Revolutionary Safety Protection for Australian Worksites

Eliminating the Leading Cause of Mining and Construction Fatalities

Every year, Australian mining and construction operations face a persistent and devastating safety challenge: collisions between heavy mobile equipment and workers. These incidents represent the leading cause of workplace fatalities in our industries, destroying families, traumatising workforces, and leaving lasting scars on entire communities. The Orlaco Collision Avoidance System (CAS) offers proven technology to eliminate these preventable tragedies.

Red Edge Resources is dedicated to protecting Australian workers through advanced safety solutions. The Orlaco CAS represents more than technology—it’s a commitment to ensuring every worker returns home safely at the end of their shift.

The Invisible Danger: Understanding Equipment Blind Spots

The Blind Spot Reality

Heavy equipment operators face an impossible challenge: operating massive machinery whilst maintaining complete awareness of their surroundings despite severe visibility limitations. The reality is stark:

Haul Trucks: Blind spots extend up to 15 metres in all directions, creating zones where multiple workers can be completely invisible to the operator.

Excavators: The rotating superstructure creates constantly shifting blind spots that can conceal workers who were visible moments earlier.

Dozers: The blade, elevated operator position, and machine bulk create extensive blind zones, particularly during reversing operations.

Loaders: Front and rear blind spots, combined with bucket operations, create multiple danger zones where workers disappear from operator view.

Graders: The long wheelbase and operator position create significant blind areas, particularly on the right side and rear of the machine.

These blind spots aren’t operator failures—they’re inherent design characteristics of heavy equipment. Even the most vigilant, experienced operator cannot see through solid steel or around massive machine components.

When Traditional Safety Measures Fall Short

Mirrors: Whilst helpful, mirrors have limited fields of view, require correct adjustment, and can’t eliminate blind spots. Dust, vibration, and lighting conditions further compromise mirror effectiveness.

Cameras: Standard camera systems provide valuable visibility enhancement but require operators to actively monitor multiple screens whilst performing primary tasks. In critical moments, operator attention may be focused elsewhere.

Spotters: Ground personnel guiding equipment provide important assistance but introduce additional workers into hazardous areas, create communication dependencies, and can’t be present for every equipment movement.

Exclusion Zones: Keeping workers away from operating equipment is ideal but often impractical in congested worksites where multiple tasks occur simultaneously in confined spaces.

High-Visibility Clothing: Bright clothing helps but doesn’t overcome blind spots, dust obscuration, or moments when operator attention is necessarily focused on the primary task.

The Orlaco CAS doesn’t replace these traditional measures—it provides the critical additional layer that transforms them from incomplete protection into comprehensive safety systems.

How Orlaco CAS Saves Lives: The Technology Behind the Protection

Active Hazard Detection

Unlike passive safety measures that rely on operator vigilance, the Orlaco Collision Avoidance System actively and continuously monitors the area surrounding heavy equipment. Advanced sensor technology creates an invisible protective shield that detects people, vehicles, and obstacles entering danger zones.

The system operates autonomously, never experiencing fatigue, distraction, or reduced awareness. Whilst operators focus on their primary tasks, the Orlaco CAS maintains constant vigilance, detecting hazards the operator cannot see.

Immediate Operator Alerts

The moment a hazard is detected, the Orlaco CAS triggers immediate multi-sensory alerts:

Visual Warnings: High-contrast displays show the exact location of detected hazards with colour-coded urgency indicators. Operators instantly understand where the danger exists and how close it is.

Audible Alarms: Distinctive warning tones cut through cab noise, immediately capturing operator attention even when focused on other tasks. Alarm urgency escalates as hazards move closer.

Directional Guidance: The system indicates which direction the hazard is located—front, rear, left side, right side—enabling rapid, appropriate operator response.

Distance Information: Real-time distance readouts show how far away the hazard is, helping operators judge whether they can proceed cautiously or must stop immediately.

These multi-layered alerts ensure operators receive critical safety information in the format most likely to trigger immediate, appropriate response.

Intelligent Discrimination

Advanced algorithms enable the Orlaco CAS to distinguish between genuine hazards requiring operator attention and stationary objects that don’t pose collision risks. This intelligent discrimination reduces false alarms that could lead to alert fatigue whilst maintaining maximum sensitivity to real dangers.

