Excavators are indispensable heavy machinery used in construction, mining, and infrastructure development. Due to the inherent risks associated with their operation, proper safety procedures are crucial for preventing accidents. This article will detail how to effectively prevent high-risk behaviors during excavator operation, ensuring safe operation.
Every excavator has a clear operating manual and safety guidelines. Operators must thoroughly study and understand these before operation. For new equipment, operators must attend manufacturer training or obtain relevant certification. Operators must be familiar with the following:
Work Area: Understand the machine's operating radius and maximum digging depth to avoid working outside the safe range. No personnel are allowed within the operating radius. When loading, ensure the transport vehicle is stationary and the driver has exited before unloading; the bucket height must be at least 0.5m lower than the vehicle bed. Maintain safe distances from power lines: over 1.5m for below 1kV, and over 3m for 1-35kV.
Equipment Inspection: Conduct a comprehensive inspection daily before operation to ensure oil levels, hydraulic system, and mechanical components are in good working order. Verify ground bearing capacity; use base plates or sleepers on soft ground. The working slope for tracked excavators should not exceed 20°, and wheeled excavators must have outriggers fully extended and leveled.
Control Levers and Systems: Ensure all control systems are responsive and functioning correctly to prevent accidents due to operator error.
2.1 Pre-Operation Environment Check
Terrain Assessment: Operators must assess the terrain to avoid working on soft, slippery, or unstable ground. If the ground is uneven or prone to collapse, take immediate action, such as using support equipment or relocating the work area.
Obstacle Removal: Ensure the work area is free of obstacles, especially hard objects like rebar or rocks, that could interfere with the excavator's operation.
Static Check: Hydraulic oil level, track tension, and wire rope wear (if applicable). Dynamic Testing: Run the machine under no-load conditions for 3-5 minutes, monitoring the instruments for any abnormalities (oil pressure ≥ 0.2 MPa, water temperature ≤ 90°C).
2.2 Reasonable Arrangement of the Work Area
Safety Distance: Operators should maintain a safe distance from other machinery or buildings, especially during excavation work, to ensure unrestricted operation.
Warning Signs: The work area should have clear warning signs to alert personnel to the danger zone and prevent them from entering.
3.1 Avoid Overloading
Overloading an excavator is a major cause of accidents. Operators should avoid exceeding the rated load, especially when lifting heavy objects. They should allocate the workload according to the excavator's capacity and maintain appropriate bucket and boom angles during excavation.
3.2 Prevent Operator Errors
Excavator operation requires precision. Operators should avoid frequent large-angle movements or high-speed operation to prevent loss of control or accidents. Specifically:
Avoid sudden turns during excavation: Sudden turns can cause instability and overturns.
Avoid improper operation during high-altitude work: When the boom is high, maintain machine balance and avoid rapid movements.
Maintain stability during operation: Avoid rapidly raising or lowering the bucket.
3.3 Enhance Communication Among Workers
In work sites with multiple machines, communication between operators and other workers is crucial. Clear communication protocols should be established between the operator, ground supervisor, crane operator, etc., to prevent accidents.
3.4 Avoid Blind Spots
Excavators have blind spots. Operators should avoid working in these blind spots, especially when people are nearby. Use rearview cameras or external cameras to monitor the surroundings and reduce the risk of collisions.
4.1 Regular Inspection and Maintenance
The lifespan of an excavator depends on maintenance. Operators and managers should follow the manufacturer's recommendations for regular maintenance to ensure that key components (hydraulic system, engine, bucket, tracks, etc.) are in optimal condition. 4.2 Timely Handling of Equipment Malfunctions
Operators must immediately shut down the equipment and conduct an inspection upon discovering any malfunction or abnormality, and report it to the supervisor for repair. Operating with a faulty machine is strictly prohibited. Ignoring minor malfunctions can accumulate into major problems, increasing safety risks.
4.3 Use of Certified Parts and Fluids
Using genuine, certified parts and fluids from reputable manufacturers not only extends the equipment's lifespan but also ensures operational safety. Unauthorized parts may compromise equipment performance and lead to safety accidents.
5.1 Emergency Response Plan
Each work site should have a pre-prepared emergency response plan, including procedures for handling emergencies such as sudden shutdowns, fires, and rollovers. Operators must participate in regular emergency drills to master skills such as emergency shutdown and personnel evacuation.
5.2 Incident Reporting and Handling
In the event of an accident, the operator must immediately report it and follow the predetermined emergency response procedures to prevent the situation from escalating. Supervisors should promptly analyze the cause of the accident and implement training or process adjustments to prevent similar incidents.
In case of a hydraulic system leak, immediately shut down the engine and use the emergency lowering device to lower the bucket to the ground.
Electrical faults must be repaired only after power is disconnected; operating with live electrical components is strictly prohibited.
6.1 Regular Safety Training
Excavator operators should participate in regular safety training, not only to learn new operating procedures but also to understand the dangers of non-standard operations through case studies. Management personnel should conduct risk assessments for all operators and ensure that each operator can independently perform necessary safety procedures.
6.2 Enhancing Safety Awareness
The high-risk operating environment of excavators requires every operator to maintain a high level of safety awareness. Managers should conduct regular inspections and real-time monitoring to ensure that all operators adhere to safety procedures and promptly identify potential safety hazards.
Consider installing a 360° panoramic monitoring system and a radar collision avoidance system to provide real-time warnings of blind spot risks.
Conduct quarterly emergency drills simulating rollover and electric shock scenarios; the pass rate must be 100%.
Safety is the lifeline of excavator operation. By implementing standardized operating procedures, ensuring a safe work environment, minimizing high-risk work practices, conducting regular equipment inspections and maintenance, establishing effective emergency response protocols, and providing comprehensive safety training, we can significantly reduce safety risks during excavator operations. Operators and supervisors should always prioritize safety, working together to create a safe work environment and ensure the smooth completion of every task.
