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Version 1.3 (21/03/2013)
Describe the main hazards and control measures associated with commonly encountered mobile work equipment;
Describe the main hazards and control measures associated with commonly encountered lifting equipment;
Describe the main hazards and control measures associated with commonly encountered access equipment and equipment for working at height.
Relevant Standards:
International Labour Standards, Guarding of Machinery Convention, C119, International Labour Organisation, Geneva, 1963.
Transposed Harmonized Standards British/European/International.
EN ISO 12100-:2010 Safety of machinery - General principles for design - Risk assessment and risk reduction.
ISO/TR14121-2:2010 Safety of machinery - Risk assessment. Practical guidance
and examples of methods.
Towed mobile work equipment includes work equipment such as towed machines and
trailers which are primarily self-supporting on, for example, their own wheels. They
may have moving parts which are:
1. powered by the vehicle (for example, a power harrow);
2. an integral power source (for example, a powered crop sprayer); or
3. they may have no moving parts and function as a result of the movement of the mobile work equipment (for example, a plough or trailer).
4. Remote-controlled mobile work equipment.
For the purposes of PUWER 98, remote-controlled mobile work equipment is operated by
controls which are not physically connected to it, for example radio control.
Turning at speed.
Operating with a soft tyre.
Uneven ground.
Turning on a slope.
Carrying load too high.
Load not centrally placed.
Articulation under load.
2) Longitudinal instability.
Where a vehicle tips over the front or the back. An example is when a tractor's front wheels lift
due to the weight applied by an attached trailer.
Longitudinal (fore and aft) stability FLT.
3) Loss of control.
Occurs when the wheels lose grip on a road surface, but does not require the vehicle to
overturn. Examples include skidding on an icy road.
Lift trucks are designed to manoeuvre loads from point 'A' to point 'B'; the mass of the
counter-weight is designed to prevent the truck from tipping. In certain circumstances, the
truck can be tipped forward due to being overloaded or the load being incorrectly positioned.
Correctly loaded FLT.
Figure 1.
FLT overloaded causing front end tipping.
Figure 2.
Incorrectly loaded FLT causing front
end tipping.
Figure 3.
The danger of the lift truck from overturning is greatly increased when the
load is carried at height or on an incline.
Figure 4.
Figure 5.
With the mast reached out, a reach truck
behaves like a counterbalance lift truck.
When laden with the mast reached in, because the load is then within the wheelbase, the reach truck is less likely to tip
forwards but its sideways stability is reduced. If the load is then elevated and the
mast tilted back, there is a risk of tipping
sideways or even backwards (though tipping backwards is likely to result in the
truck falling on its side). This risk is increased if the load is high and the wheel
base of the reach truck is short and on a
slope.
Figure 6.
Characteristics.
Failure.
This can destabilise a complete racking column, which could cause the column to collapse onto the lift truck.
Fire/explosion.
Hazardous substances.
Contact of the skin or eyes with battery acid can cause serious injury.
Petrol and liquefied petroleum gas (LPG) powered lift trucks are particularly hazardous and should not be used in confined spaces.
Exhaust fumes.
Noise.
Noise can be caused by poor silencing of the power unit. Manufacturers are required
to give information on the noise emission of their lift trucks. Exposure to noise can
lead to noise-induced hearing loss.
Vibration.
Caused by road surface, badly-inflated tyres and unsuitable seat adjustment can contribute to whole body vibration (WBV).
Manual handling.
Mechanical hazards.
Lifting chains and telescopic mast sections can cause traps. To ensure that a person
does not come into contact with any dangerous moving parts that are within the operator's normal reach in the normal operating position, guards should be provided to
prevent access.
is a difficult and potentially dangerous operation. It must be supervised by a competent person using recognised signals to guide both of the drivers. The load must be
evenly distributed between the trucks and properly secured.
Date
Details
Shift
A
Fork arms.
Carriage plate.
Back rest.
Mast.
Lift chain.
Hydraulics.
Wheels.
Tyres.
Lights/indicators.
All functioning.
Horn/beeper.
Clearly audible.
Mast Controls.
Hand/parking
brake.
Fuel/power.
Levels.
LPG.
Steering.
Operators Initials.
Hour reading when check done:
1.8 - Equipment.
Equipment (Safe Vehicle).
As lift trucks are both lifting equipment and work equipment, the Lifting Operations and Lifting
Equipment Regulations 1998 and the Provision and Use of Work Equipment Regulations
1998 apply.
Reference should be made to Part 3 Regulations 25-30 which applies to mobile work
equipment. Regulation 25 Employees carried on mobile work equipment, Regulation 26
Rolling over of mobile work equipment, Regulation 27 Overturning of Lift Trucks, Regulation
1.10 - Environment.
Environment (Safe Site).
Workplace traffic creates a significant and potential loss, both personal injury and damage to
assets. Of the many fatal accidents which occur each year involving the use of transport
within factory sites, the most common type involves victims being struck or run over by vehicles. Movement of vehicles now constitutes on of the largest single causes of deaths in factories.
You will remember from Element C1 that the condition of floors and traffic routes are dealt
with in Regulation 12 of the Workplace (Health, Safety and Welfare) Regulations 1992. Regulation 17 and its accompanying ACOP and guidance, address the requirements for the Organisation etc of these traffic routes.
Regulation 17 states that:
(1) Every workplace shall be organised in such a way that pedestrians and vehicles can circulate in a safe manner.
(2) Traffic routes in a workplace shall be suitable for the persons or vehicles using them, sufficient in number, in suitable positions and of sufficient size.
(3) Without prejudice to the generality of paragraph (2), traffic routes shall not satisfy the requirements of that paragraph unless suitable measures are taken to ensure that:
pedestrians or, as the case may be, vehicles may use a traffic route without causing
danger to the health or safety of persons at work near it;
there is sufficient separation of any traffic route for vehicles from doors or gates or
from traffic routes for pedestrians which lead onto it; and
where vehicles and pedestrians use the same traffic route, there is sufficient separation between them.
(4) All traffic routes shall be suitably indicated where necessary for reasons of health and
safety.
(5) Paragraph (2) shall apply so far as is reasonably practicable, to a workplace which is not a
new workplace, a modification, an extension or a conversion.
Protection of Personnel.
The ACOP to regulation 17 of the Workplace (Health, Safety and Welfare) Regulations 1992
states that consideration should be given to people with impaired or no sight, and those in
wheelchairs. Traffic routes for those in wheelchairs should be wide enough to allow unimpeded access, and ramps should be provided.
Any traffic route which is used by both pedestrians and vehicles should be wide enough to
enable any vehicle likely to use the route to pass pedestrians safely. On traffic routes in existence before 1 January 1993, where it is not practical to make the route wide enough, passing places or traffic management systems should be provided as necessary. Pedestrians
should be segregated, where possible, from vehicle routes by a physical barrier or routes
clearly marked. In buildings, lines should be drawn on the floor to indicate routes followed by
vehicles such as fork lift trucks.
Where an enclosed pedestrian route, or a doorway or staircase, joins a vehicle route, there
should be an open space of at least one metre from which pedestrians can see along the vehicle route in both directions (or in the case of a one-way route, in the direction of oncoming
traffic.) Similar measures should be taken where the speed or volume of vehicles would put
pedestrians at risk. In areas where traffic is particularly heavy, bridges or subways may be
appropriate.
Audible warning devices and flashing beacons can provide warnings to pedestrians; however,
the effectiveness of audible devices is dependent on the overall noise level in the operating
area, and flashing beacons could trigger epilepsy in some people. The use of such warning
devices should be based on risk assessments.
High-visibility clothing such as arm bands, tabards and jackets should be worn where other
methods cannot control the risk. Where there is a risk of falling objects, head protection
should be worn.
Loading Bays.
Loading bays should be provided with at least one exit point from the lower level. Wide loading bays should be provided with at least two exit points, one at each end. Alternatively, a
refuge should be provided which can be used to avoid being struck or crushed by a vehicle.
Road markings and Signs.
Surface markings on roads play an important part in regulating vehicle movements. White
lines should be used to divide access roads into lanes, to indicate priorities at junctions and to
delineate boundaries of parking stalls and loading bays.
Signs should also be used to alert drivers to any restrictions which apply to the safe use of a
traffic route. Adequate directions should also be provided to relevant parts of a workplace.
Buildings, departments, entrances, etc should be clearly marked, where necessary, so that
unplanned manoeuvres are avoided.
The Health and Safety (Safety Signs and Signals) Regulations 1996 Regulation 4 (6) (as
covered in Unit C1), requires the use of road traffic signs within workplaces when regulating
traffic, as they are more likely to be understood. Any signs used in connection with traffic
should comply with the Traffic Signs Regulations and General Directions 1981 (SI 1981 No
859) and the Highway Code for use on the public highway.
Where traffic route hazards, such as sharp bends, blind corners, junctions, crossings, steep
gradients, limited headroom or road works are unavoidable, suitable warning signs and mirrors can reduce the risk. Obstacles such as loading bay edges, low bridges and pipe-bridges
should also be clearly signed and marked.
Speed limits.
These should be set and clearly-displayed on vehicle routes. Suitable speed retarders (road
humps) should be provided, preceded by a warning sign.
Lighting.
You will remember from your studies of unit C1, the requirement for lighting in Regulation 8 of
the Workplace (Health, Safety and Welfare) Regulations 1992. Adequate lighting is necessary particularly at road junctions, rail crossings, near buildings and plant, in pedestrian areas
and where there is regular movement of vehicles and other mobile plant. Lighting columns
close to the edge of roads can cause difficulties, particularly on narrow two-way roads. If columns cannot be set back, wall-mounted lights should be considered.
1.12 - Reversing.
Reversing.
Where large vehicles have to reverse, measures for reducing risks to pedestrians and any
people in wheelchairs should be considered, such as:
1.
2.
3.
4.
Integrated working platform - an attachment fitted with controls for the operation of the
truck, its movements, and the lift height which are controlled by the person on the platform.
Non -integrated working platform - an attachment that has no controls in the platform
that allow a person in the platform to control the lift height of the platform or move the
truck. All movements are controlled by the truck operator.
Platforms are used to provide temporary places of work or to lift passengers from one level to
another. The selection and use of work equipment for working at height should be dependent
on the task, in accordance with Regulation 7(2)(b)The Work at Height Regulations 2005.
Falling object protective structures (FOPS)
If people carried on the mobile work equipment are at significant risk of injury from objects
falling on them while it is in use, a FOPS should be provided. This may be achieved by a
suitably strong safety cab or protective cage which provides adequate protection in the
working environment in which the mobile equipment is used.
Maintenance.
The platform shall be used and maintained in good working order and repair, and in
accordance with the instructions provided by the working platform manufacturer.
Precautions.
Where lift trucks are used as working platforms, the following precautions are necessary:
The platform should be made of suitable material, soundly constructed, of adequate strength
and properly maintained. It should be securely attached to the lift truck.
The weight of the platform plus its load must not exceed one half the actual capacity of the
truck. The platform should be marked with means of identification and the maximum
allowable load.
