturer weight limits and ensure loads are balanced properly. Overloading can negatively affect braking, steering, and stability.
Visibility and Environmental Controls
Maintaining good visibility is essential for safe loading operations. Water trucks should be used to control dust in active loading areas and along haul roads. When available, vehicle-mounted strobe lights and flagging should be used in low-visibility areas. Operations should be limited or suspended during periods of poor visibility, severe weather, or icy conditions.
Safe quarry loading operations depend on preparation, communication, and consistent adherence to established procedures. By following these best practices, quarry operations can reduce risk, improve efficiency, and create a safer working environment for everyone on site.
For more safety tips, contact your local Risk Control Consultant. Click the button below to find an agent near you.
For information purposes only. BITCO's blog content does not address all potential circumstances and is not a substitute for business, safety, or legal consultation.
