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Proximity Warning Systems for
Aggregates & Quarries
Safeguarding people and assets in challenging aggregate and quarry environments.
AGGREGATES & QUARRIES
Proximity warning systems for aggregates and quarries.
Help operators and pedestrians recognise vehicle proximity risks around mobile plant, loading areas and processing operations.
ZoneSafe provides pedestrian detection, vehicle warnings, and activated signage configured around your site, your vehicles, and how people work. Explore AI cameras, RFID proximity warning and detection or a combined approach for loading shovels, excavators, dump trucks and restricted-view crossings.
For quarry operators, sand and gravel plants, aggregate depots, and related processing sites managing mobile plant alongside groundworkers, maintenance teams, contractors, and visiting hauliers.
From Avonwood Developments, a UK manufacturer  /  UK applications at Hanson Aggregates & Eurovia Roadstone
“Prior to us installing ZoneSafe, we had one incident on site that could have led to a £60,000 claim due to damages. Thankfully, with the CCTV that we had in place, and then looking at installing the ZoneSafe system as we did, we’ve been able to eliminate all of those incidents that could have happened.“
Michael Perkins, Site Manager – Hanson Aggregates
AGGREGATES AND QUARRIES OPERATING SITUATIONS
Where does mobile plant meet pedestrian activity?
Review loading, processing and access points where mobile plant operates near groundworkers, maintenance teams and visiting hauliers.
Loading shovels and stockpile movements
Buckets, carried material and the vehicle body can restrict an operator’s view. Review loading, reversing and turning tasks, including where groundworkers or drivers may approach the working area.
Processing-area access
Sampling, inspection and maintenance can bring people near mobile plant around crushers, screens and hoppers. Review access routes and the vehicle-person interaction separately from machinery guarding and isolation.
Loading areas and
visiting hauliers
visiting hauliers
Lorries, loading shovels and drivers can converge at loading and dispatch points. Consider driver waiting areas, arrival instructions and who needs to be detected or warned.
Excavators and dump-truck interfaces
Review visibility around vehicle bodies, booms and attachments, and the movements linking loading and haul routes. Confirm the actual task and vehicle configuration before selecting a system.
Changing routes and outdoor conditions
Stockpile layouts, temporary works and maintenance activity can change routes and sightlines. Include dust, rain, low light, cleaning routines and relevant shift conditions in an evaluation.
DETECTION AND WARNING OPTIONS – PROXIMITY WARNING SYSTEMS FOR AGGREGATES & QUARRIES
Choose detection around your plant and routes.
RFID Proximity Warning & Detection
Pedestrian detection uses RFID tags without needing direct line of sight to the tag. The configured system warns the operator and tagged pedestrian. Assess actual plant, structures and material obstructions, and plan tag issue and checks.
Combined AI & RFID proximity detection
Combine HFR camera detection of visible, untagged people with RFID detection of tagged workers where the view is obstructed. Evaluate both detection paths and the warning arrangement under representative site conditions.
Vehicle-activated
Signage
Signage
Trigger a warning when an equipped vehicle approaches a crossing, doorway or fixed access point. Position the sign for the people using that route. Discuss access control where appropriate to support agreed site procedures.
Site Access Control (doors, gates & barriers)
By restricting site access to only those with a ZoneSafe tag, the system reduces the risk of accidents. Tags are required to open gates or barriers to restricted areas, and the user will be detected and warned if they get too close to a moving vehicle.
Vehicle-to-Vehicle Warnings
Warn operators when another equipped vehicle enters the configured detection zone. Consider mobile-plant junctions and loading-area approaches. Confirm the equipped fleet; do not assume every visiting lorry is detected.
MyZoneSafe
Data Management
Data Management
MyZoneSafe is our cloud-based platform that records and displays event data (such as near-miss occurrences) to inform health and safety managers of potential hazards and collision hotspots.
Which vehicles can ZoneSafe be fitted to?
Our proximity warning systems for aggregates and quarries integrate with all mobile plant, industrial vehicles and mixed fleets. Each vehicle possesses its own blind spots and collision risks. ZoneSafe significantly increases awareness for both operators and groundworkers around each vehicle.
Forklifts
Designed to overcome the significant blind spots caused by the forklift's load, cab, and unique shape, and a distorted view from the cab.
