Flagman Training

Arabtec Safety
Man and Machine

Interface
Rev. 1.0 June-2019
“Workers Lives Matter”

WELCOME
to
Safety Training Room

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Man and Machine Interface

• Every Year a significant number of people get
injured and killed by accidents involving
vehicles in the workplace

Construction Plant and Equipment
Common causes of accidents and
incidents
Rocks or
m
a
t
e
r
i
a
l
fallingby
Being struck from
bucket or
counterweight t
h Being struck by debris
e from material face
Slipping, tripping and b
falling over material lying
u
around c
6 k
e “Workers Lives Matter”
• Your EMPLOYER has a responsibility to ensure that any vehicle /
equipment that comes onto site is operated safely and with reduced risk.
This is achieved by:
 Traffic Plans
 Segregated traffic routes
 Reduced speed
 Site Maps and Signage
 Inductions
 Competent Drivers and site operatives
 Maintained plant and Equipment
 Banksmen

• Traffic Plans have
 One Way Systems where possible

 Reduced speed requirements
 Measures to reduce the need for reversing & Turning
 Segregated Pedestrians from Vehicles
 Loading and off-loading areas and lay down areas
indicated
 Applicable signage

• Reduced Speed and Signage

• PPE
Signage
10

• Reduced Speed and Signage
11

• Segregated traffic routes and Emergency Plan
12

Who is a Banksman
He/She is a:
1. Trained person who controls the movements of most construction
equipment by signaling the operator.
2. Assists operator to safely manure the equipment in congested areas where
people are working.
3. Controls the movement of people while the equipment is in
operation.
4. Erects necessary barricades to control access of vehicles and
persons clear from the equipment.
5. Coordinates the work with other banksmen if more than one
equipment is in use in the same area.
6. Banksman is the eyes and ears of the operator of the machine where he can
not see (blind spots).
13

Banksman duties?
• Check vehicle maintenance and driver are trained and
competent.
• Ensure effective traffic movements & flow
• Monitor traffic & pedestrians routes as per traffic &

strategy.
• Monitor condition of traffic and pedestrian routes
• Manage loading and off-loading activities
• Control visiting delivery drivers & provide

information
14

Banksman duties?
• Ensure effective lighting at night
• MUST stay alert and prevent others becoming unsafe
• MUST never themselves in a blind spot
• MUST be seen by driver at all times
• MUST take a safe position at all times
• Stop any construction work, activity or process when unsafe
15

Banksmen must make sure that:
• All Entrances and Exits Shall be Clearly Defined.
• Access to Work Area Will be Restricted by use of Barriers,

Warning Signs and Close Supervision.
• Banksman to Control all Vehicles within Work Area.
• All Escape Routes Shall be Kept Clear at All Times.
• Follow Good Housekeeping Procedures.
Check Digging
Grounds for Electric,
Water or Gas Lines.
16

What is required?
• Only one person shall be designated as a Banksman.
• Should be able to observe the load and other workmen at all

times.
• Must be always be in plain view of the crane operator and all

lifting trucks.
• Never assume anything.
• Make sure both workers and operators understand exactly what is

expected to safely move the loads.
All Banksmen are to Conduct Daily Toolbox Talks
17

During Operations
• Stand in proper location
As a Banksman, stand where you can

see the load and can be seen by the
operator.
18

Unattended Machinery
Do NOT
leave the controls of any
machine unattended when a
work is being suspended
19

Moving Machinery
• Remain attentive
NEVER
Stand or pass in front of a
moving vehicle or a
Machinery at anytime
20

Moving Machinery
He/She has to:
• To Inspect all equipments / trucks prior to Use.
• Report Defects to the Supervisor.
• Follow Company Policies and Procedures such as PTWs and PPE

… etc.
21

CONTRUCTION PLANT AND
EQUIPMENTS INSPECTIONS
• Dumper Trucks
• Cranes
• Excavators
• Compressors
• Fork Lift Trucks
• Concrete Mixers
• Compactors
• Shovels
• Excavators
22

