NEBOSH International Diploma in Occupational Health and Safety

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Version 1.3 (21/03/2013)

Element IC7: Work Equipment (Mobile, Lifting & Access).

Learning outcomes.
On completion of this element, candidates should be able to demonstrate understanding of
the content through the application of knowledge to familiar and unfamiliar situations and the
critical analysis and evaluation of information presented in both quantitative and qualitative
forms.
In particular, they should be able to:

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.

Minimum hours of tuition: 6 hours.

1.0 - Mobile Work Equipment Hazards & Control Measures.

For the purposes of the Provision and Use of Work Equipment Regulations, mobile work
equipment is any work equipment which carries out work while it is travelling or which travels
between different locations where it is used to carry out work. Such equipment would normally be moved on, for example wheels, tracks, rollers, skids etc. Mobile work equipment
may be self-propelled, towed or remote controlled and may incorporate attachments.
Self-propelled mobile work equipment.
Self-propelled mobile work equipment is work equipment which is propelled by its own motor
or mechanism. The motor or mechanism may be powered by energy generated on the mobile
work equipment itself, for example by an internal combustion engine, or through connection
to a remote power source, such as an electric cable, electric induction or hydraulic line.
Attachment.
Attachments are work equipment which may be mounted on self-propelled mobile work
equipment to alter its characteristics. For example, a load rotator fitted to a fork-lift truck will
alter its load-handling capabilities and may alter its safety characteristics, such as stability.
Attachments are not considered to be mobile work equipment in their own right but if they can
affect the safety of the self-propelled mobile work equipment when they are attached, they
are considered to be part of the self-propelled work equipment. Attachments may be nonpowered, powered by an independent power source or powered by the self-propelled work
equipment to which they are attached.
Towed mobile work equipment.

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.

1.1 - Stability of Vehicles.

Vehicle Stability.
One of the major problems in the safe use of vehicles is instability. Three main ways in which
a vehicle may become unstable are:
1) Lateral instability.
This is where a vehicle will tip over onto its side. An example is when a lorry is blown over in
a high wind or a loaded forklift tips whilst driving across a slope.
Lateral (sideways) instability FLT (Fork lift truck).

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.

Exceeding safe maximum working load.

Forks not fully inserted.
Violent braking.
Travelling forward down a slope when loaded.
Incorrect use of tilt at high-level loading.
Boom not fully retracted.
"Live" loads.

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.

With the load as close to the ground as

possible (150mm) the stability of the
lift truck is greatly increased.

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.

1.2 - Safe Use of Lift Trucks.

Types of Lift Truck.
The lift truck provides industry with a versatile material-handling vehicle, and is an essential
feature of many workplace operations. You will remember from your studies of Unit 6: Work
Equipment that employers have duties under Regulation 4 of the Provision and Use of Work
Equipment Regulations 1998 for the selection of work equipment that is suitable for the purpose for which it is used or provided, and the working conditions. In order to choose the correct lift truck, an assessment should be made of the environment, load, and task and the
characteristics of the truck itself.
There are many different types of lift truck which can be identified as follows:
Type of Lift Truck.

Characteristics.

Counterbalance Lift Truck.

The mass of a counterbalanced lift

truck acts as a counterweight so that
the load can be lifted and moved without the truck tipping. However, the
truck can become unstable if over-

loaded, or the load is incorrectly placed

on the forks. Instability is increased if
the truck travels with the forks raised
rather than lowered, or if the truck is
travelling across an incline or uneven
surface.

Reach Lift Truck.

When the forks are extended, the reach

truck behaves in a similar manner to
the counter-balanced truck. It is less
likely to tip over when the forks are in,
as the load is within the wheelbase of
the truck (This minimises the overall
working length and allows the aisle
width to be reduced), which increases
stability. When the load is elevated and
the mast tilted back there is significant
risk of overturning. This risk increases if
the load is high and the truck is operating on an uneven surface.

Rough Terrain Lift Truck.

Rough terrain lift trucks are designed to

operate on uneven surfaces such as
those encountered on construction sites.
They operate similarly to the counterbalance lift truck; however, care is needed
on rough ground as bouncing can cause
loss of control. The trucks should not be
used for lifting to high levels unless the
ground is reasonably level and consolidated and the truck is clear of excavations and walls. Unless specially designed, they should not be used for
stacking on inclines. Typical features of a
rough terrain lift truck include increased
load/lifting capacity, higher chassis position for uneven terrain, enclosed operator
cab to provide protection against the
elements and large diameter wheels with
deep tread.

Telescopic Materials Handlers.

The telescopic materials handlers are

also referred to as multi-tool carriers,
commonly used in construction and agri-

culture where loads need to be positioned at different heights.(different lifts of

scaffold, and hay stacking). When fitted
with the correct jib, they can be used for
crane duties.

Side Loading Truck.

