McConnell Dowell, a major player in the Australian construction industry, has taken a forward-thinking leap into virtual reality (VR) to improve safety awareness among its workforce, especially around heavy equipment on job sites. Recognising the persistent risks associated with plant machinery — including blind spots that contribute to serious injuries and fatalities — the company introduced an innovative VR Simulator Plant Awareness Program to bridge the gap between theoretical safety training and real-world experience.
The Challenges…
According to Greg Evangelakos, Health and Safety Manager at McConnell Dowell, the company recognised a critical deficiency in plant awareness among its broader workforce — not only among plant operators but also engineers, surveyors, quality teams and other personnel who work near heavy equipment. “We needed a different way… rather than standing in front of 200 people, showing them a photo and explaining where the blind spots are,” he explained, highlighting the limitations of conventional safety presentations.
The Solution…
At the core of McConnell Dowell’s new initiative are Cat® Simulators’ SimLite systems, specifically the SimLite Compact Track Loader and SimLite Excavator units, which integrate VR technology to create highly immersive, realistic simulation environments. Rather than relying on traditional classroom training and static diagrams, the program places participants in a virtual construction zone where they can experience, first-hand, how heavy machinery operates and where blind spots occur — all without the danger of actual site work.
How It Works?
The VR experience begins with participants being given an exercise sheet showing an aerial diagram of a machine with a surrounding circle, where they must mark what they believe the blind spots are. After an initial briefing, participants don a VR headset and control a virtual machine using the SimLite simulator for 10–15 minutes. Once they complete the exercise, participants are asked to revisit their blind spot diagrams and reflect on how their understanding changed after the simulated experience — with many recognising previously unnoticed hazards, such as nearby trucks or hidden obstacles.
What sets the program apart is its focus on experiential learning. By immersing learners directly into simulated plant operations, McConnell Dowell allows participants to witness the challenges and limitations that operators face — including restricted fields of view and the high concentration required to safely manoeuvre heavy machinery. Follow-up surveys have shown strong training outcomes, with high percentages of participants reporting increased awareness of blind spots, greater appreciation of the concentration needed for safe operation, and affirmation that VR was an effective learning tool.
Moving Forward…
The success of the VR Simulator Plant Awareness Program has encouraged McConnell Dowell to extend its reach beyond internal use. The company has begun offering the program, along with Cat Simulators’ SimLite systems, to other construction businesses across Australia for a two-year period, showing a commitment to elevating industry-wide safety standards. Part of the rollout includes partnering with technical education providers, such as Box Hill Institute TAFE, to integrate the VR experience into curricula so that apprentices and vocational students gain early exposure to plant awareness in a safe, controlled environment.
Lastly…
By combining cutting-edge VR technology with practical training goals, McConnell Dowell’s initiative offers a promising model for how immersive simulation can meaningfully advance workplace safety in high-risk industries.
If you would like to know more about this, you can read it here:
- “VR Plant Awareness Program – changing behaviour through living the experience” from McConnell Dowell.
- “McConnell Dowell Offers Heavy Equipment Safety Program to Construction Industry Featuring Cat Simulators” from Cat Simulators.
- “McConnell Dowell turns to virtual reality to raise plant awareness” from Inside Construction.
For more VR related news, you can read it at our VR News Compilation section.
About Author