The system can differentiate between:

Moving personnel requiring immediate alerts
Stationary infrastructure that’s part of the normal environment
Other equipment operating nearby
Environmental factors like vegetation or weather conditions

This intelligence ensures operators receive relevant, actionable warnings rather than constant nuisance alerts that reduce system credibility.

Customised Protection Zones

Every worksite, machine type, and operational scenario presents unique safety requirements. The Orlaco CAS allows comprehensive customisation to match specific needs:

Variable Detection Distances: Zones can extend from 1 metre to 15+ metres depending on machine size, operational speed, and site conditions. Fast-moving haul trucks require extended detection zones, whilst excavators in confined spaces need precisely calibrated shorter zones.

Zone Shape Configuration: Detection zones can be shaped to match machine geometry and operational patterns. Rectangular zones for dozers, circular zones for excavators, and asymmetric zones for machines with specific blind spot patterns.

Directional Sensitivity: Different sensitivity levels can be set for different directions. Reversing operations might have maximum sensitivity, whilst front zones during forward travel might be calibrated differently.

Speed-Responsive Adjustment: Advanced systems can automatically adjust detection zones based on machine speed, extending protection when travelling fast and optimising for manoeuvrability when moving slowly.

This customisation ensures maximum protection without unnecessary operational restrictions or false alarms.

Life-Saving Scenarios: When Orlaco CAS Makes the Difference

Scenario 1: The Reversing Incident That Didn’t Happen

A haul truck operator completes loading and begins reversing to exit the loading area. A maintenance worker, who was visible when the operator started reversing, moves behind the truck to access equipment on the opposite side. The operator, focused on steering and avoiding other obstacles, doesn’t see the worker enter the blind zone.

Without Orlaco CAS: The truck continues reversing. The worker, assuming the operator has seen them, doesn’t move. The collision occurs at low speed but with catastrophic consequences due to the massive weight differential.

With Orlaco CAS: The moment the worker enters the rear detection zone, the system triggers immediate alerts. The operator stops instantly, preventing the collision. The worker never realises how close they came to tragedy. The operator, initially unaware of the worker’s presence, gains renewed appreciation for the technology protecting them both.

Scenario 2: The Dust Cloud Danger

An excavator operates in dry conditions, generating substantial dust that reduces visibility to a few metres. A supervisor walks toward the excavator to discuss the next work phase, approaching from the side where dust obscuration is worst.

Without Orlaco CAS: The operator, unable to see through the dust, continues operating. The supervisor, assuming they’re visible, continues approaching. The excavator’s swing brings the counterweight toward the supervisor’s position.

With Orlaco CAS: The system detects the supervisor through the dust cloud, triggering immediate alerts. The operator stops the swing, preventing the collision. Once the dust settles, the operator and supervisor can communicate safely.

Scenario 3: The Night Shift Near-Miss

During a night shift, a dozer operator works on a stockpile under artificial lighting that creates harsh shadows and glare. A worker exits a light vehicle and walks behind the dozer, entering a shadow zone where they’re invisible to the operator.

Without Orlaco CAS: The operator, needing to reverse to reposition, checks mirrors but cannot see the worker in the shadow. The reversing operation begins.

With Orlaco CAS: The system detects the worker regardless of lighting conditions, triggering immediate alerts. The operator stops, preventing what would have been a fatal collision.

Scenario 4: The Fatigue Factor

An experienced operator nears the end of a long shift. Despite their professionalism and safety commitment, fatigue affects reaction time and awareness. A worker moves between machines in a congested area, entering the blind spot at the exact moment the operator glances at an instrument display.

Without Orlaco CAS: The momentary distraction, combined with fatigue, means the operator doesn’t see the worker. The equipment begins moving.

With Orlaco CAS: The system maintains constant vigilance despite operator fatigue. The alerts trigger immediately, compensating for the momentary attention lapse and preventing the incident.

Scenario 5: The Communication Breakdown

A spotter guides a loader in a confined area using radio communication. Radio interference causes a critical message to be missed. The operator, believing they have clearance to proceed, begins reversing whilst a worker remains in the danger zone.

Without Orlaco CAS: The communication breakdown leads to the operator proceeding without realising a worker is present. The spotter, unable to get through on the radio, can only watch helplessly.