The dimensions of the platform should be as small as possible, compatible with the number
of people it is designed to carry. No more than two passengers should be carried.
All platform edges shall be guarded by: a top rail, the upper surface being between 1000mm
and 1100mm from the platform floor; a toe-board, having a minimum height of 150mm; and at
least one intermediate rail, equally spaced between the top of the toe board and the
underside of the top rail. Other equally effective means of guarding between the top rail and
floor, such as infilling with robust wire mesh, panelling and/or safety glazing may be used.
Any gateway in the enclosure should automatically return to the closed and fastened position.
Any gate provided shall open inwards, upwards or sideways and return automatically to the
closed position. It is strongly recommended that a device is provided that locks the gate
automatically and ensures it cannot be opened once the platform is raised. If such a device is
not fitted then the gate shall be self-locking in the closed position.
The floor of the platform should be even and non-slip.
All trapping, crushing and shearing points must be guarded. Where overhead hazards, such
as roof trusses, exist, protection is necessary to prevent potential crushing injuries to
passengers. Suitable handholds within the confines of the working platform and safety
harness anchorages should be provided.
The platform should be painted a conspicuous colour and display a notice, visible to the truck
driver, which states that the parking brake should be on and the transmission in neutral
before the platform is elevated.
Before a truck is used for the first time as a working platform, the manufacturer or supplier
should be requested to confirm whether the truck is suitable for such use.
It is preferable that the raising and lowering of the platform is controlled by the person on the
platform. The controls should be of the "dead man's handle" type. Emergency control may be
appropriate at ground level.
Warning cones, barriers, lights or signs should be located around the truck to segregate working at height from normal work activities.
Pre-use checks shall be carried out by an authorised person to ensure that the working platform is properly located and secured to the truck each time and before it is
used .
People should not lean out of the truck or stand on guardrails.
All people involved in the operation must be trained on safe systems and work and
emergency procedures. When using hand signals, an agreed system should be used
and all involved trained in its proper use. An example of commonly-used hand signals
is given in BS 7121 part 1.
Trucks should only be used on firm, level surfaces.
Where controls are at ground level, the driver must stay in attendance for the duration
of the operation.
Parking brake should be applied and the whenever the working platform is elevated.
Transmission placed in neutral where possible, before the platform is elevated.
If people have to lean out of the platform when working at height, then lanyards and
harnesses should be supplied.
Provision of communications devices, for noisy environments and for working at a
height of more than four metres.
Special precautions may be necessary to ensure that personnel in the platform are
not endangered by hazards such as live electrical conductors, overhead travelling
cranes, etc.
When using hand-held communication devices, account shall be taken of any foreseeable hazards due to electromagnetic compatibility.
mounted.
Clamps:
These are made in a variety of shapes and sizes purpose designed to lift reels, bales, carton,
boxes, drums etc. They are usually mounted on the fork carriage and may incorporate a
rotator. Some clamps for reels or drums may also have the facility to tilt the load forward from
the vertical to the horizontal and beyond (sometimes known as 'tipplers'). The load is held by
the pressure on the clamp which is provided by hydraulic cylinders.
Lifting hooks:
These usually consist of a small beam mounted on the forks of a truck bridging the space
between the forks with a lifting hook suspended from the centre of the beam. The capacity of
the fork lift truck and attachment combination will depend on the position of the hook
attachment on the forks. Moving it near to the end of the forks beyond the rated load centre
will significantly decrease the capacity. The self-weight of the hook attachment should be
included as part of the load.
Push-pull units:
These are generally used in palletless load handling systems, where the load is assembled
on a slip sheet instead of a pallet. A slip sheet of cardboard or plastic fibre board is used to
enable the sliding of the load. The unit is generally mounted on the fork carriage, but fork
mounted models are available. The unit has very wide platens in place of forks to provide
adequate support under the load.
Crane jib:
These may be mounted directly onto the fork carriage or carried on the forks. They may be
fixed length or they may be extending jibs with several lifting points. Moving the hook toward
the outer end of the jib increases the load moment and can significantly reduce the capacity
of the truck and attachment combination. The self-weight of the attachment will further reduce
the capacity and should be taken into account.
Self dumping hoppers:
Usually carried on the forks of a fork lift truck, the hoppers have a release mechanism which,
when operated, causes the hopper to roll forward to discharge it contents. The hopper then
rolls backward into its normal position, where it is held by a latch. At the end of the forward
roll, the hopper stops sharply. This applies to forward force to the mast of the fork lift truck
particularly if the load is difficult to discharge. If the hopper discharges into a bin or skip, the
force can be applied high up the mast and can cause the fork lift truck to tip forward. Damage
to the hopper or uneven distribution of its contents may make the hopper reluctant to roll
when released.
Booms:
A circular section of various diameters and length, usually mounted on the fork carriage.
Booms are designed for lifting carpets, coils of wire, steel strip and similar cylindrical loads.
Serious overloading of a fork lift truck fitted with a boom attachment can occur if an operator
uses the end of the boom to reposition a load prior to lifting it.
Removable attachments should be marked with the identity of the lift truck for which they are
suitable
Lifting chains are subject to a statutory examination under the Lifting Operations and
Lifting Equipment Regulations (LOLER) 1998.
Section 2 (2)(c) of the Health and Safety at Work etc. Act 1974;
Regulation 13 of the Management of Health and Safety at Work Regulations 1999;
Regulation 9 of The Provision and Use of Work Equipment Regulations 1998;
The Approved code of Practice (ACOP) 26, Rider Operated Lift Trucks - Operator
Training.
This section will look at the requirements of the Provision and Use of Work Equipment
Regulations 1999 and the Approved Code of Practice, (ACOP) 26 Rider-Operated Lift Trucks.
The Provision and Use of Work Equipment Regulations 1998.
Regulation 9, Training, states that:
1. Every employer shall ensure that all persons who use work equipment have received
adequate training for purposes of health and safety, including training in the methods
which may be adopted when using the work equipment, any risk which such use may
entail and precautions to be taken.
2. Every employer shall ensure that any of his employees who supervises or manages
the use of work equipment has received adequate training for purposes of health and
safety, including training in the methods which may be adopted when using the work
equipment, any risks which such use may entail and precautions to be taken.
Regulation 9 - Approved Code of Practice.
You should ensure that self-propelled work equipment, including any attachments or towed
equipment, is only driven by workers who have received appropriate training in the safe
driving of such work equipment.
Guidance to these regulations states the need to evaluate employee's competencies in the
operation of lift trucks (work equipment), and make up the shortfall between competence and
that which is required to carry out the work. It also recognises that training needs are likely to
be the greatest on recruitment, but that other changes in working tasks, systems of work, the
introduction of new technology or in situations where an employee is expected to 'step in' and
deputise would necessitate the need for refresher training. For management and supervisors
to recognise safe and unsafe practices, and the risks involved in the operation of lift trucks, it
would also be advisable for them to receive some basic training in the safe operation of lift
trucks.
The Approved code of Practice (ACOP) 26, Rider-Operated Lift Trucks - Operator
Training.
This document is directed at the basic training of all employees whose employment after 1
April 1989 includes for the first time the operation of rider-operated lift trucks of the four most
commonly used (including reach and counterbalanced lift trucks). Employers must ensure
that all operators they employ, both new and existing, are adequately trained and competent.
Failure to comply with the code is not an offence, but may be taken as proof that Section 2 of
the Health and Safety at Work etc. Act 1974 has been contravened.
No person should be permitted to operate a lift truck unless properly trained, competent and
authorised in writing by the employer to do so. This authorisation should only be given for the
type or types of truck for which training has been successfully completed. The employer
alone will determine how long this authority remains valid, but as you have already learnt
from Unit A: Element A10 (Measuring Health and Safety Performance), it is good practice to
ensure that the performance of all operators is formally monitored. Co-operation between
employers and site controllers would ensure that only adequately-trained and authorised
people operate lift trucks.
Note: There is no such thing as a lift truck driver's licence, as there is no central lift truck
licensing authority. Anyone wishing to use a lift truck on a public highway should contact The
Drivers and Vehicles Licensing Agency (DVLA) for information on restrictions.
Selection.
Those selected should be:
1.
2.
3.
4.
5.
6.
reliable;
able to do the job;
responsible in their attitude;
physically capable;
have good eyesight and hearing;
over 17 years old.
1. CITB;
2. Lantra;
3. The Independent Training Standards Scheme and Register (ITSSAR), operated by
AITT;
4. National Plant Operators Registration Scheme;
5. RTITB;
To gain accreditation, ATPs must use qualified and experienced instructors only, they must
follow course syllabuses approved by the accrediting body and be subjected to regular
monitoring visits. The training must also be carried out in suitable premises. Generally
speaking, training courses last on average of five days, influenced by the instructor:trainee
ratio, and the type of training required e.g. basic or refresher training. Use the link to access
more information on accreditation.
http://www.hse.gov.uk/workplacetransport/factsheets/hscrecognition.htm
Training.
The operator should receive training on each type of equipment that s/he will be expected to
operate. The training should consist of three stages, basic, specific job training and
familiarisation training:
1. Basic training.
This includes the basic skills and knowledge required for safe operation of the type of fork lift
truck and attachments, an understanding of the basic mechanics of the truck, and the need to
carry out routine daily checks. This should be off-the -job training, which means that it is
conducted at the premises of the training organisation, or at the employer's own premises (inhouse). If training is conducted on the employer's premises, the area must be large enough to
allow for manoeuvring, and suitably closed off from other employees and work activities.
2. Specific Job Training.
This type of training should cover knowledge of the workplace, any special requirements of
the work to be undertaken and the use of specific attachments. Again it should be training offthe-job and is often combined or integrated with basic training.
This should include training and practice in the controls of the lift truck to be used; loading
and unloading, stacking and de-stacking, routine inspections of the truck, which should be
carried out by the operator; use of the truck in various locations such as gangways, loading
bays, slopes and in rough terrain and problems of working in poor weather conditions. Site
rules such as one-way systems, speed limits, work near overhead lines, excavations; work to
be undertaken such as loading particular vehicles and using working platforms on forks.
3. Familiarisation Training.
Familiarisation training is conducted on-the-job and under close competent supervision.
Familiarisation training should be company and site specific, covering company safety rules,
site layout, personal protective equipment requirements and emergency procedures.
Previously Trained Operators.
Where an operator possesses previous experience and/or training, the evidence should be
examined before the operator undertakes any driving tasks. It is necessary to assess whether
previous experience and training are suitable and sufficient to enable the operator to safely
use the type of lift trucks and attachments in the new work environment. Previous training
certificates could be examined and where they are not available, the operator should undergo
an assessment whilst actually driving the new lift truck.
Certification.
There is no legal requirement for the issue of certificates by training providers. However, the
HSE encourage the issue of certificates for employers to provide evidence that training has
been given. Certificates should always provide sufficient information to enable a trace to be
made back to the course content. This may include details of any limitations (e.g. lifting
height), the name of the accrediting body and the name and registration number of the
instructor. On completion of the training, it is usual for the operator to be issued with a
certificate or copy as evidence of training, which can be used in the event of a change in
employment. An operator's training records can then be updated by the employer.
