During yard loading operations a potential high consequence near miss took place.

A wagon was being loaded with loose aluminium by a front end loader. On completion of loading, the shovel reversed away from the wagon and became stationary in the middle of the yard. Two pedestrians and a forklift truck passed the loading shovel in the yard, the loading shovel operator then proceeded to park adjacent to the loaded lorries cab door and spoke to the wagon driver. The wagon driver then exited the cab to check their external weigher. As he was climbing back in to his cab the shovel operator started to reverse and hit the lorry cab door, narrowly missing the driver.

Contributing factors

• Yard rules not followed by members of staff. ‘No go zone’ entered on numerous occasion by forklift truck and pedestrians. Loader operator did not take charge of the yard and say no to access whilst loading operations taking place.
• Parked alongside the lorry, lack of hazard awareness of positioning when pedestrian in close proximity.
• Low loader operations were also taking place in the yard, providing a distraction to the loader operator and limiting space in the yard for loading to take place. No one was appointed to liaise with the low loader operations – and suspend other yard activities.

• Check all individuals working within yard are trained and competent
• Ensure that any Safe Systems of Work understood and are being followed
• Consider who is responsible for the safe operation and control of activities in yard
• Consider enforcements of ‘no go areas’ or ‘exclusion zones around vehicles’ during certain activities
• Ensure that loader operators are trained to recognise potential hazards and understand their responsibilities in terms of controlling other activities in yard
• When operating loaders or forklifts in yard remain alert to other activities and stop operations if necessary
• Consider warning systems on loaders and use of technology that could prevent collisions
• Ensure that appropriate risk assessments and SSOW are in place for loader operator.