Help Protect Your Heavy Equipment from Fires [Checklist Included]

Experienced contractors know that many unexpected obstacles may arise on the way to completing a successful project. One of these obstacles is when equipment becomes damaged or unusable, leaving workers without the tools they need for the job. Along with theft, equipment catching fire can present a significant threat, not only to the project, but also to the people on-site.

Having equipment in good condition with proper maintenance and operational controls is crucial for worker safety and business continuity, emphasizing the importance of thorough preparation for each job site. One of the best ways to facilitate staying on schedule is to help ensure that preventative measures are in place for company equipment.

What Causes Heavy Equipment Fires?

There are many scenarios that can lead to an equipment fire, but most can be categorized under four main causes:

1. Electrical Malfunction: While the complexity varies—from hand tools to heavy equipment—most machines contain a series of wires and connections that must remain in good condition to operate in unison. Defective wiring, damaged insulation, and short or overloaded circuits are common examples of hazards that can result in flames.
2. Fuel Leakage: Equipment with a motor typically runs on gasoline or diesel fuel, so refueling is an especially common procedure on all job sites. Fuels are a dangerous source of ignition if not properly contained. If tanks or lines rupture and leaking fuel touches a hot equipment surface or spark from an electrical component, it can quickly lead to a fire.
3. Mechanical Failure: Even the most reliable machines can malfunction. Heavy equipment generates a significant amount of heat, which makes overheating a potential hazard. Hot working environments only increase the potential for stress and damage. Cooling down equipment properly at the end of the day is critical. Hydraulic lines exposed to friction can rupture and spray fluid, which can then be ignited by a hot engine component or electrical spark.
4. Flammable Materials: Common job site exposures can include the buildup of dust and grease on equipment or the accumulation of trash and debris, which can also be natural materials like grass, leaves and brush. Aside from fuel, many projects also involve the use of various flammable chemicals or substances. Without proper daily housekeeping protocols in place, these exposures can easily ignite a fire.

How You Can Help Prevent Equipment Fires

To minimize the chance that a project is set back by the loss of equipment due to fire, risk managers should address maintenance, inspection and operation.

Maintenance

For machinery to remain reliable throughout a project and from job site to job site, it requires consistent care from workers and supervisors. Each piece of equipment has a unique maintenance schedule, meaning there could be different requirements to remain in proper working condition depending on the degree to which it is used. Managers should consult manuals and other relevant manufacturer documentation to become familiar with maintenance requirements for each piece of equipment that will be deployed.

Equipment maintenance should be addressed from at least three angles:

• Preventative: Establishing a schedule based on the particular piece of equipment’s rate of usage.
• Corrective: Implementing procedures for maintenance when an issue arises that minimizes the amount of time until the equipment can be used again.
• Condition-Based: Properly assessing unique job sites to determine if “special” maintenance may be required.

At a minimum, basic daily maintenance practices should include proper equipment cooldown, cleaning and sanitation, replenishing fuel and fluid levels, verifying functional safety devices, and checking components.

For a helpful tool in staying diligent about equipment maintenance, click here for a printable checklist of daily measures.

Download Checklist

Inspection

A robust prevention program means going beyond maintenance to incorporate thorough inspections of equipment at set intervals. This may be best accomplished between job sites when there is no immediate need for the equipment. It may also require the use of separate devices specifically designed for inspection tasks. Like maintenance, it is best to consult the user manual and other relevant manufacturer specifications.

Inspections should be documented using written checklists. Recordkeeping is also important because preserving each machine’s history allows for more efficient repair efforts or to know when replacement is necessary. At a minimum, inspections should occur annually for all equipment.

Operation

Assuming equipment has been properly inspected and a regular maintenance protocol has been established, the last key prevention factor is ensuring that workers on the job site know how to properly use the equipment and react appropriately if a malfunction is encountered. Both operators and their managers should be adequately trained using manufacturer guidelines. When applicable, such as forklift operators, hire employees who have been certified for the particular task.

Best practices for daily operations include the following:

• Shut down all equipment when not in use.
• Properly cool down equipment prior to refueling or performing maintenance:
• Let equipment idle for 5-10 minutes instead of turning it off immediately.
• Use a maximum rate of 100°F per hour to avoid stress and damage.
• Use custom injector nozzles to minimize cold spots.
• Consider using equipment to control the process.

• Maintain sufficient clearance from other operations, equipment, storage, etc., on the job site to prevent ignition from incidental contact.
• Store flammables away from work areas, and use approved tanks and containers when possible.
• Post fire extinguishers conspicuously on the job site or, if possible, directly on the equipment.
• Maintain a continuous ground between nozzles and filler pipes.
• Train employees to identify warning signs that may come in the form of abnormal noises, unusual smells, etc.
• To prevent spills, utilize secondary containment measures such as curbs, liners, drip pans and buckets, portable berms, etc.
• Know the location of emergency shut-down switches.

Don’t Forget Security Measures

While the focus of this article has been on equipment loss due to fortuitous causes, it should also be mentioned that fire can result from deliberate acts. To help protect your project from arson and other criminal acts like theft and vandalism, risk managers should also incorporate measures into their prevention plans to help ensure job sites remain as secure as possible. Provide local authorities with the information they need to respond efficiently.