Summary.
To reduce the number of accidents involving fork lift trucks, safe systems of work including
procedures for training, traffic and pedestrian control, maintenance of trucks and suitable
working environment, should be adopted.
(2) Where there is a risk of anyone being carried by mobile work equipment being crushed by
its rolling over, the employer shall ensure that it has a suitable restraining system for him.
(3) This regulation shall not apply to a fork-lift truck having a structure described in subparagraph (b) or (c) of paragraph (1).
(4) Compliance with this regulation is not required where;
ures necessary to protect employees carried on mobile work equipment where there are risks
from roll-over while it is travelling, for example a moving dumper truck on a construction site
or an agricultural tractor forwarding or manoeuvring on a slope.
It covers roll-over in which the mobile work equipment may only roll over onto its side or end
(ie through 90 degrees) or turn over completely (ie through 180 degrees or more).
It does not apply to the risk of mobile work equipment, such as an excavator or a vehicle with
a winch, overturning when operating in a stationary position. This is covered by regulation 20.
Risk assessment.
To assess the likelihood and potential consequences of roll-over, you will need to take into
account the following to determine what safety measures are needed:
1. nature of the mobile work equipment and any attachments or accessories fitted to it;
2. the effects of any work being carried out on or by the mobile work equipment; and
3. the conditions in which it is used.
When mobile work equipment is travelling, roll-over may be encouraged by uneven surfaces,
variable or slippery ground conditions, excessive gradients, inappropriate speeds, incorrect
tyre pressures and sudden changes in direction.
It can also occur due to the inertia transmitted to the mobile work equipment by attachments
used with it, particularly if those attachments are not securely restrained from movement.
When mobile work equipment is under power but is restrained from movement, for example
when a forestry tractor is being used to drag fallen trees or logs from one place to another
and the tree or log snags, you will need to take account of the inherent stability of the mobile
work equipment and the forces it can apply.
When carrying out a risk assessment it is important to remember that although drivers should
be trained to minimise the risk of roll-over, this is not a substitute for hardware measures to
prevent roll-over (for example counterbalance weights) or protective structures (for example
roll-over protective structures (ROPS) to minimise the risk of injury in the event of a roll-over)
WHERE THEY ARE NECESSARY.
Stabilisation.
Measures that can be taken to stabilise mobile work equipment (ie measures to reduce the
risk of roll-over) include fitting appropriate counterbalance weights or increasing its track
width by fitting additional or wider wheels. Also, moveable parts which could otherwise create
instability by moving around when the mobile work equipment is travelling, may be locked or
lashed in stable positions, particularly where locking features are provided for such purposes,
for example locking devices for excavator back hoes.
Structures which prevent rolling over by more than 90 degrees.
Some types of mobile work equipment will only turn onto their sides if roll-over occurs (ie 90
degree roll-over). For example, the boom of a hydraulic excavator, when positioned in its
recommended travelling position, can prevent more than 90 degree roll-over.
Regulation 26(1)(b).
If parts of the mobile work equipment prevent it rolling over by more than 90 degrees, the
requirements of regulation 26(1) will be met.
Roll-over protective structures (ROPS).
You should fit suitable roll-over protective structures to mobile work equipment where
necessary to minimise the risks to workers carried, should roll-over occur.
Regulation 26(1)(c).
ROPS are normally fitted on mobile work equipment which is at risk from 180 degree or more
roll-over. They may be structures, frames or cabs which, in the event of roll-over, prevent the
work equipment from crushing the people carried by it. ROPS should be capable of
withstanding the forces that they would sustain if the mobile work equipment were to roll over
through 180 degrees or more.
Limitations on fitting protective structures.
A protective structure may not be appropriate where it could increase the overall risk of injury
to people operating, driving or riding on mobile work equipment. In these circumstances,
where possible, the risks of roll-over should be addressed by other means. An example of
where protective structures are not appropriate is when mobile work equipment is required to
enter and leave buildings with low roofs and contact could increase the risks to workers.
In workplaces such as orchards or a glasshouse, it may not be reasonably practicable to
operate mobile work equipment fitted with a ROP.
Regulation 26(4)(c).
Before fitting ROPS to older mobile work equipment, which has no anchorage points provided
on it (in use before 5 December 1998), an engineering analysis would be necessary. The
analysis would need to assess whether it is reasonably practicable to fit adequate anchorage
points to the equipment and the structural integrity of any anchorage provided. Some mobile
work equipment may not be capable of being fitted with protective structures because
mounting points of sufficient strength cannot be provided. This will be true of some equipment
in use before 5 December 1998. If the risks associated with the use of the equipment are
sufficiently high and it is not reasonably practicable to fit mounting points to allow the fitting of
a protective structure, you may need to use other equipment which has, or can have, a
protective structure fitted to it.
Restraining systems.
You should provide restraining systems on mobile work equipment, where appropriate, if they
can be fitted to the equipment, to prevent workers carried from being crushed between any
part of the work equipment and the ground, should roll-over occur.
Regulation 26(2).
Where the operator is at risk of falling out and being crushed by the mobile work equipment
or its protective structure in the event of roll-over, you should provide a restraining system (for
example, a seat belt) if it can be fitted. This restraining system may also be necessary under
the more general requirements of regulation 25 to protect against other risks.
If the operator is in a fully enclosed protective structure and unable to fall out of the mobile
work equipment, they will not be at risk of being crushed between the mobile work equipment
and the ground. However, if the operator or people carried are likely to be injured through
contact with the inside of the structure during roll-over, a restraining system may be
necessary.
Mounting points for restraining systems.
Any restraining system needs to be fitted to appropriate anchorage points on the mobile work
equipment to ensure its integrity and reliability in use. Substantial structural modification may
need to made on some older types of work equipment in use before 5 December 1998 to
allow a restraining system to be fitted. Under these circumstances it would only be
considered reasonably practicable to fit a restraining system if the risks involved were of a
sufficiently high order to justify the necessary modifications. Alternatively, you may need to
use other work equipment which has or can have a restraining system fitted to it.
Tractors.
If a tractor is fitted with a ROP rather than a cab, a restraining system will be needed.
Despite compliance with the Agriculture (Tractor Cabs) Regulations 1974, if the operator or
people carried are likely to be injured through contact with the inside of the structure during
roll-over, it is likely that you will need to provide a seat restraining system.
Overturning accidents are not confined to steep slopes. Fifty per cent of investigated
overturning accidents occurred on slopes of 10 or less and half of these on slopes of 5 or
less.
Fitting seat restraints.
Employers should fit seat restraints if the machine is used for operations where there is a risk
of overturning in which the driver could be crushed between the machine and the ground.
Where a seat already has mounting points for a seat restraint, then fitting a lap strap or seat
belt costs very little.
HSE considers such risks are foreseeable in the following situations, based on accident
history.
Seat restraints could reduce the likelihood of injury when:
using a machine fitted with a roll bar or cab with no door where a 90 overturn is possible, e.g. on rough or sloping ground, or with attachments and/or conditions which
could contribute to an overturn;
using a cabbed tractor on sloping ground with attachments and/or conditions which
could result in loss of control and overturning, e.g. loaded trailers, lime or fertiliser
spreading, extracting timber in forestry etc;
using a cabbed tractor for rolling silage clamps or mowing steep ditch sides;
using a self-propelled machine designed to be used on steep terrain, e.g. forestry machines and all-terrain vehicles (except for ATV quad bikes);
using a rough terrain forklift truck on slopes or rough ground or using a counterbalanced forklift truck with a mast or r oll bar/cage on uneven ground.
Most tractor seats have provision for fitting lap straps although these are not always obvious.
Check with the manufacturer to ascertain the correct mounting points and follow fitting
instructions.
Situations where seat restraints are not so likely to be required or where seat
restraints are inappropriate are:
Where existing seats have no mounting points for seat restraints, the only alternative may be
to replace the seat. This may not need doing if you can show that the technical difficulties of
fitting a new seat, of ensuring its mounting points are strong enough and the extra costs
involved outweigh the risk of having no seat restraint, ie the risk of an overturn in the
In each case these requirements could be applied to a failure to wear seat restraints where
there was a foreseeable risk of injury from not wearing them.
sible to the driver. Self-propelled mobile work equipment which will not stop in a safe distance, for example through transmission drag, if service brake failure or faults occur, are
normally fitted with secondary braking systems.
The selection of these devices for use on mobile work equipment is a matter for risk
assessment, taking account of the purposes for which the devices are provided and their
ability to improve driver visibility.
Regulation 28(f).
Equipping mobile work equipment with lighting for use in the dark.
In terms of this regulation, 'dark' means any situation where the light levels are not good
enough for the driver to operate the self-propelled work equipment safely without risks to
themselves or other people in the vicinity.
Safe stop:
You need to take extra precautions when safe stop is not possible, for example when using
slurry tankers or external controls.
Key points:
Never use a machine unless you are trained and know how to use it safely.
Never use a machine unless it is properly maintained.
Keep away from moving machinery - remember that some machine components will
continue to rotate or move even after the engine has stopped.
Wear footwear with a good grip - safety boots are best.
Wear clothes which will not snag on machinery - preferably overalls.
Keep long hair tied back.
Remove any jewellery which might snag - don't forget watches and rings.
Find and read the operator's manual - keep it handy.
Always use access steps and handholds. Don't jump from the cab.
Use the nearside cab door whenever you can.
Keep floors, doors, pedals and your boots clean and mud-free.
Do not keep tools, drawbar pins or top links on the cab floor.
Before leaving the seat follow safe stop.
Get out facing inwards so that you have a good grip.
Never get on or off a moving tractor.
Seat belts:
Seat belts are a legal requirement on all tractors where there is a risk of overturning
and it is reasonably practicable to fit one.
A seat belt will prevent you being thrown out of the cab in an overturn or road accident, where you are most likely to be killed or injured.
Wear a seat belt when driving on slopes, silage clamps, working on ditch sides and
when on public roads.
Controls:
Look in the operator's manual to find out what each control does.
Make sure you know how the controls are operated.
Never use any control unless you are correctly seated in the cab.
Know where the controls should be before you start the tractor.
Don't forget that different tractors have different controls.
Never use a machine that you have not been taught how to use.
External controls:
Look in the operator's manual to find out where to stand when using external controls.
Only use external controls to hitch equipment in accordance with the operator's manual.
Do not place any part of your body in between the tractor and any mounted implement
when operating these controls.
Never drive a tractor or other machinery unless you have been trained to do so.
Make sure you understand the controls before you operate the tractor.
Before moving off, always check whether independent brakes are locked together.
They should always be locked together for road and transport use.
Make sure no one else is near before you start the engine.
Check that no one is in danger before you move.
Check that the brakes and steering operate correctly.
Make sure you know what each control does.
Don't drive tractors unless they are properly maintained and safe. Fix or report defects
as soon as possible.
Take your time and never rush when operating tractors.
Watch out for obstacles and blind spots.