This is a form of lift truck commonly

found in timber yards. It is a type of reach
truck used to carry long lengths of timber.
During travelling, the load is usually resting on the truck structure.

Pedestrian Controlled Truck (ride-on).

A pedestrian operates these via a control

handle. Sometimes referred to as pallet
trucks. Usually powered by a hydraulic
hand pump or battery the operator can
either 'ride on' or walk steering it. Operators should always face the direction of
travel and not walk backwards nor directly in front of the control handle, which
should act as a "dead man's handle"
upon release by the pedestrian in the
event of an emergency.

1.3 - Video: [News bulletin] Fork Lift Truck.

Fork Lift Truck Video.
http://www.sheilds-elearning.co.uk/file.php/4/videos/NEWs_Intro_scene-FLT.flv

1.4 - Hazards Associated with Use of Lift Trucks.

Overloading.

Exceeding the maximum rated capacity of the lift truck.

Failure.

Load bearing part (e.g. chain or hydraulic system), inadequate maintenance.

Dangerous stacking or de-stacking technique.

This can destabilise a complete racking column, which could cause the column to collapse onto the lift truck.

Fire/explosion.

Fire is often caused by poor maintenance resulting in fuel leakages or engine/motor

burn out, or through using a fork lift truck in areas where flammable liquids or gases
are used and stored.
Hydrogen is evolved from the cells during the charging of lead-acid batteries. An accumulation of hydrogen with air creating a flammable mixture could present a risk of
fire and 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.

Lifting batteries or gas cylinders can cause musculoskeletal injuries.

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.

Fig: Passengers should not be carried on loads or forks!

1.5 - Description of Precautions in the Use of Lift Trucks.

Precautions in the use of lift trucks.
The precautions to be taken to prevent and reduce the hazards previously identified
with the use of lift trucks, shall be described under the following headings:

Operator (Safe Driver).

Equipment (Safe Vehicle).
Environment (Safe Site).

Operator (Safe Driver).

Operators should drive lift trucks in accordance with their training. (Training requirements are
discussed in Section 2.5). There are however, a number of basic rules which operators
should follow.
Basic Rules for Operators.
(1) Particular care should be taken in the vicinity of pedestrians, and as a general rule drivers
should keep to the left. However, in restricted areas where visibility is poor, a central rather
than a left-hand side position may improve visibility. Prescribed lanes or routes should always
be used.
(2) All parts of the driver's body must be kept within the limits of the truck and no part of the
body placed between the uprights of the mast.
(3) Under no circumstances should passengers be carried on loads or on forks. Passengers
should not be carried on any part of the truck unless a properly-constructed position is
provided, such as a working platform or attachment. Alternatively, more suitable equipment
should be selected such as Mobile Elevated Working Platforms (MEWPs).
(4) When approaching potential danger points such as road junctions, before entering
doorways and at blind corners, speed should be reduced and the horn sounded. Sounding
the horn warns other vehicles and pedestrians, but does not automatically give the driver the
right of way.
(5) When driving on inclines, ensure that:

(i) when carrying the load, it faces uphill;

(ii) when no load is carried, the fork arms face downhill;
(iii) where fitted, the tilt is adjusted to suit the gradient and the fork arms are raised to provide
ground clearance.
(6) When driving, the forks should be lowered to within 150 mm of the ground and the mast
tilted back, wherever possible. Driving with the load elevated increases the risk of
overturning. Operators should always ensure that they are facing the direction of travel.
(7) The truck must be stationary with the handbrake applied when the forks are raised or
lowered, whether loaded or not.
(8) Trucks should not run over cables or pipes unless they are suitably protected to prevent
mechanical damage.
(9) Violent braking of a loaded truck should be avoided as sharp movements could cause the
load to fall off or the truck to tip.
(10) When a high load restricts vision, the truck should be driven in reverse except when
driving up an incline. The horn should be used when necessary e.g. at blind corners or
doorways.
(11) Trucks must be driven at an appropriate speed for the conditions and visibility. Where
speed restrictions have been set, they must be obeyed. Particular care must be taken when
reversing and when driving on greasy, icy or wet roads. All defects such as holes in the road
surface and obstacles should be avoided and reported to management.
(12) A truck should not be left unattended on a gradient. If it has to be parked in an
emergency, the wheels should be chocked to prevent unexpected movement. If a truck has to
be left, even for a short period of time, it should be left in neutral, the parking brake applied
and the forks lowered.
(13) When a truck is not in use, the keys should be kept in a secure place. At the end of the
work period, the engine should be switched off, the forks lowered to the ground and the
brakes applied. On battery trucks, the battery should be disconnected

1.6 - Lifting Loads.