DUMPER TRUCKS
If “DUMPER” trucks are being used,

check:
 Load carried are within the capacity of

the dumper truck?
 Speed limits are not exceeded when
being driven?
 No passengers to ride on the dumper

when being driven?
 No traveling over steep embankments
and rough terrains?
 No sharp turning to avoid overturning of
dumper?
 Tyres are at the correct inflated
pressure?
 Operators are trained and
competent?
23

Dumper / Trucks Tipping Hazards / Control Measures
• Loading
Maintenance
• Dumping
Stability
• Hazard control
24

EXCAVATORS
If “EXCAVATORS” are being used, check:
• Operators to be trained and competent?
• No passengers to ride on the excavators?
• Speed limits are not exceeded when
carrying loads?
• No travelling near to edge of

excavations?
• All warning signals are operating?
• A banksman to be used during

operations?
25

FORK LIFT TRUCKS
If “FORK LIFT TRUCKS” are being used,
check:
• Operators to be trained and competent?
• No passengers to ride on fork lift trucks?
• Speed limits are not exceeded when
carrying loads?
• No traveling at speed around corners?
• All warning signals are operating?
• Gas powered fork lift trucks not to be used in
enclosed spaces?
• Warning signs of Fork Lift Truck in Operation
to be posted?
26

CONCRETE MIXERS
If “CONCRETE MIXERS” are being used
check:
• All moving parts are secured when in

Transport?
• The truck is “locked off” before cleaning
the drums?
• Trucks not parked too close to excavation
edge?
• Observation of safe work practices and
exclusion zones?
• Correct personal protective equipment's is
being worn eg. Safety Halmet, safety boots,
gloves and hearing protectors, safety Jacket?
• Observation of safe disposal of excess
concrete?
27

Driver and Operator’s PPE: Non – Compliance
(Serious, repetitive, widespread and cultural
For some unknown and inexplicable reason, and despite all the Arabtec rules and regulations on
PPE, all ATC projects are continuing to permit drivers and machine operatives on to their sites
(“Safety Starts Here – No – PPE – No Work”) who are:
 wearing sandals, flip-flops, trainers instead of SAFETY BOOTS.

 wearing casual clothes or national costume (generally loose, baggy and light clothing)
instead of industrial PROTECTIVE CLOTHING.
 wearing dark jumpers or other top clothing instead of HIGH VISIBILITY VESTS
 not wearing eye protection (in open vehicles) initial of SAFETY GOGGLES
 no nose and mouth protection (in open vehicles) initial of FACE MASKS
 wearing caps, cloths or nothing on their heads instead of SAFETY HELMETS
 not wearing (unbuckled) SEAT BELTS (which is a key PPE item for drivers)
There are NO EXCEPTIONS in the Arabtec or legal safety requirements in the wearing of PPE.
The other serious issue which concerns our Management, Construction, Plant and HSE teams, is
that we Do Walk By, do not check, and do not stop and the practice, which legally is condoning
the practice which do not discipline (= termination) which puts your project and Arabtec in legal
jeopardy.
ACT IMMEDIATELY AND DAILY TO ERADICATE THIS LEGACY AND HABITUAL CULTURE BY
DRIVERS, AND OUR FAILURE TO CONTROL.3
28

Tyre Safety
Tyre related accidents cause around 5% of the UAE traffic fatalities. All vehicle tyres must be procured, fitted and maintained properly,
considering the climate of the UAE. Proper tyre maintenance is an important safety function often neglected. Maintaining proper tyre
pressure, observing tyre and vehicle load limits and inspecting tyres for cuts, slashes and other irregularities are important to avoid tyre
failure such as tread separation or blowout and flat tyres. Remember, tyres are the only contact between your vehicles and the road and
poor tyre Maintenance could result in serious accidents.
Under-inflation/Over-inflation
Lower tyre pressure can create overload on tyres and overheat the tyres resulting in tyre damage. Over inflation causes increased stress to
internal materials which can result in premature failure, poor traction and change in vehicle handling/stability.
Check the tyre pressures at least once per month using a reliable or calibrated gauge. The recommended pressures are quoted in the
vehicle owner’s manual or on a sticker usually attached to a door frame or fuel cover. Make sure that the pressures are checked when the
tyres are “cold”, i.e. driven less than 3 km before the check.
Tyre Wear-Visual Check:
Check for obvious signs of wear such as wear of the treads, cuts, cracks or other visual damage.
The legal minimum level for tyre tread depth is 2mm. Once a tyre reaches this point it will have
lost 90 per cent of its performance. The RTA recommends replacing tyres no later than 5 years.
Also, regularly check the age, condition and air pressure of spare wheel to avoid having a spare
tyre unfit for use when needed.
29