Take care with projections such as bale spikes. Remove them or carry them in a safe
position both on and off the road.
Comply with warning signs.
Remember, other people and children may be around, even if you're not expecting
them.
Equipment, loads, bad weather or bright sunshine make it harder to see, so take care.
Get help if visibility is reduced, especially when reversing.
When reversing, use mirrors and horns and any other reversing aids fitted to the tractor.
Remember that confined or dark buildings and small farmyards make spotting and
avoiding dangers difficult.
Agree safe routes for other tractors and machines to avoid accidents.
Watch for rear-end swing when travelling with long implements such as ploughs.
Never allow them to ride on a tractor - remember it is illegal to have a child under 13
years old as a passenger.
Keep them away from working tractors.
Always use safe stop.
Always be aware of places where children may be.
If you see any children, stop work and make sure they move to a safe place.
Follow safe stop whenever possible - it makes sure nothing will move.
Take extra care when using a PTO-driven machine, e.g. a slurry tanker, in a stationary
position.
Ensure guards are in place - check they are properly chained, lubricated and free from
defects.
Report any faults immediately.
Do not use a machine with a damaged PTO shaft guard.
Ensure the tractor is chocked or that there is a mechanical connection between the
tractor and a stationary PTO-driven machine to ensure the tractor or machine does
not move, causing the PTO shaft to separate.
Trailers:
Using tractors and trailers without an adequate braking system has led to loss of control, jackknifing and tractor-overturning incidents.
Tractors and trailers used on or off the road need to stop safely within a reasonable
distance under all conditions.
Inadequate trailer brakes can lead to accidents when manoeuvring on slopes or slippery surfaces, as the tractor may be pushed sideways and slide out of control.
If trailer brakes are inadequate (ie are not doing their share of the braking) the tractor
braking system can be subjected to excessive wear.
Safe towing requires the use of a large enough tractor and selecting the most suitable
gear to stop the combination within a safe distance.
Make sure you buy trailers that have a suitable braking system to match your tractor
and ask the supplier for brake efficiency information.
Failsafe trailer braking provides emergency brakes if the tractor stalls.
Properly maintain and adjust braking systems for tractor-trailer combinations to ensure efficiency and safety. Testing on the move may be necessary after maintenance.
Keep hydraulic brake couplings clean and avoid contamination.
Make sure linkages are properly lubricated and operate freely and keep them maintained.
After use clean mud and contamination from brakes (including parking brakes). Make
sure the cleaning method does not lead to deterioration of the brakes (e.g. rusting
caused by pressure washing).
Tractors which are not fitted with a self-balancing braking system require more frequent checks to ensure the brakes are evenly balanced.
Follow the manufacturer's recommendations for frequency and detail of inspection.
Some older brake linings may contain asbestos. Take appropriate precautions to
avoid breathing dust and when disposing of waste material.
Other machinery:
Check the machine is properly guarded and the guards have no defects.
Check the machine for defects.
Check the brakes are connected.
Make sure you are trained and competent to use the machine.
Always use safe stop.
Don't use the machine unless it is properly maintained.
Always lower machines to a safe position before leaving the seat.
Contact with any overhead power line can kill, so plan to avoid work near them if possible.
Be aware of minimum line heights and get them checked by your distribution network
operator if you have doubts about their height.
Find out ways of reducing the risk of contact with overhead power lines (see INDG389
Shock horror).
Check that lines are marked on the farm map and pass on this information to contractors and other visitors that need to know where the lines are.
Be aware of the height and reach of machinery you buy and operate.
Use alternative access points and routes to avoid the lines.
Look out for warning signs, barriers, posts and warning tapes.
Always use safe tipping areas.
Always plan work in advance so that the work methods are safe at all stages.
Drive slowly where the ground surface is not easily seen, e.g. in long grass, bracken
etc.
Ensure you use a large enough tractor for the machine or trailer you are using, taking
account of the weight of the machine, trailer and any load.
Always descend straight down the gentlest possible gradient of a slope, rather than
driving diagonally across it.
Avoid working across slopes if your tractor has large diameter, tubeless, low-groundpressure tyres.
Avoid turning down a slope - this is especially hazardous.
Plan work across slopes so that turns are made uphill rather than downhill.
Use the widest practicable wheel track setting to reduce the likelihood of the tractor
overturning.
Rearward overturns:
A tractor with its rear wheels turning at only 2 mph will be vertical in 1 second if the object it is
pulling resists movement. An inexperienced driver may need as much as 1.5 seconds to
decide on and carry out remedial action.
Vertical jackknifing of tractor and trailer combination:
Ensure trailers are not overloaded and the load is evenly distributed.
When tipping take care to ensure the load slides freely from the trailer.
Adding rear ballast (e.g. wheel weights or water ballast) will increase the stability of
the tractor.
Pick-up hitch hooks and trailer eyes should be free from wear that may resulting unhitching, especially when tipping.
If the tractor becomes bogged down, try to reverse out. If this fails you will need help.
Never chain the wheels or jam them with blocks of wood. They may be forced into the
ground and the tractor may overturn rearwards.
To avoid overturning the tractor during winching, always see that it is set straight in
line with the pull
Clutch use:
Select the correct gear at the beginning of the slope, so there is no need to change
gear on the slope.
Engage four-wheel drive (if available) before working on slopes.
Suddenly engaging the clutch can cause a rearward overturn.
Let the clutch in slowly and avoid snatching. This is particularly important when driving
up slopes.
Keep the pedals, footwear and tractor floor/footplates as dry and free from mud as
possible.
Be aware that electrohydraulically operated clutches may engage more suddenly than
mechanically operated clutches.
Parking:
Before dismounting, stop the tractor engine and apply the parking brake fully.
Do not park with a heavy load on a steep slope.
Remember parking brakes may have a lower capability than service brakes, and
some transmission systems provide no engine braking when the engine is stopped.
Try to park on level ground, especially when loading and unloading.
Ensure the sides of the clamp are properly supported and fitted with sight lines.
Keep away from the edges and ensure the clamp is made properly.
Select a tractor that is suitable for the job.
Avoid using a tractor that is not fitted with an approved safety cab.
Be aware of soft spots and hollows that may affect stability.
BS 7121, The Safe Use of Cranes, requires the appointment of a crane coordinator to have
overall control of any lifting activities. The duties of this person are contained in the Standard,
as are those for driver and banksman.
On larger lifts or those with special restrictions, a permit to work may become appropriate.
To ensure that the lift can be achieved safely, we must ensure that we select the correct
crane for the lift.
Selection.
The selection of the appropriate type of crane will depend upon the following factors:
tended to various lengths, dependent on the lift they are completing. Crawler cranes are very
versatile on construction sites as they can carry an assortment of attachments, such as augers for digging holes for piles. They are mobile but slow-moving and cumbersome.
Has the lifting appliance received the following inspections for safe working:
Crane Incident.
These pictures are of a crane incident that occurred in the Netherlands at Shell's Antwerp
Refinery. During a major turnaround, fan tubes were being lifted using a tube tray. During the
lift and while the tube tray was directly over the crane operator's cab, the tube tray deviated
from horizontal and the fan tubes slid off and plunged like arrows into the operator's cab. Note
that the tubes were not properly secured to the tray during the lift operation. The attached
pictures show the condition of the operator's seat just after the accident. The pictures tell the
tale.
Lucky Crane Driver.
There are a number of factors which can affect the stability of the crane; the following
must be considered when the crane is on site:
Access/egress routes. As the crane may be the largest item of plant on site, this will
also include any weight limits that are on the roads including bridges.
Routes may mean that cranes have to move on inclines, increasing the risk of overturning.
Location of adjacent building, structures, etc. which could be hit by the load or the
crane rear as it swings around.
The oversailing of adjacent properties (e.g. Railtrack in the UK does not allow cranes
to oversail land until specific conditions are met).
The ground is firm enough to take the loading imposed by the crane, especially the
outriggers.
No voids exist under the crane position, e.g. manholes, culverts, gas/water routes,
etc.
Presence of overhead power lines.
Safety helmets are required to be worn by all staff in the vicinity of a lifting operation. This is
not to protect them if the load falls on them, but to protect them from small items, which may
be attached to, or placed on, the load.
Safety Devices.
A number of safety devices are available which assist the crane driver in ensuring that
capacity is sufficient for the lift. Two of these are safe working load/radius indicators and the
automatic safe load indicator (see Regulations 4 and 8 of LOLER and the accompanying
ACOP).
Safe Working Load/Radius Indicator.
The safe working load of a crane is calculated by the angle of the jib. The safe working Load
(SWL)/ Radius Indicator device indicates the safe working load applicable to the crane when
the angle of the jib is varied. If the jib can be moved horizontally, the safe working load can be
related to the length of the radius of arc made by the hook.
The safe working load/radius indicator only provides information for the operator. It may
operate automatically or be given in tabular form and displayed where it can be easily seen
by the crane operator. The information gives the safe working load for a given jib angle or the
horizontal distance to the hook from the point of rotation of the crane.
Automatic Safe Load Indicator (ASLI).
This is a device which gives a visual warning to the crane driver when the safe working load
of the crane is being approached (about 95% SWL) and an audible warning to the driver and
to the surrounding work area when the safe working load is exceeded (about 105% SWL).
Automatic safe load indicators must be tested before the crane is put into use, and inspected
weekly when in use. Records must be kept of tests and inspections. Testing can be carried
out only by raising known loads under the control of a competent person. Where electricallyoperated ASLIs are used, a source of confusion can arise from a button marked "TEST". This
applies only to the testing of the electrical efficiency of the system, not to load indicating
integrity of the unit.
It is vitally important when jib angles are changed that the ASLI is recalibrated to operate at
the new SWL. If the jib angle changes during the working operation, the ASLI should be set at
the smallest SWL.
Inspection.
Regulation 9, LOLER requires that before lifting equipment (including accessories) is used for
the first time, it is thoroughly examined. Lifting equipment may need to be thoroughly
examined in use at periods specified in the Regulations (i.e. at least six-monthly for
accessories and equipment used for lifting people and, at a minimum, annually for all other
equipment) or at intervals laid down in an examination scheme drawn up by a competent
person. A competent person should perform all examination work and following a thorough
examination or inspection of any lifting equipment, a report (in accordance with Schedule 1,
LOLER) is submitted by the competent person to the employer to take the appropriate action.
If it is intended to use excavators as cranes for lifting material, the excavator must be
examined in the same way.
Note: Lifting equipment includes such equipment as cranes, lift trucks, goods lifts, vehicle
inspection hoists, ropes, bell hoists, vehicle tail lifts, chain slings, eyebolts etc. The
regulations apply whether the equipment is existing, new, second-hand or leased.
Definitions.
Regulation 2(1) defines lifting equipment as work equipment for lifting or lowering loads, and
its attachments used for anchoring, fixing or supporting it. It includes any lifting accessories
that attach the load to the machine in addition to the equipment which carries out the actual
lifting function. The scope of these Regulations is therefore very wide and includes a range of
equipment from an eyebolt to a tower crane. A load includes any material, people or animals
(or any combination of these) that are lifted by the lifting equipment. In some circumstances,
such as in the use of a mobile crane, the weight of the lifting accessories including the hook
block will need to be considered as part of the load being lifted.