Shovel Loaders
Mitigates the high risk posed to pedestrians by the vehicle's large size and attachments, which create significant driver blind spots.
Excavators
Specifically addresses blind spots created by the boom arm, grab attachment, and the vehicle's 360-degree rotation.
Dump Trucks
Mitigates the high risk posed by a dump truck's large size by addressing significant blind spots at the back, front, and sides of the vehicle.
PROXIMITY WARNING SYSTEMS FOR AGGREGATES & QUARRIES
See how aggregates and related operations use ZoneSafe.
UK examples of site traffic management and loading-shovel pedestrian warnings.
These examples describe individual implementations. Follow each case study for its application and context.
Leading building materials suppliers, Hanson – Dagenham integrates site-wide access control and pedestrian safety solution.Â
Eurovia Roadstone, one of the world’s largest asphalt producers installed a ZoneSafe proximity safety solution in Dagenham.
Some of the clients who have purchased proximity warning systems for aggregates & quarries:
FOR THE PEOPLE MAKING THE DECISION
Get the answers your team needs.
Quarry / site manager
Define the priority interaction, loading arrangements and access routes. Agree who owns the system and how it fits daily site operations.
EHS / SHEQ
Review vehicle-person interactions within existing controls. Define evaluation criteria and warning response without treating alerts as a substitute for segregation.
Plant / fleet management
Confirm loading-shovel, excavator and dump-truck models, attachments, hired plant and any vehicle-to-vehicle requirements.
Engineering / maintenance
Check mounting, power, vibration, exposure, cleaning, commissioning and routine checks. Plan for plant replacement or attachment changes.
Weighbridge / logistics
Review haulier arrival, driver waiting areas, loading instructions, contractor access and tag issue or return where required.
Procurement
Compare the full installation and support scope. Define what must be demonstrated before extending to other vehicles or sites.
FROM OPERATING PROBLEM TO AGREED SCOPE
Plan around your shifts and peak periods.
Review representative working conditions and the practical requirements for installation and ownership.
1. Describe the
interaction
interaction
Share the task, routes, vehicle types, pedestrian access and existing controls. Include representative loads and busy periods.
2. Review a representative configuration
Consider coverage, alert recipients, warning response, visitors and tag routines. Agree the scenarios and criteria to review during any evaluation.
3. Plan installation & ownership
Discuss vehicle availability, shift windows, commissioning, staff induction and routine checks. Confirm scope and ownership before extending to more trucks or sites.
BEFORE YOU MAKE ANY DECISIONS
Practical questions regarding proximity warning systems for aggregates & quarries.
Will it work in dusty conditions, in rain, or around stockpiles?
Can it be fitted to loading shovels, excavators and dump trucks?
Do visiting drivers and contractors need tags?
Will vehicle-to-vehicle warnings detect every visiting lorry?
How do warnings work in noisy areas or with hearing protection?
Does it stop moving plant or make it safe to enter an operating area?
How do we handle unwanted alerts or changing routes?
What do you need to scope a quotation or trial?
Does it replace existing controls?
DISCUSS YOUR AGGREGATES & QUARRIES WORKSITE
Tell us what you need to address.
Has a near miss, audit finding, change in layout or fleet expansion prompted a review? Tell us why you are looking, what needs covering and how soon you need to act. You don’t need to choose a safety technology before contacting us. We can suggest the right technology and safety system to suit your requirements.
Help your employees
to feel safe at work
Protect your
employer reputation
Improve your
safety culture
Other projects we’ve delivered
Peterson,
Transport & Logistics
Transport & Logistics
The implementation encourages workers to be vigilant where vehicles work in close proximity.
Ball Packaging,
Aluminium Packaging
Aluminium Packaging
Ball wanted additional safety measures to be put in place to avoid a serious workplace accident.
Mondi,
Paper & Packaging Manufacturer
Paper & Packaging Manufacturer
Mondi is a leading manufacturer in packaging and paper, with over 26,000 employees around the world.
Liberty Steels,
Steel Manufacturer
Steel Manufacturer
Liberty Steel implemented a vehicle safety and asset protection system to stop cranes from colliding.
See how ZoneSafe can provide a solution for you Get in touch