Tyre Safety
Tyre Rotation and wheel alignment:
Tyre rotation reduces irregular wear. For maximum mileage, rotate tyres every 10,000
km. A wheel balance and alignment check at this time will help the potential life of the
tyre
Other Precautions:
 Use only reputable branded and certified tyres. Avoid fitting tyres which may be
substandard and therefore potentially unsafe.
 Use the correct tyre type and dimension for your vehicle. Refer to the vehicle
owner’s manual or ask for expert advice if not sure.
 Inflating tyres with Nitrogen instead of air can help to maintain pressure stability
for longer periods
 It is highly recommended that all four tyres be replaced at the same time
 Respect the load and speed capabilities of the tyres fitted to the vehicle by not
exceeding them
 Use the correct size of tyres as recommended by the vehicle manufacturer.
30

Mobile Elevated Work Platforms (MEWPs)
Mobile Elevated Work Platforms (MEWPs) must be certified by an approved third

party as per the applicable regulations and valid inspection and testing certificates
must be displayed. Everyone working on MEWPS shall wear a full body safety harness
fitted with double lanyards attached at all times to a fixed anchorage point.
The following must be ensured when MEWPs are being used:
 A written pre-operational checklist for the MEWP must be completed and signed off by the
supervisor.
 Risk Assessment must be conducted and a Permit To Work must be obtained before use.
 Ensure tool box talks and pre-start briefings on MEWPs are site specific and a safe system of
work is in place.
 MEWPs should be operated on level ground surfaces which are stable and will not compress
under the weight of the MEWP, operatives and/ or material.
 Prior to operation of MEWP, the weather conditions need to be assessed and MEWPs must not
be operated in adverse weather.
 The area around the MEWP must be barricaded and warning signs must be placed.
 A minimum of three trained, experienced, competent and certified operatives (two at the
platform and one at the ground) must be available for every MEWP being used. This will
ensure that in case of an emergency, the operative at the ground can take control the MEWP.
 The platform must be fully lowered when the MEWP is being moved and the flagman to guide
the movement.
 Strictly manage other equipment which is in close proximity (for example, other MEWPs,
cranes, teleporters) and ensure it is under competent supervision.
 Have the SWL displayed In a prominent location.
 Be equipped with flashing warning lights, audible warning device, fire extinguisher and a first
aid box.
Ensure maintenance records are kept up to date and documented
31

What is required?
Eyes on the Machine
Whistle Ready to Blow
Red Vest
32

Safety observations
A group is busy in discussion near

the excavator and generator
No barricade provided before

33 the start of the job.
Safety observations
34

Safety observations
35

Managing Heavy Vehicles
• Where the driver can see with his
mirrors.
• Observe Traffic signs
• Do not allow reversing operations
unless it is controlled and safe to do so
36

YOUR REAR VIEW (INSIDE) MIRROR
IS NOT ENOUGH
gives you good
what you see with information about
rear view mirror the traffic behind
only you
CLEAR
VIEW
BUT
you cannot see traffic on your left and right until it
gets very close
37

NORMAL SIDE MIRROR POSITION –
(YOU CAN SEE THE SIDE OF YOUR
CAR)
using your side the blind zones
mirrors plus rear are smaller
view mirror
CLEAR
VIEW
AND
other traffic stays in your view for longer
38

NEW SIDE MIRROR POSITION –
(YOU LOOK ALONG THE ROAD, NOT THE SIDE OF YOUR
CAR)
turn your mirrors out you get only 4 small
- make sure you see blind zones
the road, not the side
of your car
CLEAR
VIEW
clear
clear
view
you can see other traffic sooner and for longerview
39

