SAND, GRAVEL, AND CRUSHED STONE

ON-THE-JOB TRAINING MODULES

Module 10 - “Truck Haulage”
UNITED STATES DEPARTMENT OF LABOR
ELAINE L. CHAO
SECRETARY

MINE SAFETY AND HEALTH ADMINISTRATION

DAVE D. LAURISKI
ASSISTANT SECRETARY

Originally Published AUGUST 2000

INSTRUCTION GUIDE SERIES

MSHA IG 40
MODULE NUMBER 10
OF
INSTRUCTION GUIDE NUMBER 40

ON-THE-JOB TRAINING
FOR THE
SAND, GRAVEL, AND CRUSHED STONE INDUSTRY

TRUCK HAULAGE

This module describes the proper procedures and the associated hazards involved in
operating and loading quarry trucks, customer finished-product trucks, and pit-run trucks.

The safety of the truck driver and other personnel should be the primary concern of the mine
operator. This training module is designed to present safe loading and haulage procedures,
which will help ensure that customer truck drivers, mine employees, and other personnel are
protected from accident and injury.

Heavy-duty trucks are used in mining to transport finished material to customer job locations,
and to transport unfinished material from the quarry to the crusher, or from the pit to the
primary dump station. Large haulage trucks may cause serious accidents and injuries on the

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road, or in the quarry, if safe haulage procedures are not followed at all times.

Persons can be struck or run over when working near or around trucks. Drivers can be
injured if they lose control of their trucks, or over-travel a dump point. Even if truck accidents
do not injure anyone, these mishaps often result in damaged equipment, lost efficiency,
lowered production, and higher maintenance costs.

Safe driving procedures are generally the same for highway vehicles and for large over- the-
road haulage trucks. Off-road trucks, however, have different hazards. Off-road truck drivers
need to be trained in special procedures for vehicle loading and operation.

In order to reduce dangers to the operator from falling material, a truck should be spotted so
that the bucket of a front-end loader, shovel, or drag-line that is loading the truck does not
swing over the cab of the truck. The operator should dismount and stand in a designated
safe area while the truck is loaded, if the truck does not have a protective cab, or cannot be
spotted to avoid swinging the bucket over the cab.

Mobile equipment operators, who transport materials, must know haulage policies and
procedures. Signs must be posted at the mine site to show traffic patterns and speed limits.

Equipment that has an obstructed view to the rear must be provided with a back-up alarm.

Modern, heavy-duty haul trucks are carefully engineered, expensive pieces of equipment.
These trucks must only be operated by drivers who are qualified through training and
experience. Prospective drivers must thoroughly familiarize themselves with the truck’s
mechanical features, safety rules, and emergency procedures.

Truck accidents caused by unsafe operating practices outnumber truck accidents caused by
unsafe equipment conditions. Therefore, the time required for effective training is well worth
the effort. After drivers have had appropriate training, and demonstrated safe performance,
constant supervision is necessary to make sure that drivers continue to operate haul units in
the way in which they were instructed.

Mobile equipment operators must be especially cautious during bad weather. Potential
hazards include slippery ladders and platforms, slippery haulageways, poor visibility, rock
falls, and brake failure. Frozen material in truck beds could cause the truck to overturn while
dumping.

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The following safe job procedures involving truck loading and haulage will help to minimize
incidents which may cause injuries and adversely affect production:

REQUIRED PERSONAL PROTECTIVE EQUIPMENT:

HARD HAT, STEEL-TOED SHOES

I. OPERATION OF CUSTOMER HAULAGE TRUCKS ON MINE PROPERTY

SEQUENCE OF POTENTIAL ACCIDENTS RECOMMENDED SAFE JOB

BASIC JOB STEPS OR HAZARDS PROCEDURES
1. Report to office 1. A) Collision with 1. A) Follow designated route,
or scale house. another vehicle. and observe and obey
Struck by another traffic control signs. Wear
vehicle after exiting seat belts. Park or stop at
cab. designated areas.
Receive hazard training as
required. Obtain loading
instructions, including
locations, traffic patterns,
and other pertinent
information.

2. Weigh empty 2. A) Collision with A) Follow designated truck

truck. another vehicle. route to scale. Stay on
your side of the road.
B) Truck roll-over. B) Drive onto scale correctly.