With Orlaco CAS: Despite the communication failure, the system detects the worker and alerts the operator. The technology provides backup protection when communication systems fail.

Protecting the Most Vulnerable: Ground Personnel Safety

The Ground Worker Perspective

Ground personnel working near heavy equipment experience constant awareness of the danger surrounding them. Despite following all safety protocols—maintaining awareness, wearing high-visibility clothing, and staying alert—they understand that their safety ultimately depends on operator awareness and equipment visibility.

The psychological burden of working in these conditions affects concentration, decision-making, and long-term wellbeing. Workers who’ve witnessed near-misses or been involved in close calls carry lasting anxiety about equipment operations.

Additional Protection Layer

The Orlaco CAS provides ground workers with an additional protective layer that doesn’t depend solely on their vigilance or visibility. Even when workers make mistakes—becoming distracted, entering danger zones inadvertently, or misjudging equipment movements—the system detects them and alerts operators.

This protection is particularly valuable for:

New Workers: Personnel unfamiliar with equipment blind spots and danger zones benefit from technology that compensates for their inexperience.

Contractors and Visitors: People who don’t work regularly on site may not fully understand equipment hazards. The collision avoidance system protects them despite their unfamiliarity.

Emergency Situations: When incidents occur and personnel rush to respond, normal safety protocols may be compromised. The Orlaco CAS maintains protection during these critical moments.

Routine Complacency: Even experienced workers can become complacent about familiar hazards. The system provides consistent protection regardless of worker attention levels.

Psychological Safety Benefits

Beyond physical protection, collision avoidance technology provides psychological safety benefits:

Reduced Anxiety: Workers experience less constant stress about potential equipment collisions, improving mental wellbeing and job satisfaction.

Increased Confidence: Knowing that equipment has collision avoidance systems allows workers to focus on their tasks rather than constant equipment monitoring.

Cultural Signal: The investment in advanced safety technology demonstrates organisational commitment to worker protection, building trust and morale.

Family Reassurance: Workers’ families gain peace of mind knowing their loved ones are protected by proven safety technology.

Operator Wellbeing: Protecting Those Behind the Controls

The Operator’s Burden

Equipment operators carry enormous responsibility for the safety of everyone around them. Despite their best efforts, training, and vigilance, they understand that visibility limitations create scenarios where incidents can occur through no fault of their own.

Operators involved in serious incidents, even when not at fault, experience:

Immediate Trauma: The shock and horror of being involved in a serious injury or fatality.

Ongoing Psychological Impact: Post-traumatic stress, anxiety, depression, and guilt that can persist for years.

Career Consequences: Many operators cannot return to equipment operation following serious incidents, losing their livelihood and professional identity.

Relationship Strain: The psychological impact affects families and personal relationships.

Legal Exposure: Operators may face legal consequences even when incidents result from inherent visibility limitations rather than negligence.

Technology as Protection

The Orlaco CAS protects operators by preventing incidents that would otherwise occur despite their best efforts:

Confidence Enhancement: Operators work with greater confidence knowing the system monitors their blind spots continuously.

Stress Reduction: The cognitive load of maintaining constant 360-degree awareness is reduced, allowing operators to focus on primary tasks.

Career Protection: By preventing incidents, the technology protects operators’ careers and professional reputations.

Mental Health Protection: Eliminating the trauma of being involved in serious incidents protects operators’ long-term mental health and wellbeing.

Supporting Professional Excellence

The Orlaco CAS doesn’t replace operator skill and vigilance—it enhances professional excellence by providing tools that enable operators to work safely despite inherent equipment limitations.

Operators using collision avoidance systems develop:

Enhanced Awareness: The technology reinforces awareness of blind spots and hazard patterns.

Better Habits: Regular system feedback encourages safe operational practices.

Professional Pride: Working with advanced safety technology enhances professional identity and pride in safety commitment.

Improved Skills: Understanding detection zones and system capabilities deepens operational knowledge.

All-Conditions Reliability: Protection When It’s Needed Most

Dust and Particulate Environments

Australian mining and construction sites frequently operate in dusty conditions that severely compromise visibility. Earthmoving, drilling, blasting, and vehicle movements generate dust clouds that can reduce visibility to metres or even less.