Fatal Incident Involving Reversing PMV
On 18th May, 2019, approx. 9:13 am, while working in a trench, an Infrastructure
Subcontractor worker was struck and fatally injured by a reversing mechanical Shovel
which was working in the same area, on a different work task. Emergency Services
were immediately called, and Ambulance & Police attended to the incident location
shortly after the incident.
1. There was no consideration for two separate teams of workers conducting

different tasks, one involving plant
2. There were no physical barriers between plant and manual works
3. There was no flagman, no charge hand, no supervisor/foreman, and no
engineer overseeing either tasks (Neither subcontractor nor Arabtec).
Location of fatally 4. There was no PTW for the Shovel - (only one for an excavator which had just dug
injured person the small shallow cross trench), the “All Clear Safe to Work” was a "Tick and
Flick” exercise with location, task and PTW number left blank.
5. No records of TBT or Pre-Start Briefing.
6. The reversing alarm on the shovel was not working.
7. The shovel operator had been allowed by all to operate in this area for 20 days
Reversing into with all the same points 1 to 6.
the trench
NOTE: The incident could have been easily avoided by implementing the “Arabtec
Man -Machine-Task-Environment” risk assessment process, involving a physical pre-
start visual assessment.
40

Fatal Incident Involving Reversing PMV
Lessons Learnt:
 Two concurrent work activities in the same area must never be allowed without
exclusion zone/physical hard barriers. Man-Machine overlap must never be
allowed. Re-schedule, or Segregate.
 Hard barriers or Jersey Barriers must be filled as per Manufacturer’s Instructions
and not left empty (as communicated via HSE Alert 56 Jersey Barriers). Empty
Jersey Barriers and/or ticker-tape are not barriers.
 Inspect and test all PMV before operation, including brakes, reversing alarms,
lights, and reversing mirrors.
 Ensure trained flagmen are assigned.
Location of fatally  Ensure works are supervised.
injured person  Arabtec Construction team must never rely on subcontractors to fully self-manage
their own safety planning, controls, training or supervision.
 Important Notice (which is included in a new Arabtec Safety Standard # 40):
Reversing cameras are mandatory and must be installed on all PMV, including
Reversing into those of subcontractors, to ensure 360 degree view.
the trench
41

Construction Plant and Equipment
Accident and Incident Photos
42

If there is a danger?
1. Banksman must stop operator by using whistle and hand
signal if there is any danger to people or other machine.
2. Banksman must check clearance around excavations, under pipe

racks, structure foundations or Scaffoldings before taking his
machine near or around such areas.
3. Banksman should remain alert to see any danger due to

machine’s operation and should stop the operation
immediately if a danger is occurring.
4. Always remain in operator’s view otherwise machine can be

dangerous to banksman as well as workers.
5. Lastly arrange to remove all signs, cones, barriers, and lamps

after finishing the work ?
43

Flagmen’s Safety
• Always face traffic
• Flagmen not facing oncoming
traffic
44

Flagmen’s Hazards
• Confusing signals
• Never walk ahead.
45

Lesson Learnt From Incidents!!!
Person struck
by moving 1.No person is permitted into the work area of any
plant moving plant unless the plant is stopped and all
drivers are aware of your presence
2.Any person found in the vicinity of moving

plant will be immediately released from the
project
3.The use of “banksmen” is NOT PERMITTED to

control vehicles during earthworks operations
46

Lesson Learnt From Incidents
Lesson Learnt From Incidents – Always Use your Commonsense & observe Safety Rules!!!
Always Use your Commonsense & observe Safety Rules!!!