Equipment and Operations Covered by LOLER.
The Regulations are aimed primarily at the type of equipment which was covered by previous
lifting legislation, i.e. cranes, lifts and hoists, and components including chains, ropes, slings,
hooks, shackles and eyebolts. However, LOLER now applies in whichever industry this range
of equipment is used, including those, such as agriculture, which previously were not covered
by specific regulations.
Examples of the types of lifting equipment and operations covered include:
LOLER also applies to a range of other lifting equipment which presents risks similar to those
associated with the 'traditional' equipment listed above.
For instance:
Ropes used for climbing or work positioning during arboriculture, climbing telecommunication towers to work on overhead lines, and structural examination of a rock
face or external structure of a building.
A paper roll hoist on a printing machine.
An automated storage and retrieval system.
A front- end loader on a tractor used for raising and lowering loads such as a bale of
hay.
A bath hoist lifting a resident into the bath in a nursing home.
A loader crane fitted to a lorry for delivery duties.
A refuse vehicle loading arm used for tipping.
An air cargo elevating transfer vehicle.
Vehicle recovery equipment.
LOLER does not apply to escalators. This equipment is covered by more specific legislation,
namely Regulation 19 of the Workplace (Health, Safety and Welfare) Regulations 1992.
Application (Duty Holders) (Regulation 3).
LOLER only applies to work activities. It does not apply, for example, to persons who provide
lifting equipment principally for use by members of the public, such as lifts provided for use by
the public in a shopping centre. In such circumstances, employers will have to satisfy the
requirements of the HSWA, principally Sections 3 and 4, but if they use the requirements of
LOLER as a guide, they will probably satisfy these legal duties. The following paragraphs
give examples of how LOLER applies in particular circumstances:
Crane on hire to a construction site.
The crane hire company has a duty under LOLER to ensure that when a mobile crane is
hired out, physical evidence accompanies it (e.g. a copy of the last examination report), and
the user should ensure that this evidence is available. After installation of a tower crane, the
user should ensure that the crane is thoroughly examined by a competent person before it is
put into use, to make sure it is safe to operate. Normally the hire company will do this,
Patient Hoists
Hoists used to lift patients, e.g. from beds and baths, in hospitals and residential homes are
provided for use at work, and are lifting equipment to which LOLER applies. The duty holder
e.g. the NHS Trust running the hospital or the owner of the residential home, must satisfy
their duties under LOLER.
Suitability of Lifting Equipment (PUWER).
Before we look at the more specific requirements of LOLER, remember the general
requirement of PUWER 98 for every employer to ensure that work equipment is so
constructed or adapted as to be suitable for the purpose for which it is used or provided, and
to have regard to the working conditions and risks to health and safety in the place in which
that work equipment is to be used.
The risk assessment will need to include:
Lifting equipment is of adequate strength and stability for each load, having regard in
particular to the stress induced at its mounting or fixing point.
Every part of a load and anything attached to it and used in lifting it is of adequate
strength.
Account should be taken of the combination of forces to which the lifting equipment will be
subjected as well as the weight of any associated accessories used in the lifting operation. A
competent person should ensure that the strength and stability of the lifting equipment
continues to be adequate for the tasks for which the equipment is intended to be used.
Where appropriate, suitable effective measures to provide sufficient resistance to overturning
must be taken in order to ensure the adequate stability of the lifting equipment. Where there
is a significant risk of overturning and/or overloading arising from the use of the equipment, it
should be provided - where appropriate - with equipment or devices such as rated capacity
indicators and rated capacity limiters. Such devices provide audible and/or visual warning
when the safe lifting limits are being approached.
Lifting Equipment for Lifting Persons (Regulation 5).
Every employer shall ensure that lifting equipment for lifting persons is designed:
1. to prevent a person using it being crushed, trapped or struck or falling from the carrier;
2. to prevent so far as is reasonably practicable a person using it, while carrying out activities from the carrier, being crushed, trapped or struck or falling from the carrier;
3. with suitable devices to prevent the risk of a carrier falling;
4. so that a person trapped in any carrier is not thereby exposed to danger and can be
freed.
If the above risks cannot be prevented for reasons inherent in the site and height differences,
then the carrier must have a competent person inspect an enhanced safety coefficient
suspension rope or chain, and the rope or chain every working day.
The raising and lowering of people by work equipment which is not specifically designed for
the purposes should only be undertaken in exceptional circumstances, when it is not
practicable to gain access by less hazardous means. Where it is necessary to use such work
equipment, then all necessary precautions must be taken to ensure safety, including
appropriate supervision.
Examples of lifting machinery which is not specifically designed for lifting people but which
could be used if the necessary precautions are taken include a fork- lift truck, a telescopic
handler and a crane (fixed or mobile). When fitted with a suitably-designed carrier or working
platform, these can provide a safer alternative to other means of access (such as a ladder).
However, such an arrangement will not provide the same level of safety as purpose-built
equipment such as a mobile elevated work platform (MEWP).
Positioning and Installation (Regulation 6).
1. Every employer shall ensure that lifting equipment is positioned or installed in such a
way as to reduce to as low as is reasonably practicable the risk of the lifting equipment or a load striking a person; or from a load drifting, falling freely or being released
unintentionally.
2. Every employer shall ensure that there are suitable devices to prevent a person from
falling down a shaft or hoistway.
Marking of Lifting Equipment (Regulation 7).
1) Every employer shall ensure that:
machinery and accessories for lifting loads are clearly marked to indicate their safe
working loads.
2) Where the safe working load of machinery for lifting loads depends on its
configuration:
2. as soon as is practicable, make a report of the thorough examination in writing authenticated by him to the employer and any person from whom the lifting equipment
has been hired or leased;
3. where there is, in his opinion, a defect in the lifting equipment involving an existing or
imminent risk of serious personal injury, send a copy of the report as soon as possible
to the relevant enforcing authority.
Employers who have been notified of defects must ensure that the lifting equipment is not
used before the defect is rectified.
Keeping of Information (Regulation 11).
The employer has a duty to ensure that the information contained in every report made
to him is kept available for inspection:
In the case of a thorough examination of lifting equipment other than an accessory for
lifting, until he ceases to use the equipment.
In the case of a thorough examination of an accessory for lifting, for two years after
the report.
They are of good construction, sound material, and adequate strength and free from
patent defects.
The safe working load (SWL) must be displayed or, for lifting accessories, plainly
marked on it; only items listed or marked may be used in a lifting operation.
The safe working load must NEVER be exceeded.
Before being taken into service, all items must be tested and thoroughly examined by
a competent person, and at six-monthly intervals during service.
Certificates must be issued for all items.
Wrought-iron equipment must be periodically annealed (i.e. subjected to heat treatment which enables the wrought iron to revert to its "safer" crystal structure).
Registers must be kept, except for fibre rope slings, giving details of equipment.
It is now possible to select a suitable rope from the different strengths and properties of the
material available to suit most purposes. As there is no official test certificate for ropes, it is
very important that ropes are obtained from a reliable source where adequate quality control
during production, and testing of the final product are carried out, and where reliance can be
placed upon the manufacturer's new rope test certificate. It is therefore important to have a
visual inspection regime in place.
Nylon Ropes.
The compounds belong to a group of polymers called thermoplastics. Thermoplastic means
they can be repeatedly softened with heating and hardened by cooling without the material
becoming degraded.
Nylon Rope
Nylon ropes are the strongest of all ropes, and have a high resistance to creep when under
heavy stress. The material has an elastic property which enables it to withstand considerable
shock loading. However, elasticity does cause some problems when lifting is carried out
where headroom is restricted.
Where high stress situations require the best quality rope, the "braid over braid" construction
is the type recommended. This kind of rope is constructed in two parts: an inner core covered
with a sheath. Load bearing is divided equally between the sheath and the core, so if the
sheath becomes damaged, the rope would retain about 50% of its strength. Because of its
braided construction, this type of nylon rope has very good operational characteristics. It is
soft and flexible, resists twists and kinks, creates little friction and, being soft and smooth,
does not damage delicate surfaces.
Nylon, being a thermoplastic, will soften when heated, but the softening process is not linear
with rise in temperature. It retains its physical strength up to its melting temperature (about
250C). Nylon rope can be used continually up to temperatures of 150C without any
appreciable loss of tensile strength. Nylon rope is highly resistant to alkaline conditions and
fungal attack; it is, however, rapidly attacked by acids and can be degraded slightly by
weathering, e.g. sunlight. It is slightly hygroscopic and can lose up to about 8% of its breaking
strength under saturated conditions; when it is dry, full strength returns.
Terylene Ropes.
These are not as strong as comparatively-sized nylon ropes, but they still have considerable
strength compared with natural fibre ropes. They are highly resistant to creep and possess a
lower stretch property than nylon, which enables them to be used to advantage when lifting in
limited headroom. The ability to resist shock loading is about two-thirds that of nylon.
Being a thermoplastic, Terylene will soften when heated, but (as with nylon) the softening is
not linear with temperature and it retains its tensile strength to relatively high temperatures
and may be used in hot conditions; its melting temperature is about 260C. Terylene loses
only a small proportion of its strength when wet, has a higher resistance to weathering than
nylon, and is not degraded by fungal attack. It is attacked by alkali, but not by acids (the
reverse of nylon). Nylon and Terylene have been used to advantage where slings are used in
acid and alkaline conditions, e.g. pickling steel with hot acid and alkali dips. Such conditions
would cause considerable corrosion problems if wire ropes or chains were used.
Polypropene Ropes.
Polypropene is a thermoplastic polymer, which provides a material for rope-making with
intermediate properties between the natural fibres and nylon and Terylene. Being a
thermoplastic it softens with heating, and as its melting temperature is about 165C it soon
loses strength from any simple heat generating condition; e.g. in a winch, in a pulley system,
or by friction generated by a "running" rope around an anchor point.
Polypropene ropes resist acids and alkali, do not lose tensile strength when wet and resist
fungal attack. Sunlight and organic solvents degrade them. To reduce attack by sunlight,
special additives are incorporated into the polypropene.
Polythene Ropes.
These ropes have little value in lifting operations; they have a much lower tensile strength
than the other man-made fibres, they soften progressively with temperature rise, and have
the lowest melting temperature of the man-made fibres, about 135C.
Nylon Rope Strength Ratio of Various Ropes.
The table below summarises a comparative relationship in terms of weight/breaking strength
of various ropes. The scale is based upon manilla grade 1 material, which is given a standard
grading of 100.
Rope
Weight
Breaking Strength
Manilla grade 1
100
100
100
88
Nylon
93.5
250
Terylene
115
200
Polypropene
65
167
Polythene (Polyethylene)
71
You can see from the table that man-made fibre ropes are superior to natural fibre ropes.
Wire Ropes.
