McConnell Dowell Deploys VR to Strengthen Site Safety
McConnell Dowell is introducing virtual reality training to boost safety on its construction sites and raise awareness of risks when working around heavy plant.
Safety shapes company operations, from planning through daily worker and community engagement. Identified opportunities lead to operational changes.
Interactions between people and heavy machines are among the most complex construction tasks. Limited visibility, rapid decision-making, and the mental demands on operators are often misunderstood by nearby workers. Safe Work Australia data shows that plants are a top source of serious injuries and deaths.
The issue became urgent after two plant-related incidents led to an enforceable undertaking with WorkSafe Victoria. The company then reviewed how it communicated plant risks and challenges.
The review found many new entrants to the workforce, including graduate engineers and those new to heavy equipment. The company saw a need to boost awareness of machine blind spots and real operational limits.
Traditional training, such as classroom presentations, provided only a limited understanding of operators’ real challenges. These methods explained the concepts but could not convey the pressure of tracking moving machines on site.
Practical exercises let people sit in stationary equipment to see the operator’s view. But this method was logistically difficult, time-consuming, and hard to scale for large or frequent groups.
McConnell Dowell began seeking a solution to bridge the gap. Recognising the gap between theory and practical site safety, McConnell Dowell sought a solution to raise hazard awareness among its entire workforce. This led to the exploration of virtual reality platforms as a targeted training method.
The option of developing a custom platform, but early solutions did not meet requirements for realism, portability, or ease of deployment. The company subsequently selected Cat Simulators’ SimLite system.
The SimLite unit is a portable trainer with real Caterpillar controls and cab designs. It replicates blind spots and conditions to reflect real-world scenarios.
While Cat Simulators’ technology has traditionally been designed for operators, McConnell Dowell broadened its use to give all site personnel a clearer understanding of operator limitations and the critical importance of focused attention for site safety.
All risks identified on site, including personnel entering operating zones, are visible to the operator. By providing an immersive experience, the company intends to increase awareness of operational constraints and support safer decision-making across its projects.
