Safety First: Mounting and Dismounting Heavy Equipment at Scrap Metal Facilities

Every day at scrap metal facilities, workers climb on and off forklifts, skid steers, excavators, and material handlers dozens of times. It’s such a routine task that it’s easy to become complacent. Yet slips, trips, and falls during mounting and dismounting are among the most common causes of serious injuries in our industry. A moment of carelessness can result in broken bones, sprains, or worse.

Why This Matters

The scrap yard environment presents unique challenges. Oil and hydraulic fluid can make steps slippery. Mud, scrap debris, and uneven ground surround your equipment. You’re often in a hurry to meet production demands. These factors combine to create significant hazards during what should be simple entries and exits from your machine.

Falls from equipment can result in injuries that keep you off the job for weeks or even end careers. Beyond the personal cost, these incidents affect your coworkers who must cover your duties and your family who depends on your income.

The Three-Point Contact Rule

The single most important safety practice is maintaining three-point contact whenever mounting or dismounting equipment. This means keeping three of your four limbs in contact with the machine at all times—either two hands and one foot, or two feet and one hand.

When climbing up, step up with one foot while keeping both hands on handholds. Then bring your second foot up while maintaining those hand grips. When climbing down, the process reverses. Face the machine, grip the handholds, step down with one foot, then the other, keeping your hands in place until both feet are firmly on the ground.

Never jump down from equipment, no matter how small the distance seems. That “quick hop” off a forklift might save two seconds, but it significantly increases your risk of ankle injuries, knee damage, or losing your balance on uneven ground.

Know Your Equipment

Each type of heavy equipment has specific mounting and dismounting considerations:

Forklifts typically have steps on one side and grab handles. Always mount and dismount from the designated side. Never climb over the forks or use the steering wheel as a handhold. Before dismounting, ensure the forks are lowered to the ground, the parking brake is set, and the engine is off.

Skid steers present particular challenges due to their compact design and attachment systems. Use the designated steps and handholds, which may be on the loader arms or cab frame depending on the model. Be especially cautious of hydraulic lines and moving parts. Always lower the bucket or attachment completely before exiting.

Excavators require you to climb higher and often have rotating cabs. Make certain the house is aligned properly with the tracks and the attachment is lowered before dismounting. Use both handrails and take your time climbing down the steps. The greater height makes falls more dangerous.

Material handlers in scrap facilities often have extended reach and high cabs. These machines may have multiple steps and platforms. Clean each step as you go if possible, and never rush the climb down. The cab height that gives you great visibility also means a longer fall if something goes wrong.

Pre-Operation Walk-Around

Before you ever climb onto equipment, walk around it. Check that steps, handholds, and platforms are free from oil, grease, mud, and debris. Look for damage to steps or missing handrails. If you find hazards, clean them or report them before operating the machine. Wipe your boots on the ground to remove mud or debris that could cause you to slip.

This walk-around serves double duty as your pre-operation inspection, where you also check for leaks, tire damage, and other mechanical issues.

Environmental Awareness

Pay attention to ground conditions around your equipment. Scrap yards rarely have perfectly level, paved surfaces. You might be dismounting onto gravel, mud, uneven ground, or surfaces covered with small metal fragments.

Before you step down, look where you’re stepping. Is there stable ground? Are there tripping hazards? Is there enough clearance, or are you blocked by scrap piles or other equipment? Never dismount into an area where another vehicle or piece of equipment is operating nearby.

Weather conditions matter too. Rain, ice, and snow make surfaces more hazardous. Take extra time and care during inclement weather, and consider requesting additional anti-slip treatments for equipment steps.

What Not to Do

Several dangerous practices have become common in some facilities, but they remain unsafe no matter how often workers get away with them:

Never use the steering wheel, joysticks, or control levers as handholds. These aren’t designed to support your weight and may move unexpectedly.

Never carry tools, materials, or other items while mounting or dismounting. Your hands need to be free to grip handholds. Use a tool belt, or hand items to a coworker, or make a second trip.

Never mount or dismount while the equipment is moving, even at slow speeds. Wait until the machine is completely stopped.

Never dismount facing away from the equipment except as a last resort in an emergency. Facing the machine gives you better control and allows you to maintain three-point contact.

Never rush. Production demands are real, but the seconds you save by rushing don’t justify the weeks of recovery from a preventable injury.

Proper Footwear and PPE

Your steel-toed boots are critical for mounting and dismounting safety. Boots should have good tread that isn’t worn smooth and soles that provide grip without collecting mud in deep treads. Laces should be tied and tucked so they don’t catch on steps or pedals.

Keep your gloves on during mounting and dismounting if they improve your grip, but remove them if they’re bulky, slippery, or make it harder to grasp handholds securely. Some workers prefer to remove gloves for better tactile feedback on handholds.

Loose clothing can catch on controls or protrusions. Make sure jackets are zipped and nothing is hanging loose that could snag.

Special Situations

End of shift fatigue: You’re more likely to make mistakes when tired. The last dismount of the day deserves the same attention as the first. Take an extra moment to focus.

After incidents or near misses: If something unexpected just happened—a close call, an equipment malfunction, or a stressful situation—take a breath before dismounting. Adrenaline and distraction increase fall risk.

Training new operators: If you’re training someone, emphasize proper mounting and dismounting from day one. Bad habits are hard to break once established. Set the example by following procedures yourself every single time.

Maintenance and repairs: When mechanics or operators need to access unusual areas of equipment for maintenance, standard access points may not work. Plan these activities carefully, use ladders or platforms when needed, and never improvise handholds on parts not designed for that purpose.

Creating a Culture of Safety

Safety isn’t just about individual actions—it’s about the workplace culture we build together. When you see a coworker jumping off equipment or rushing, say something. When someone takes the time to clean debris off steps before dismounting, recognize that positive behavior.

Supervisors and experienced operators set the tone. If leadership cuts corners on mounting and dismounting procedures, newer workers will assume those behaviors are acceptable. Consistency matters.

Final Thoughts

Mounting and dismounting heavy equipment safely requires no special skills, costly equipment, or extra training. It simply demands that you pay attention, follow established procedures, and resist the temptation to cut corners for convenience.

Three-point contact, facing the machine, taking your time, and checking your path may seem like small things. But these small things prevent big injuries. Every time you climb into or out of your equipment, you’re making a choice about your safety and your future.

Make the choice that gets you home safely at the end of every shift. Your family is counting on you.