Wire ropes are constructed of strands, which are twisted together; the twists are called the
lay. Each strand contains a number of wires and the rope will have a certain number of
strands. A commonly used wire rope is the 6 x 19 construction; i.e. the rope has 6 strands
and each strand is made up of 19 wires. Another common rope used in lifts is the 8x19.
In docks the safety factor is 5, as given by the Docks Regulations: this factor now applies
generally to wire rope supplied to metric specification, e.g. 13 mm diameter rope with a
breaking load of 10.6 tons is given a safe working load of 2.1 tons.
= 2.1
10.6
5
Wire ropes are susceptible to chemical corrosion from acids and alkali, other corrosive
chemicals such as common salt (sodium chloride) or ammonium chloride, and atmospheric
corrosion. Any wire rope which is exuding rusty dust should be considered suspect; internally
corroded wire ropes cannot be made safe by lubricating - the damage has already been
done!
Wire ropes should contain enough lubrication to prevent ordinary corrosion taking place, but
not sufficient for a positive oily film to be easily seen. Excessive oiling can cause wire ropes
to slip on drive units.
It is a salutary thought that, if wire ropes break under tension, the whiplash causes the wire to
pass through an unfortunate human body in its path, like a wire through cheese. There is also
the danger of being cut by broken (needled) strands. Persons working with wire ropes should
wear heavy leather gloves.
Proof Load.
Proof load is defined as the force applied in a static tensile test, to which every item must be
subjected without showing any visual defects. Proof loads are generally twice the safe
working load. All chains after heat treatment must be proof tested in order that any defective
work, faulty welding or inherent weakness will be exposed.
Joining Ropes, Wire Ropes and Chains.
Natural and man-made fibre ropes can be spliced, but it is a skilled job and should not be left
to the untrained. Splicing reduces the strength of a rope; when well-made, 90% of the original
strength can be maintained, but this can drop dramatically when "amateur" skills are used.
Where possible, metal or nylon thimbles should be used for eye splices on lifting systems. A
splice should never be used for lifting hooks; the bending and flexing tends to "spring" the
splice.
Never use knots where ropes are used for lifting. Reef knots and other joining knots reduce
the rope strength by about 50%. Attachment knots such as the bowline, sheet bends, and
clove hitch cause a reduction of about 70%.
Wire Rope Slings.
Wire rope slings have an eye (a loop) at each end. The rope is passed round a thimble to
form the eye, and is then secured by a choice of methods. It may be manually spliced,
secured by a ferrule, or by a group of bulldog clips. Manual splices reduce the safe working
load of a wire rope to 90% of the original, ferrules to 95%. Using bulldog clips reduces the
safe working load to 85% of the original for the rope, and their use is not recommended. A tag
should be attached to each wire sling to show an identifying number and the safe working
load.
Connection Components.
The metal components used to connect ropes, wires and chains, and for attaching loads (i.e.
rings, shackles, eyebolts and hooks) must be subjected to proof load tests. Up to 25.5 ton (25
ton) working load limit, the proof load should be at least twice the safe working load.
A problem with eyebolt fittings arises from the fact that the eyebolt thread can be mismatched
with the tapped hole. This problem, which has always existed, has beer accentuated by the
introduction of metric sizes.
Hooks can be a potential source of hazard in lifting; apart from forming a heavy projection in
relative motion that can cause a serious head injury, there is always the possibility of a load
becoming dislodged from a simple open hook. It must now be considered good safety
practice, and a legal requirement under the Construction Regulations, for all hooks to be fitted
with safety catches.
Safe Use of Ropes, Wires, Chains and Lifting Accessories.
The following points summarise various factors in the use of ropes, wires, chains and lifting
accessories that are considered to be of importance for their safe use.
Ropes and Wires.
Ropes and wires must be in good condition before use, i.e. not frayed or corroded.
Splices must be properly made and positioned in the standing part of the rope, not or
the hook or passing over a corner.
The thimbles in eye splices should not be damaged.
Ropes and wires must be protected from sharp edges of load by the use of packing
e.g. wooden block or heavy rubber fillets.
No knots or hitches are to be made in slings or lifting ropes.
Never drag ropes or wires over the ground, or position the initial fixing so that they slip
as the slack is taken up.
When using two or more slings on a load, ensure that all slings are made of the same
material and that the hook will line up over the centre of gravity of the load when the
slack is taken up.
Chains.
Chains with links locked, stretched or without free movement should never be used. Distorted
links - or a link out of position - should never be hammered into position. Corroded, worn or
pitted chains should never be used.
The following precautions should always be observed:
Do not cross, twist, kink or knot any chain. Do not drag a chain from under a load. Do
not drop a chain from a height.
Do not roll loads over with a chain, or let running loads pass over chains lying on the
ground. Do not use a chain over sharp comers without protective padding.
Do not form a loop by inserting the point of a hook into a link.
Special precautions should be taken and a strong chain or sling should be used when there is
liability to shock load. The conditions are abnormal or severe. There is exceptional hazard to
life and limb.
Lifting Accessories.
Lifting accessories should only be used when there is no obvious sign of damage. Hooks
should not be used if there is any distortion and should be examined for cracks. Safety
catches should be operating correctly. Eyebolts should be checked to see that the bolt and
thread match up, and to determine whether there is any distortion of the thread system.
Bulldog clips, if used, should be checked to see that they are securely fixed. Rings and
shackles must be checked to see they are not distorted or cracked.
Sling Angles.
It is possible to calculate the tension in ropes etc. in an equilibrium system by the triangle of
forces. As the angle between a two-leg sling increases, so does the tension in the sling legs.
At 120, the tension in each leg is equal to the tension in the main lifting system. Another
method that can be used is to carry out measurements on the sling system and use the
following formula:
"credit" to the company balance sheet and not a "debit". Remember that as lifting operations
usually involve production schedules and costly capital equipment, failure of such equipment
results in a costly "debit" from profits. When human injury or death is involved, the obvious
loss is costly but the hidden costs cannot always be calculated.
Storage Conditions:
All stores must be dry, well-ventilated and free from corrosive atmospheres and conditions.
Ropes, both natural and man-made fibre types, must be stored away from direct sunlight and
heaters. Stored material must have a systematic layout, where it can easily be located when
required, and have a place to be returned to after use. Ideally, the store should have an area
where simple routine maintenance can be carried out, e.g. cleaning, oiling and checking used
equipment. The store area should be secure, so that equipment cannot be removed until it
has been officially issued by an authorised storeman.
Rope and friction: used for goods only with a limited reach. Use is now becoming less
as rough terrain fork lift trucks can be used as an alternative.
Rope and geared drive: a more sophisticated machine.
Rack and pinion drive: the drive turns a small cog where the teeth engage with similar
teeth on the pinion. Extensively used, particularly on passenger carrying hoists and
lifts, as the locking of the cog acts as an effective brake. It is capable of carrying considerable weights and may be used on very high lifts. (Safety of these types of hoists
is described in HSE Guidance PM 24.)
There are two main categories of hoist/lift.
Goods hoists used for lifting goods only and must not be used for transporting passengers. Clear signage to this effect must be displayed.
Passenger hoists which are suitable for lifting persons and goods. Although not a legal
requirement, good practice is not to carry goods and people in the lift at the same
time.
Hazards.
Enclosure is required to prevent any person being struck by the hoist and to prevent
people falling down hoist ways (LOLER, Regulations 5 and 6).
It must be fitted with a device, where practicable, to hold the platform in the event of
failure of the cable (LOLER, Regulation 5).
It should be fitted with a device to prevent over-run at the highest point.
Where the operator does not have a clear view throughout the distance of travel,
some form of signalling arrangement is required to enable stopping the platform in the
correct position (LOLER, Regulation 8).
When a winch is used to provide the operation, the winch should be fitted with a brake
which is applied when the lever is not in the operating position.
Safe working load to be marked and displayed in a prominent position, either as a
weight or, in passenger-carrying hoists, as the maximum number of persons (LOLER,
Regulation 7).
Hoists must have a statutory thorough examination every twelve months or six months
where it is used for lifting persons and for all lifting accessories, by a competent person.
The hoist to be loaded in such a manner that no goods can fall off.
Hoists and lifts are important pieces of equipment commonly encountered by the
safety practitioner. The effective maintenance, inspection and control of misuse of
such equipment is a legal obligation under LOLER, Regulation 9.
Further Precautions.
Ties - the hoist must be tied securely to the scaffold or building and the mast should
remain vertical.
Gates - Gates must be fitted at all access landings, including at ground level. The
gates must be kept closed except when access is needed for loading and unloading.
The enclosure gates must also be interlocked to the hoist platform so they cannot be
opened when the platform is not there, so preventing falls of people and material
down the hoist route. The interlocking must also prevent the platform from moving until the enclosure gates are correctly closed. The construction of the enclosure must be
such as to prevent any trapping of people or goods on the hoist.
Controls -The controls should be arranged so that the hoist can be operated from one
position only.
Platforms - platforms must be maintained and in good condition and have a notice
stating the safe working load.
Guards - and an arrestor device to support the platform or cage, fully loaded, in the
event of failure of the hoist rope or driving gear.
Wind speeds - manufacturers should quote the wind speed limits which should not be
exceeded.
ultiple ropes -can be fitted to prevent free-fall.
Factors in people falling or being thrown from the carrier typically include:
Precautions.
tion.
Scissor Lift.
These are a type of MEWP designed for vertical lifts and may be fitted with outriggers. The
hazards and precautions for this type of lift are the same as those of general MEWPs, with
the addition of the sheer effect of the scissor mechanism as it closes.
Vehicle Inspection Lift.
As their name suggests, vehicle lifts are mostly found in vehicle repair shops, so access can
be gained to the underside of vehicles. Poor maintenance and improper use can lead to
accidents. Hazards include the risk of vehicles rolling off the stands and the crushing of legs
and feet when the vehicle is lowered to the floor. Modern lifts have automatic chocking
systems which move into position as the vehicle is lifted.
Classic Passenger Lift.
The classic passenger lift can be found in hotels, shopping centres and business and
residential tower blocks. The Lifts Regulations 1997 apply to classic lifts.
The Lifts Regulations 1997.
The EU Directive on Lifts 1995 was implemented in the UK by the Lifts Regulations 1997, and
came into effect on 1 July of that year, with a two-year transition period to 30 June 1999.
During this time, the installers of lifts and manufacturers of safety components (the suppliers)
had the option of complying with either the provisions of the regulations or with existing
national regulations. Now this transitional period has passed, all suppliers have to comply
with the regulations.
The Regulations cover all aspects of the design, manufacture, assembly, installation, final
inspection and test of all lifts before they are placed on the market. This structure provides a
logical regulatory framework on which the safety throughout all these stages of the lift's life
can be ensured. Details of thorough examination and testing of classic lifts has been
produced by the HSE. Click on the link below for more information.
http://www.hse.gov.uk/pubns/indg339.pdf
fitted with emergency trip wires or stop buttons which must be fully operative at all times.
(b)Trapping:
Controls:
Guards are required between each pair of powered and free-running rollers.
