PLT/Specific Plant/TBT-PLT-030

Plant Maintenance and Defect Reporting

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Poorly maintained plant is a leading cause of mechanical failure, hydraulic bursts, and brake failure on UK construction sites. Every operator has a legal duty to report defects and ensure their machine is safe before use. Ignoring a defect or continuing to operate faulty equipment puts yourself and everyone around you at risk. This talk explains the maintenance checks operators must carry out and how to report defects correctly.

Key Hazards

Brake failure causing runaway plant on slopes or haul roads

Hydraulic hose burst spraying high-pressure fluid causing burns

Structural failure of booms, arms, or chassis from fatigue cracks

Electrical fire from damaged wiring or corroded battery terminals

Control Measures

Complete the daily pre-start inspection checklist before operating any plant each shift.
Check engine oil, coolant, hydraulic fluid levels, and fuel before starting the machine.
Inspect tyres or tracks, mirrors, lights, seatbelt, and all safety devices during the walk-around.
Test brakes, steering, horn, and emergency stop before moving the machine from its parking position.
Report all defects immediately to the supervisor using the site defect reporting system.
Do not operate any machine with a known safety-critical defect until it has been repaired.
Tag defective machines as out of service and remove the key to prevent unauthorised use.
Ensure planned maintenance is carried out at the intervals specified by the manufacturer.
Keep maintenance and inspection records on site and available for HSE inspection.

Remember

Complete the daily pre-start inspection checklist before operating any machine each shift
Report all defects immediately to the supervisor using the site reporting system
Never operate a machine with a known safety-critical defect until it is repaired
Tag defective machines as out of service and remove the key to prevent use
Planned maintenance must be carried out at the intervals specified by the manufacturer

Applicable Legislation: PUWER 1998 · LOLER 1998 · CDM 2015 · Health and Safety at Work etc. Act 1974

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