3. Load truck with 3. A) Collision with 3. A) Obey posted traffic

material. another vehicle. patterns and speed limits
to loading point. Watch for
other traffic.
B) Hit by loader. B) Make sure loader operator
sees you.

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 SEQUENCE OF POTENTIAL ACCIDENTS RECOMMENDED SAFE JOB
BASIC JOB STEPS OR HAZARDS PROCEDURES
C) Struck by falling C) Stay in cab of truck. Make
material. sure truck is spotted
correctly at hopper, or
stockpile, so material does
not strike cab.
D) Equipment failures, D) Follow emergency safety
such as brakes, procedures applicable to
steering, engine, equipment and mine site.
and tires.

4. Weigh full truck. 4. A) Uneven load may A) Make sure material is

affect vehicle loaded evenly.
control.
B) Collision with B) Follow designated truck
another vehicle. route to scale. Stay on
your side of road.
C) Truck roll-over. C) Drive onto scales correctly.

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 II. LOADING TRUCKS USING FRONT-END LOADERS

SEQUENCE OF BASIC POTENTIAL ACCIDENTS RECOMMENDED SAFE

JOB STEPS OR HAZARDS JOB PROCEDURES
1. Conduct pre-shift 1. A) Slips and falls. 1. A) Make sure work
inspection of loader - area is clear of
check the following: slipping hazards.
a. Tires and wheels
B) Area around vehicle
C) Engine compartment
D) Fluid levels
E) Hydraulic lines
F) Fire extinguisher
G) Loader linkage
H) Ladders, platforms
1. Loose objects/debris
in cab
j. Seat-belt
k. Back-up alarm
l. Clean windows
m. Engine operation
n. Wipers and lights
o. Service and parking
brakes
p. Steering
B) Burns. B) Wear gloves.

2. Spot the truck. 2. A) Run over by truck. 2. A) Make sure the

truck drivers see
you, if you are not
in the loader.

3. Load the truck. 3. A) Running over 3. A) Be aware of

someone. everyone’s
location in the
work area.
B) Dropping material B) Do not move
on cab and driver bucket near cab of
truck.

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SEQUENCE OF BASIC POTENTIAL ACCIDENTS RECOMMENDED SAFE
JOB STEPS OR HAZARDS JOB PROCEDURES
C) Uneven loading C) Load truck evenly.
may affect control of
truck.
D) Equipment failures, D) Follow emergency
such as brakes, safety procedures
steering, engine, applicable to
and tires. equipment and
mine site.

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 III. OPERATION OF HAUL UNITS AND PIT-RUN TRUCKS

SEQUENCE OF BASIC JOB POTENTIAL ACCIDENTS RECOMMENDED SAFE

STEPS OR HAZARDS JOB PROCEDURES
1. Conduct pre-shift 1. A) Slips and falls. 1. A) Use handrails.
inspection of truck - check Make sure that
the following: ladders and
a. Tires and wheels walkways are
b. Area around vehicle clean and in good
c. Engine compartment repair.
d. Fluid levels
e. Hydraulic lines
f. Fire extinguisher
g. Loader linkage
h. Ladders, platforms
I. Loose objects/debris
in cab
j. Seat-belt
k. Back-up alarm
l. Clean windows
m. Engine operation
n. Wipers and lights
o. Service and parking
brakes
p. Steering
q. Gauges and warning
lights
r. Retarder
B) Burns. B) Wear gloves.

2. Follow designated truck 2. A) Collision with 2. A) Stay on your side

route to pit or quarry. another vehicle. of the road.
B) Run off road. B) Watch for other
traffic.
C) Loss of control of C) Follow posted
vehicle. traffic patterns
and speed limits.

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SEQUENCE OF BASIC JOB POTENTIAL ACCIDENTS RECOMMENDED SAFE
STEPS OR HAZARDS JOB PROCEDURES
D) Equipment failures, D) Follow
such as brakes, emergency safety
steering, engine, procedures
and tires. applicable to
equipment and
mine site.

3. Load truck with raw 3. A) Collision. 3. A) Follow

material. established
procedure for
loading trucks.
B) Struck by shovel or B) Spot truck in
drag-line bucket, or proper position.
falling material.
C) Run over by loader. C) Do not leave
truck cab unless
necessary, and
then only after
assuring loader
operator is aware
of your position.
D) Covered by D) Dismount truck
material. and stand clear if
a hazard of falling
material exists.
E) Uneven load may E) Make sure
affect control of material is loaded
vehicle. evenly.