Rollers that are designed to jump out should be provided at the transfer point between
a belt conveyor and roller.
Walkways should be provided to prevent people from walking across rollers.
Where overhead conveyors are used, screens should be installed to protect those below from falling objects.
Where roller conveyors are power-driven, the additional controls should be applied:
they could be struck by them. Where overhead mineral carrying takes place, there is a danger of falling material and the erection of barriers and clear demarcation of pedestrian areas
is required. Safety features to consider with the use of monorails are that they occupy a fixed
space that can be easily defined and access-controlled.
As with all mechanical handling devices, maintenance must be carried out at regular intervals
by competent persons and operatives must be trained and instructed in their safe use.
Trapping points between mechanical handling devices, palletised loads and the structure of transfer point;
Collapse of palletised load;
Trapping points between automated storage retrieval machines, palletised load, mechanical handling devices and the structure of transfer point.
Collision between AGVs and people at transfer points and during maintenance of
equipment.
Trapping points between AGVs and fixed structures or stationary objects.
Dangerous occurrences by inadvertent movement of the AGV, for example where
AGVs interact with storage and retrieval machines, the AGV could move off before the
load transfer is complete, causing displacement or collapse of the load or other devices.
The erection of perimeter fencing, made from rigid panels 2 metres high, can be positioned to prevent and restrict access to dangerous parts of machinery in the stacking
areas.
Signage around the fence could warn people that access to the stacking area is restricted.
It is essential that safe systems of work based on risk assessment are established,
when routine maintenance work and inspections are undertaken. Control of the operation of the machines should rest with the person working in the area.
For each activity involving access to the restricted automated storage areas, a formal
written safe system of work should be adopted and permits-to-work where appropriate.
should be in good condition, made from sound material, of adequate strength and be free
from faults apply in all cases. A comprehensive system of testing, examination and planned
maintenance is essential and records should be available and retained. All operators should
be competent to operate the equipment, and will require training in its use (Provision and Use
of Work Equipment Regulations 1998).
Question 1.
The name of the gas evolved during the charging of lead-acid batteries is
Multiple Choice (HP)
Answer 1:
helium
Response 1:
Jump 1:
This page
Answer 2:
halon
Response 2:
Jump 2:
This page
Answer 3:
hydrogen
Response 3:
Jump 3:
Next page
Question 2.
Familiarisation training of lift truck drivers is conducted
Multiple Choice (HP)
Answer 1:
off-the-job
Response 1:
Jump 1:
This page
Answer 2:
on-the-job
Response 2:
Jump 2:
Next page
Question 3.
Lateral instability is where a vehicle will tip over onto its front or back
Multiple Choice (HP)
Answer 1:
true
Response 1:
Jump 1:
This page
Answer 2:
false
Response 2:
Jump 2:
Next page
Question 4.
_____ are used to transport palletised goods in an automated warehouse
Multiple Choice (HP)
Answer 1:
Response 1:
Jump 1:
This page
Answer 2:
Response 2:
Jump 2:
Next page
Answer 3:
Response 3:
Jump 3:
This page
Question 5.
Which of the following is a lifting accessory?
Multiple Choice (HP)
Answer 1:
person
Response 1:
Jump 1:
This page
Answer 2:
shackle
Response 2:
Jump 2:
Next page
Answer 3:
crane
Response 3:
Jump 3:
This page
Question 6.
Information to be contained in a report of a thorough examination can be found in Schedule
_____ of LOLER 1998
Multiple Choice (HP)
Answer 1:
Response 1:
Jump 1:
This page
Answer 2:
Response 2:
Jump 2:
This page
Answer 3:
Response 3:
Jump 3:
Next page
3.0 - Access & Work at Height Equipment: Hazards & Control Measures.
An aerial device or elevating work platform is a mechanical device used to provide temporary
access for people or equipment to inaccessible areas, usually at height. These two distinct
types of mechanized access platforms may also be known as a "cherry picker" or a "scissor
lift".
They are generally used for temporary, flexible access purposes such as maintenance and
construction work or by fire-fighters for emergency access, which distinguishes them from
permanent access equipment such as elevators. They are designed to lift limited weights
(usually less than a ton, although some have a higher safe working load (SWL)),
distinguishing them from most types of cranes. They are usually capable of being fully
operated (including setup) by a single person.
Regardless of the task they are used for, aerial work platforms may provide additional
features beyond transport and access, including being equipped with electrical outlets or
compressed air connectors for power tools. They may also be equipped with specialist
equipment, such as carrying frames for window glass.
Lifting mechanisms There are several distinct types of aerial work platforms, which all have
specific features which make them more or less desirable for different applications. The key
difference is in the drive mechanism which propels the working platform to the desired
location. Most are powered by either hydraulics or possibly pneumatics. The different
techniques also reflect in the pricing and availability of each type.
Aerial devices were once exclusively operated by hydraulic pistons, powered by diesel or
gasoline motors on the base unit. Lightweight electrically-powered units are gaining popularity
for window-cleaning or other maintenance operations, especially indoors and in isolated
courtyards, where heavier hydraulic equipment cannot be used. Aerial devices are the closest
in appearance to a crane consisting of a number of jointed sections, which can be controlled
to extend the lift in a number of different directions, which can often include 'up and over'
applications.
This type of AWP is the most likely of the types to be known as a 'cherry picker', owing to its
origins, where it was designed for use in orchards (though not just cherry orchards). It lets the
picker standing in the transport basket pick fruit high in a tree with relative ease (with the
jointed design ensuring minimum damage to the tree). The term 'cherry picker' has become
generic, and is commonly used to describe articulated lifts (and more rarely all AWPs).
This type of AWP is now widely used for maintenance and construction of all types, including
extensively in the power and telecommunications industries to service overhead lines, and in
arboriculture to provide an independent work platform on difficult or dangerous trees. A
specialist type of the articulated lift is the type of fire apparatus used by firefighters worldwide
as a vehicle to provide high level or difficult access. These types of platforms often have
additional features such as a piped water supply and water cannon to aid firefighters in their
task.
Some articulated lifts are limited to only the distance accessible by the length of each boom
arm, however, by the use of telescoping sections, the range can be vastly increased. Some
large hydraulic platforms mounted on a lorry can reach heights of over 100 metres.
The majority of articulated lifts require a wide supportive base to operate safely, and most
models have extending legs/struts to help accomplish this. These legs can be manual or
hydraulic (usually depending on size and price of the machine). Some AWPS are classified as
'spiders' due to the appearance of these legs. Spiders are also available in especially
compact form, to fit through doorways for use inside buildings.
Scissor Lift.
A scissor lift is a type of platform which can usually only move vertically. The mechanism to
achieve this is the use of linked, folding supports in a criss-cross 'X' pattern, known as a
pantograph. The upward motion is achieved by the application of pressure to the outside of
the lowest set of supports, elongating the crossing pattern, and propelling the work platform
vertically. The Platform may also have an extending 'bridge' to allow closer access to the work
area (because of the inherent limits of vertical only movement).
The contraction of the scissor action can be hydraulic, pneumatic or mechanical (via a
leadscrew or rack and pinion system). Depending on the power system employed on the lift, it
may require no power to enter 'descent' mode, but rather a simple release of hydraulic or
pneumatic pressure. This is the main reason that these methods of powering the lifts are
preferred, as it allows a fail-safe option of returning the platform to the ground by release of a
manual valve.
"Hotel Lift".
There are a number of smaller lifts which use mechanical devices such as rack and pinion or
screw threads to extend. These often have juxtaposed sections which move past each other
in order to create the movement, usually in a vertical direction only. This lifts usually have
limited capability in terms of weight and extension, and are most often used for internal
maintenance tasks such as changing lightbulbs.
Motive mechanisms.
AWPs, by their nature, are designed for temporary works and therefore frequently require
transportation between sites, or simply around a single site (often as part of the same job).
For this reason, they are almost all designed for easy movement.
Unpowered.
These usually smaller units have no motive drive and require external force to move them.
Dependent on size and whether they are wheeled or otherwise supported, this may be
possible by hand, or may require a vehicle for towing or transport. Small non-powered AWPs
can be light enough to be transported in a pickup truck bed, and can usually be moved
through a standard doorway.
Self propelled.
These units are able to drive themselves (on wheels or tracks) around a site (they usually
require to be transported to a site, for reasons of safety and economy). In some instances,
these units will be able to move whilst the job is in progress, although this is not possible on
units which require secure outriggers, and therefore most common on the scissor lift types.
The power can be almost any form of standard mechanical drive system, including electric or
gasoline powered, or in some cases, a hybrid (especially where it may be used both inside
and outside).
Telescoping articulated platform mounted on fire-fighting appliance. These provide more
flexibility than ladder engines.[edit] Vehicle mounted. Some units are mounted on a vehicle,
usually a truck or it can be mounted on a flat back pick up van known as a Self Drive),[3]
though other vehicles are possible, such as railway cars. This vehicle provides mobility, and
may also help stabilize the unit - though outrigger stabilizers are still typical, especially as
vehicle-mounted AWPs are amongst the largest of their kind. The vehicle may also increase
functionality by serving as mobile workshop or store.
Control.
The power assisted drive (if fitted) and lift functions of an AWP are controlled by an operator,
who can be situated either on the work platform itself, or at a control panel at the base of the
unit. Some models are fitted with a panel at both locations or with a remote control, giving
operator a choice of position. A control panel at the base can also function as a safety feature
if for any reason the operator is at height and becomes unable to operate his controls. Even
models not fitted with a control panel at the base are usually fitted with an emergency switch
of some sort, which allows manual lowering of the lift (usually by the release of hydraulic or
pneumatic pressure) in the event of an emergency or power failure.
Controls vary by model, but are frequently either buttons or a joystick. The type and
complexity of these will depend on the functions the platform is able to perform.
The controls can control features such as:
Vertical movement:
Lateral movement.
Rotational movement (cardinal direction).
Platform / basket movement - Normally, the system automatically levels the platform
regardless of boom position, but some allow overrides, tilting up to 90 degrees for
work in difficult locations.
Ground movement (in self propelled models).
Safety.
The majority of manufacturers and operators have strict safety criteria for the operation of
AWPs. In some countries, a licence and/or insurance is required to operate some types of
AWP. Most protocols advocate training every operator, whether mandated or not. Most
operators also prescribe a range of pre-usage checks on the unit itself, and manufacturers
recommend regular maintenance schedules.
Work platforms are fitted with safety or guard rails around the platform itself to contain
operators and passengers. This is supplemented in most models by a restraining point,
designed to secure a harness or fall arrestor. Some work platforms also have a lip around the
floor of the platform itself to avoid tools or supplies being accidentally kicked off the platform.
Some protocols require all equipment to be attached to the structure by its own lanyard.
Extreme caution must be taken when using AWPs in the vicinity of overhead power lines as
electrocution may result if the lift comes in contact with energized wiring. Non-conductive
materials, such as fibreglass, may be used to reduce this hazard.
