Plant Person Interface

Toolbox Talk Record

Ref: TBT-PLT-059  |  Issue: 1  |  Date: April 2026
PresenterProject
LocationDate

What?

Why?

Prevent deathsBeing struck or crushed by plant is almost always fatal — there is no safe speed for a collision between a machine and a person.
HSE priorityPlant person interface is an HSE strategic priority — inspectors specifically assess PPI controls during every site visit.
Everyone's dutyBoth operators and ground workers share responsibility — operators must watch for people and workers must respect zones.
Do Don't
  • Separate pedestrian routes from plant routes using physical barriers wherever possible.
  • Plan and brief the PPI arrangements at every pre-start meeting before work begins.
  • Make positive eye contact with the operator before entering any plant working area.
  • Wear high-visibility clothing appropriate to the site conditions at all times on site.
  • Appoint trained banksmen for all operations where pedestrians work near mobile plant.
  • Use designated crossing points to move between work areas separated by haul routes.
  • Stop and reassess if a planned segregation arrangement breaks down during the task.
  • Report every near miss involving plant and pedestrians — they are warnings of fatalities.
  • Use radios to communicate positions between operators and ground workers continuously.
  • Review PPI arrangements whenever the site layout, work sequence, or plant types change.
  • DON'T walk through a plant operating area without confirming the safe system with the operator.
  • DON'T assume an operator can see you — blind spots exist on every machine regardless of mirrors.
  • DON'T take shortcuts across haul roads or through active excavation zones to save time.
  • DON'T rely on reversing alarms alone as an effective warning — they create alert fatigue.
  • DON'T allow familiarity with daily plant movements to reduce your awareness of the danger.
  • DON'T store materials, skips, or welfare units where they force pedestrians into plant routes.
  • DON'T wear earphones, hoods, or anything that reduces your hearing near operating plant.
  • DON'T allow new workers into plant areas without a specific PPI briefing for that zone.
  • DON'T stand in the swing arc of a slewing excavator even during breaks or conversations.
  • DON'T dismiss near-miss reports — each one represents a potential fatality that was narrowly avoided.

See also: Plant and Pedestrian Segregation | Reversing and Banksman Procedures