4. Follow designated route to 4. A) Collision with 4. A) Stay on your side

crusher or pit run hopper. another vehicle. of the road.
B) Run off road. B) Watch for other
traffic.
C) Loss of control of C) Follow posted
vehicle. traffic patterns
and speed limits.

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SEQUENCE OF BASIC JOB POTENTIAL ACCIDENTS RECOMMENDED SAFE
STEPS OR HAZARDS JOB PROCEDURES
D) Equipment failures, D) Follow
such as brakes, emergency safety
steering, engine, procedures
and tires. applicable to
equipment and
mine site.

5. Dump material. 5. A) Collision with A) Stay on your side

another vehicle. of road.
B) Run off road. B) Watch for other
traffic.
B) Backing into C) Back up slowly
crusher. until rear tires
reach stop block.

6. Return to pit or quarry. 6. A) Collision with 6. A) Stay on your side

another vehicle. of the road.
B) Run off road. B) Watch for other
traffic.

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 IV. WORKING AT NIGHT, AND NIGHT ILLUMINATION

SEQUENCE OF BASIC POTENTIAL ACCIDENTS RECOMMENDED SAFE

JOB STEPS OR HAZARDS JOB PROCEDURES

1. Working at night, and 1. A) Driving off benches. 1. A) Drive slower at

night illumination. night.
B) Run over. B) Watch out for
moving equipment.
Wear light colored,
or reflective,
clothing.
C) Trips, slips, and C) Watch step. Work
falls. areas must be
safely illuminated.
D) Struck by falling D) Look out for, and
material. avoid, overhead
hazards.
E) Running into E) Keep equipment
objects (rocks, etc.) lights on, and clean.
In haulageways. Watch for
obstacles.
F) Blinded by F) Dim headlights
headlights. when approaching
equipment and
personnel.

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GENERAL INFORMATION

This module is part of an Instruction Guide that was developed to assist the sand, gravel, and
crushed stone industry in conducting effective, on-the-job training (OJT) of new employees,
or employees reassigned to different jobs. The use of training materials, such as this module,
is an important part of an effective, systematic, OJT program.

This Instruction Guide uses a generic Job Safety Analysis (JSA) of jobs common to the
industry. The JSA format facilitates uniform basic training in safe job procedures, while
requiring only a minimum of time and effort on the part of the trainer. This material is generic
to the industry; therefore, each company using this guide will need to tailor the material
somewhat to fit their particular requirements. In some cases, the material must be general
in nature, and will not include specific details of procedures or equipment that must be taught
by the trainer.

Recommendations for an overall OJT program are contained in the Mine Safety and Health
Administration (MSHA) guide: “Structuring Effective On-The-Job Training Programs”

TRAINING RECOMMENDATIONS

On-the-job training is usually best done by the employee’s immediate supervisor. If the
supervisor relies on another employee to do certain parts of the training, the supervisor
should be present to monitor the training. OJT is conducted at the actual job site, where the
work will be done.

The supervisor/trainer should use the training materials (this module, or other materials) while
the training is being done, to help ensure that all job steps are covered, and that no important
safety precautions are omitted. Effective OJT should begin with an explanation (lecture
and/or discussion) of the safe job procedure. The explanation should be followed by a hands-
on demonstration of the proper job procedure. A good demonstration is, perhaps, the most
important part of OJT. The demonstration is followed by supervised practice, during which
the supervisor/trainer coaches (corrects and encourages) the employee, and evaluates when
the employee is ready to do the job without direct supervision.

The first step - explaining the job to the employee - can be done in different ways. The
supervisor/trainer and the employee can sit down and go through the training materials
together. It may be advantageous to provide the employee with a copy of the training
modules that are applicable to his/her job. The fact that most of the training is conducted at
the job site does not preclude the use of a classroom, or a quiet office, for the first part of the
training. Any general theory, or knowledge training, as well as the initial explanation of the
job procedure, may be best done in an office/classroom setting; especially when noise levels,
or other conditions at the job site, make communication difficult. A complete series of job
steps could be presented through the use of slides developed at the mining operation.