The Orlaco CAS sensors penetrate dust that defeats visual observation, maintaining reliable detection when operators most need assistance. This all-weather capability ensures consistent protection regardless of environmental conditions.

Darkness and Low Light

Night shift operations, underground mining, and early morning/late evening work occur in lighting conditions that compromise human vision. Shadows, glare from artificial lighting, and darkness create visibility challenges that traditional safety measures struggle to address.

The Orlaco CAS detection technology operates effectively regardless of lighting conditions, providing equivalent protection during night operations as during daylight hours.

Adverse Weather

Rain, fog, and extreme weather conditions create additional visibility challenges throughout the Australian climate spectrum. The system maintains reliable detection through weather conditions that would compromise camera systems or visual observation.

Challenging Terrain

Uneven ground, stockpiles, and varied terrain create situations where workers may be below operator sight lines or obscured by terrain features. The Orlaco CAS detection capability adapts to terrain variations, maintaining protection across diverse operational environments.

Integration with Safety Culture and Management Systems

Technology and Culture

The Orlaco CAS delivers maximum safety benefits when integrated into comprehensive safety cultures that value:

Proactive Protection: Moving beyond reactive incident response to proactive hazard elimination.

Technology Adoption: Embracing proven safety technology as essential rather than optional.

Continuous Improvement: Using near-miss data and system insights to continuously enhance safety practices.

Worker Involvement: Engaging workers in safety technology implementation and refinement.

Near-Miss Learning

The Orlaco CAS provides valuable data on near-miss events that would otherwise go unrecorded. Each system alert represents a potential incident that was prevented. Analysing this data reveals:

Hazard Patterns: Identifying specific locations, times, or operational scenarios with elevated collision risks.

Training Opportunities: Recognising situations where additional training or procedural changes could further reduce risks.

System Optimisation: Understanding how detection zones and sensitivity settings can be refined for maximum effectiveness.

Cultural Insights: Gauging overall safety awareness and identifying areas requiring cultural reinforcement.

Regulatory Compliance

Australian workplace health and safety regulations require employers to eliminate or minimise risks “so far as is reasonably practicable.” With collision avoidance technology proven effective and commercially available, regulatory expectations increasingly include such systems as essential risk controls.

Operations without collision avoidance technology face:

Increased Regulatory Scrutiny: Inspectors questioning why available safety technology hasn’t been implemented.

Post-Incident Liability: Following incidents, failure to implement available safety technology may constitute regulatory breaches.

Industry Standard Expectations: Major clients and contractors increasingly mandate collision avoidance systems as contract requirements.

Choosing Orlaco CAS with Red Edge Resources

Proven Technology

The Orlaco brand represents decades of experience in heavy equipment safety systems, with collision avoidance technology proven across thousands of installations worldwide. This isn’t experimental technology—it’s mature, reliable protection with extensive real-world validation.

Australian Expertise

Red Edge Resources brings deep understanding of Australian mining and construction environments, operational practices, and safety requirements. We ensure Orlaco CAS implementations are optimised for Australian conditions and regulatory frameworks.

Comprehensive Implementation

Our collision avoidance system implementation includes:

Site Assessment: Thorough evaluation of your specific hazards, equipment types, and operational patterns.

System Design: Custom configuration of detection zones, sensitivity settings, and alert parameters matched to your needs.

Professional Installation: Expert installation by certified technicians ensuring optimal sensor positioning and system integration.

Operator Training: Comprehensive training ensuring operators understand system capabilities and appropriate alert responses.

Maintenance Support: Ongoing technical support with 2-hour response times for emergency service calls.

Performance Monitoring: Assistance with near-miss data analysis and system optimisation.

Long-Term Partnership

Red Edge Resources doesn’t just install technology—we partner with clients for long-term safety improvement. Our ongoing support ensures your Orlaco CAS continues delivering maximum protection throughout its operational life.

The Moral Imperative: Every Worker Deserves Protection

Beyond regulatory requirements, financial considerations, or operational efficiency, implementing collision avoidance technology represents a fundamental moral obligation. Every worker deserves protection from preventable hazards. Every family deserves confidence that their loved ones are protected by the best available safety systems.

The technology exists.