Equipment Exclusion Zone Calculator

Calculator Inputs

Equipment type CraneExcavatorForkliftTelehandlerAerial LiftLoaderOther

Sets baseline multiplier for dynamic movement risk.

Max reach or working radius (m)

Use maximum expected reach at the task position.

Tail swing / counterweight radius (m)

Include rear swing for rotating equipment.

Load length (m)

Used as half-length beyond the hook/forks.

Lift or handling height (m)

Adds a small drift margin for elevated operations.

Base buffer (m)

Recommended minimum: 1–3 m, per site rules.

Wind speed (km/h)

Higher wind increases swing and load drift.

Ground slope (%)

Steeper ground increases instability and travel error.

Nearby access level Low (Controlled access)Medium (Mixed trades)High (Public/traffic nearby)

Higher access increases recommended zone size.

Controls in place No additional controlsBarriers / fencingDedicated spotterBarriers + spotter

Controls can slightly reduce uncertainty in boundaries.

Submit Reset

Example Data Table

Sample inputs and the resulting recommended radius. Values are illustrative for planning.

Formula Used

The calculator starts with a conservative base radius and then applies margins and multipliers. All distances are in meters.

Area and perimeter are calculated as: Area = πR² and Perimeter = 2πR.

How to Use This Calculator

1. Choose the equipment type and enter the maximum expected reach.
2. Add tail swing for rotating equipment and the load length handled.
3. Enter lift/handling height, wind speed, and site slope if applicable.
4. Select the nearby access level and the controls you will enforce.
5. Press Submit to display the radius, area, and barricade outputs.
6. Use the CSV/PDF buttons to attach results to permits.

Professional Guidance

1. Why exclusion zones matter

Exclusion zones reduce struck-by and caught-between events by separating people from moving plant. On busy projects, overlapping trades, deliveries, and changing work fronts raise exposure frequency. A defined radius, clearly marked and enforced, turns “stay clear” into a measurable control.

2. Base geometry you can verify

The starting radius is a simple reach-and-swing envelope: maximum working reach, tail swing, half the load length beyond the hook or forks, plus a buffer. This captures the space the machine and load can occupy during normal motion, without assuming perfect operator precision.

3. Environmental drift data inputs

Wind can make suspended loads drift and amplify swing. A practical rule adds 0.5 m per 10 km/h. Ground slope affects braking distance, travel accuracy, and stability; steeper slopes warrant extra margin even for slow maneuvers. These values are conservative planning aids for daily permits.

4. Height and dynamic movement

Higher lifts increase pendulum effects and time exposed to gusts. This calculator adds 2% of lift height as a drift allowance, which scales with elevated picks. For highly dynamic lifts or long travel paths, increase the base buffer or divide work into smaller, rechecked zones.

5. Risk multipliers by equipment and access

Different equipment types carry different movement variability. Cranes and rotating plant typically warrant larger multipliers than aerial lifts. Access level represents people density and proximity to public routes; high access increases the recommended radius because boundary breaches are more likely.

6. Controls reduce uncertainty, not duty

Barriers and dedicated spotters can tighten boundaries by improving compliance and visibility. The control multiplier provides a modest reduction, but never below base geometry. Controls must be paired with briefings, signage, and a clear stop-work trigger if the zone is compromised.

7. Barricade and marker planning

Perimeter helps plan cones, tape, or fencing. Using 2.5 m spacing provides frequent visual cues and reduces “shortcut” crossings. Expect more markers near entrances, blind corners, and pinch points. Record the radius and perimeter so crews can rebuild the zone after breaks.

8. Documenting and recalculating

Export the CSV/PDF and attach it to lift plans, JHAs, and daily permits. Recalculate whenever the machine position changes, the working radius shifts, the load configuration changes, or wind increases. A documented update cycle supports supervision and demonstrates consistent risk management.

FAQs

1) What is an equipment exclusion zone?

An exclusion zone is a defined area around equipment where unauthorized people must not enter, reducing struck-by and pinch-point risks during operation.

2) Should I use the maximum reach or the typical reach?

Use the maximum expected reach for the task. If the machine can extend farther during the shift, the zone should cover that maximum to avoid underestimating exposure.

3) How do I choose the base buffer value?

Start with your site standard, often 1–3 meters, then increase near edges, overhead hazards, or public routes. The buffer is a practical allowance for human and machine variability.

4) Why does wind change the exclusion zone size?

Wind can push suspended or long loads, increasing swing and drift. A larger boundary helps prevent people from entering the probable path of a moving load.

5) Do barriers and spotters eliminate the need for an exclusion zone?

No. Controls improve compliance and visibility, but the boundary is still required. If the zone is repeatedly breached, stop the task and strengthen controls or increase the radius.

6) How many cones or markers should I plan for?

Use the perimeter output and divide by your preferred spacing. The calculator estimates markers at 2.5 m spacing, then add extra around entrances and areas with poor sightlines.

7) When should I recalculate during the day?

Recalculate when equipment relocates, radius changes, loads change, or wind increases. Update the printed report so supervisors and crews share the same current boundary.