Incident Details: Recent examples of workers sleeping/resting under vehicles, plant, stockpiles
and other unsafe areas.
X
X X
X X
X
X
47

Lesson Learnt From Incidents
Lesson Learnt From Incidents – Always Use your Commonsense & observe Safety Rules!!!
Incident Details: Recent examples of workers sleeping/resting under vehicles, plant, stockpiles and
other unsafe areas.
X X Good Practice
X X
48

Man & Machine Interface – Filling & Leveling
Construction vehicles used for filling and leveling have significant

mass, are slow to stop and often have visibility
restrictions to the driver (especially when reversing).
The consequences of being struck by a truck, grader or water truck is

very serious.
Separating people from this equipment either with distance or

barriers is important to preventing struck by
injuries.
Hazard: Person struck by Machine
49

Threat:
•Foreman/ worker shows the exact location of dumping,
• Foreman/worker must check the level and status of compaction
• Workers come behind the mobile equipment without any valid

reason (purely behavioral issue)
• Workers from other areas crossing the filling & leveling area
• Worker manually spraying water holding water hose standing

behind the water tank truck
50

Key Safety Controls:
Foreman:
• Conducts effective STARRT
• Establishes exclusion zone by installing soft barricades around the entire
work area
• Deploys spotters at the boundary of the exclusion zone
• Provides, explains and demonstrates roles & responsibilities to
spotters and operators and verifies that spotters
and operators understand their responsibilities by asking questions and
watching them executing the tasks
• Establishes separate ‘Entry’ & ‘Exit’ for all the mobile equipments
inside the exclusion zone
• Installs warning signs
51

Operator:
•Stops driving/ operating equipment when notices personnel entry inside
the exclusion zone
• Follows the instruction of the foreman
•Parks mobile equipments at designated parking in reversed
direction
Spotter:
•Does not allow personnel entry inside the exclusion zone, while
mobile equipments are in operation
• Stops all equipments before allowing personnel to enter inside the
exclusion zone to check the level or
compaction or any other technical reason
• Follows the instruction of the foreman
52

Photo 1 – Typical Arrangements
53

Photo 2 - Visibility Restriction
54

A Fatal incident
Lack of supervision, training, failure identify hazard & non

availability of Banks men
55

Safety Slogan
Safety is our No1 Priority Safety

rules are your best tools Worker
Lives Matter
Safety a culture to live by; Communication Urge Leadership Teamwork

Understanding Recognition Empowerment
56

QUESTIONS?
57

Thank you
for
attending.
58

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Arabtec Safety

Man and Machine

“Workers Lives Matter”

“Workers Lives Matter”

“Workers Lives Matter”

“Workers Lives Matter”

“Workers Lives Matter”

This is achieved by:

“Workers Lives Matter”

 One Way Systems where possible

“Workers Lives Matter”

“Workers Lives Matter”

“Workers Lives Matter”

“Workers Lives Matter”

“Workers Lives Matter”

“Workers Lives Matter”

• Ensure effective traffic movements & flow

• Monitor traffic & pedestrians routes as per traffic &

• Monitor condition of traffic and pedestrian routes

• Manage loading and off-loading activities

• Control visiting delivery drivers & provide

“Workers Lives Matter”

• MUST stay alert and prevent others becoming unsafe

• MUST never themselves in a blind spot

• MUST be seen by driver at all times

• MUST take a safe position at all times

• Stop any construction work, activity or process when unsafe

“Workers Lives Matter”

• Access to Work Area Will be Restricted by use of Barriers,

• Banksman to Control all Vehicles within Work Area.

• All Escape Routes Shall be Kept Clear at All Times.

• Follow Good Housekeeping Procedures.

“Workers Lives Matter”

• Should be able to observe the load and other workmen at all

• Must be always be in plain view of the crane operator and all

• Never assume anything.

• Make sure both workers and operators understand exactly what is

All Banksmen are to Conduct Daily Toolbox Talks

“Workers Lives Matter”

As a Banksman, stand where you can

“Workers Lives Matter”

“Workers Lives Matter”

“Workers Lives Matter”

• Report Defects to the Supervisor.

• Follow Company Policies and Procedures such as PTWs and PPE

“Workers Lives Matter”

• Fork Lift Trucks

“Workers Lives Matter”

If “DUMPER” trucks are being used,

 Load carried are within the capacity of

 No passengers to ride on the dumper

“Workers Lives Matter”

“Workers Lives Matter”

If “EXCAVATORS” are being used, check:

• Operators to be trained and competent?

• No passengers to ride on the excavators?

• Speed limits are not exceeded when

• No travelling near to edge of