As with most dangerous mechanical devices, all AWPs are fitted with an emergency stop
button or buttons for use in the event of a malfunction or danger. Best practice dictates fitting
of emergency stop buttons on the platform and at the base as a minimum. Other safety
features include automatic self checking of the AWPs working parts, including a voltmeter,
which detects if the lift has insufficient power to complete its tasks (which will result in it
refusing to operate for safety). Some AWPs provide manual lowering levers at the base of the
machine, allowing operators to lower the platform to the ground in the event of a power or
control failure or deliberate use of the machine (e.g. by unauthorized persons).
MEWPs include cherry pickers, scissor lifts and vehicle-mounted booms. A familiarity
with them will enable you to:
Things to consider.
If you are thinking of using a MEWP look at the following questions.
Height.
How high is the job from the ground?
Application.
Do you have the appropriate MEWP for the job? (If you are not sure, check with the hirer or
manufacturer.).
Conditions.
What are the ground conditions like - is there a risk of the MEWP becoming unstable or
overturning?
Operators.
Are the people using the MEWP trained, competent and fit to do so?
Obstructions
Could the MEWP be caught on any protruding features or overhead hazards, e.g. steelwork,
tree branches or power lines?
Is there passing traffic, and if so, what do you need to do to prevent collisions?
Restraint.
Do you need to use either work restraint (to prevent people climbing out of the MEWP) or a
fall arrest system (which will stop a person hitting the ground if they fall out)? Allowing people
to climb out of the basket is not normally recommended - do you need to do this as part of the
job?
Checks.
Has the MEWP been examined, inspected and maintained as required by the manufacturer's
instructions and daily checks carried out?
Fall protection systems (harness, lanyard and shock absorber) cannot be relied upon as the
only means of protection as if the M.E.W.P falls over, being attached to it by fall protection
system will still result in serious injury.
Mechanical failure.
This issue can be addressed by means of inspection before dispatch from the hire company.
On delivery the machine will have an inspection sheet to show it has been checked over and
is in working condition.
Also for machines that have been hired out on a long-term basis the operative should
check the following on a daily basis before use:
It is advisable to have a banks man to help guide the operator when moving the machine form one worksite to the next.
Operator must asses the risks above him before using the machine.
Pay attention to the position of the arms during rotation assent and descent.
Before use always walk the route to survey for obstacles.
Never use:
MEWPs collapsing;
MEWPs overturning;
people being thrown from the carrier;
the carrier being trapped against fixed structures (the carrier is commonly referred to
as the basket or cage).
Equipment failure;
Ground conditions;
Outriggers (not used or faulty);
Trapping against fixed structure;
MEWP being struck by vehicle;
Load/unload of MEWP under power;
Overloading a carrier;
Carrier struck by a load.
The risk of falling from a MEWP is from sudden movements caused by an impact, ground
movement, failure of a stability critical part, or overreaching. The wearing of appropriate fall
protection equipment can provide protection against the residual risk of falling, or being
thrown out of the carrier.
In practice, work restraint will often be the most suitable form of personal fall protection (see
the 'Types of fall protection equipment' section for a definition).
Assessing the risk.
Employers and others responsible for the use of MEWPs must assess the risks of people
falling from or being thrown from the carrier, or the MEWP overturning, and take precautions
to eliminate or control those risks.
The following points should be considered:
What other vehicles, mobile plant or work equipment (e.g. overhead cranes) could be
close by?
Could parts protrude beyond the site boundary (e.g. buses have struck MEWPs)?
What are/will be the general ground conditions (e.g. softness, slopes)?
Are there any localised ground conditions that could be a hazard?
Has the MEWP been examined, inspected, maintained and daily checks carried out?
Could the carrier be caught on protruding features (e.g. steel work, tree branches)?
Remove uneven ground or excavations (e.g. adjusting the phasing of the work);
Remove soft ground by compacting.
If elimination is not reasonably practicable then assess the measures that should be put in
place to minimise the risk of falling from or with the carrier.
Examples of control measures are divided into three categories: safe plant; safe site; and
safe operator.
Safe plant:
Select the right MEWP for the job (consider ground conditions, working height, the
task including the range/sensitivity of movement, the anticipated load, e.g. people and
tools). A MEWP must not be used as a crane.
Ensure the MEWP has a thorough examination by a competent person at least once
every six months. Inspections may be more frequent depending on the use and operating conditions. Inspection intervals should be stated in the examination scheme.
Normally a MEWP has daily checks and a weekly inspection.
Check if a different make or model of MEWP is delivered to the site. Check that it is
suitable for the task. This is important with poor ground-bearing capacities. Control
systems can vary, leading to operator errors. MEWPs designed to be used on firm
level slabs should not be used elsewhere.
Safe site:
Segregate other site traffic (delivery vehicles, dumpers, etc) from the work area.
Ensure parts of a MEWP cannot protrude into roads or other transport routes. If this is
not possible, you need to use systems of work (e.g. temporary road closure at quiet
times).
Check the work area for localised features, e.g. manholes, service ducts, potholes, etc
(e.g. a hole 75 mm deep caused an overturn).
Check temporary covers are strong enough to withstand the applied pressure.
Check temporary covers are secured and monitor them. Take similar action for permanent covers.
Establish the load bearing capacity (general and point loading, e.g. outriggers) when
working inside in a building or on a structure (e.g. a jetty).
Ensure there is supervision to ensure safe systems of work are appropriate and being
used.
Check for overhead crushing or contact hazards.
Have agreed systems of communication (e.g. between MEWP operators and
banksman during steel erection work).
Check weather conditions have not altered ground conditions (e.g. heavy or prolonged rain).
Establish limits for safe operation (e.g. maximum wind speed). Remember conditions
can change internally (e.g. if roller doors are opened).
Comply with permit to work systems where sites have them (e.g. chemical plants).
Ensure you have a rescue plan agreed and in place for a fall. Are trained people and
rescue equipment onsite? Do all operatives understand what to do?
Assess other alternative work methods or equipment before operating near a steep
slope or edge. If you must operate near an edge or steep slope, can barriers be provided that will retain the MEWP? If this is not possible, where should a barrier be positioned (you need to know the braking performance)? If this is not possible, how will
the work be sequenced so that the MEWP can operate in a safe manner (e.g. in line
with the edge rather than towards it)?
Safe operator:
Ensure you have procedures for loading/unloading during delivery/removal from site.
Does this procedure apply to all your MEWPs (e.g. some do not have braking on all
wheels)?
Ensure operators are trained and familiar with the performance and controls of the
MEWP they going to use (e.g. do they know the types of ground/slope it can operate
on or when outriggers will require packing?).
Ensure operators have any task specific training (e.g. use of a chainsaw).
Ensure daily checks are done (in accordance with the manufacturer's instructions).
Ensure operators know when further operation would be unsafe. Do they know how to
position the MEWP for optimum use?
Ensure there is a system for recording faults, repairs and maintenance. What types of
fault would prevent further use of machine (e.g. controls not responding correctly)?
When working next to or in a live highway (e.g. street-lighting work or treecrown lifting)
where there is a risk of a vehicle hitting the MEWP;
When travelling with the carrier in a raised position, where it may strike fixed objects in
its path (e.g. branches, steel work);
When travelling with the carrier in a raised position over uneven ground;
Steel erection where the carrier has to move in and around the steelwork.
The MEWP must be suitable for travelling with the carrier in a raised position.
Types of fall protection equipment.
There are two types of fall protection that a person can use in the carrier:
Work restraint system (also known as fall restraint and incorrectly referred to as work
positioning) - this stops a person falling from the carrier in the first place (unless it is a
MEWP overturn).
Fall arrest system this stops a person after they have fallen from the carrier (unless it
is a MEWP overturn).
When deciding, as part of a risk assessment, which system should be used, the
following points should be considered:
Check with the manufacturer that the MEWP can be used as part of a fall arrest system. Does the carrier have suitable anchor points? The majority of anchor points are
currently rated for work restraint and not fall arrest. The testing of anchor points is
covered in BS EN 795: 1997.1 Anchor points in the carrier should be marked for work
restraint or fall arrest and the number of persons for which they are rated (arresting a
fall could also generate enough force to cause an overturn - check the MEWP can absorb this shock load).
After a fall the MEWP will flex, causing more severe swinging movements than normal
(this could lead to a higher risk of striking the MEWP or webbing or rope other nearby
structures).
Could the dynamic impact of a fall arrest cause other occupants, loose materials or
tools to be ejected from the carrier?
The user needs to establish the height the carrier will be working at and select fall arrest equipment that will work within that height. A typical fall arrest system with a full
body harness, 2.0 m lanyard and shock-absorbing device requires over 5m clearance
height to deploy and arrest a fall. Contact the fall arrest equipment supplier to establish the minimum clearance height for the proposed equipment.
Check that there are no projections (balconies,canopies) that a person could strike
during a fall.
After a person's fall has been arrested, how are you going to rescue them? There
should be a rescue plan and people should be practised in this.
considered after detailed consultation with the manufacturer as to their suitability and the
parameters under which they have been designed and, more importantly, tested. Do not use
retractable equipment unless it has been specifically tested in the proposed manner of use.
Lanyard length (of both fixed length and retractable systems) should be carefully selected
and matched to the carrier of the specific MEWP that is going to be used. They must be set
short enough to prevent a person reaching a position where they could fall.
Working near water.
When working next to water, a harness should not be worn due to the risk of drowning if the
MEWP falls into the water. Life jackets should be worn.
Instruction in use of fall protection equipment.
Operators will need instruction in the use of the harness, lanyard, rescue equipment and the
procedures for periodic inspection, maintenance and storage of fall protection PPE
(especially textile equipment).
The Law.
If you own, hire or otherwise operate or control the operation of MEWPs (e.g. as principal
contractor), you have duties under health and safety law.
The specific legal provisions are (or will be) contained in the following pieces of
legislation:
The ground key for the MEWP should ideally be left in the base unit where this is
practicable, or at least quickly available at ground level if not.
While the MEWP manoeuvre is taking place at least one (and as many as is appropriate) designated ground rescue person should be appointed who knows the rescue
procedure and has been familiarised with the MEWP being used (including emergency rescue controls). They should always be readily available in the event of an
emergency.
A system must be in place to identify that an operator may have become trapped, particularly for lone workers working close to an overhead structure. This needs very
careful
consideration if the operator cannot be seen from the ground. Operators must take
advice if such a system has not been put in place when a risk of entrapment is present.
Decide who should effect the rescue and how:
This depends on the complexity of the operation and therefore the relative risk of effecting a rescue from the ground compared to the risk of an operator, possibly in a
state of panic, trying to rescue himself. It also depends on how the controls for the
specific MEWP being used function if the load cell has been activated.
auxiliary power at first which gives the slowest and most controlled manoeuvre of the
boom until it is obvious that the basket is clear of any obstructions at height.
powered descent: once clear of obstructions, it is then recommended to switch to
powered descent to maximise the speed of recovery.
3) Another MEWP: In some situations the use of another MEWP to gain access to the
platform may be the safest option. This will only be acceptable if such rescue has been
planned and includes means of transferring between platforms which prevents anyone falling.