Lifting loads.
1. Before lifting, the weight of a load must be assessed as well as its centre of gravity to
ensure that the truck is capable of lifting the load.
2. The forks must be suitably adjusted for the load and placed in the correct position, i.e.
fully inserted so that the forks are evenly loaded during lifting.
3. The mast should not be tilted forwards when a load is being raised or lowered.
4. When lifting and lowering loads during stacking operations, the handbrake should be
on and care should be taken not to dislodge other stacks.
5. A load should not be picked up if someone is standing close to it and people should
not walk or stand beneath a load when it is elevated.
6. Loads that are unsuitable, or pallets which are damaged, should not be picked up and
further advice should be sought.
7. Tandem lifting, where two lift trucks are used to manoeuvre heavy or awkward loads,

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.

1.7 - Pre-operational Checks.

Pre-operational Checks.
In order to ensure that the lift truck is safe to use, the operator should carry out preoperational checks. These should be carried out when the truck has been left standing for
any length of time and especially at the beginning of each shift.
The following is an example of a pre-shift check list:
Lift-truck

Lift truck No.

Date

Pre-shift Check List

Item

Details

Shift
A

Fork arms.

No cracks or distortion. Evenly spaced

on carriage plate and clips engaged.

Carriage plate.

No obvious damage. End stops secure.

Back rest.

Load backrest extension secure and not

damaged or distorted.

Mast.

No damage, distortion or cracks. Inner

channels or runners reasonably clean
and smooth.

Lift chain.

Free from damage or rust, all pins in

place.

Hydraulics.

No damage or leakage from any point.

Wheels.

Undamaged. All nuts tight.

Tyres.

No excessive wear, cuts or foreign bodies. Is pneumatic tyre pressure correct?

Lights/indicators.

All functioning.

Horn/beeper.

Clearly audible.

Mast Controls.

Lift/lower, tilt and side shift operating

properly.

Hand/parking
brake.

Strong enough to prevent truck being

driven.

Driving & service

brake.

Works properly in both directions when

tested slowly.

Fuel/power.

Adequate for shift.

Levels.

Coolant and engine oil levels correct.

LPG.

Cylinder secure, pipes and hoses satisfactory.

Electric truck batter- Battery levels must be topped up with

ies.
distilled water, where necessary, once a
week.
Chain lubrication.

Chain should be sprayed with a suitable

lubricant every month or 250 hours.

Steering.

Works properly in both directions, at

standstill and when moving.

Operators Initials.
Hour reading when check done:

Tick items that are satisfactory.

Cross faulty items and describe fault overleaf. Report directly to supervisor. Do not use truck
until safe to do so.
Draw a line through rows that do not apply (e.g. battery on LPG truck).
If any item is found to be defective, the fault must be reported immediately to the supervisor
and the truck taken out of commission until it has been rectified and certified safe. It is
recommended that each truck has an individual log where these tests, as well as other
checks and remedial measures, are recorded. No operator or other person should make any
repair or adjustment unless specifically trained and authorised to do so.

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

28 Self-propelled work equipment and Regulation 29 Remote control self-propelled work

equipment.
We have seen from Element C6 that Regulation 5 of the Provision and Use of Work Equipment Regulations (PUWER) 1998deals with the Maintenance of work equipment. In addition
to the pre-operational checks to be conducted by the operator before the commencement of a
shift, a system of regular maintenance by competent persons must be in existence and records kept and logged. They should be operated within defined safe operating limits, e.g. the
maximum lift height and capacity. Trucks should be properly maintained according to manufacturers' instructions on inspection, maintenance and servicing. In addition to these checks,
which should be carried out by a competent person on a routine basis, the operator should
carry out a daily safety check.
Weekly or 50 running hours' maintenance checks should include items on the daily check list
plus operational checks on steering or lifting gear and on the condition of the mast, forks,
attachments, chains etc.
Six monthly or 1000 running hours' maintenance checks should also be carried out. The
manufacturer may recommend differing maintenance periods. A record of all checks and
repairs carried out should be retained.
Lift trucks are subjected to a 12 monthly statutory examination, but this is dependent on the
application, the intensity of use and the nature of any attachments. The interval would be
reduced to six months when using working platforms to carry people. The thorough
examination is usually by an engineer employed by an insurance company, and this is
preferable to those by the usual maintenance engineer as it provides an additional level of
independence. The competent person will be able to determine the correct interval for
examination. The thorough examination report must comply with the requirements of
Schedule 1 contained in the LOLER Regulations.

1.9 - Fire and Explosion.

Fire and Explosion.
There are risks associated with both means of powering lift trucks, electric batteries or internal combustion engines, each of which demand specific precautions.
Battery-Powered Lift Trucks.
The charging of batteries should be conducted in a separate room designated for this purpose. Where batteries are recharged, care must be taken to avoid the risk of explosion from
an accumulation of hydrogen that is produced in the charging process. Adequate high level
ventilation situated immediately above the batteries (as hydrogen is lighter than air) and the
prohibition of smoking and other sources of ignition (e.g. electrical apparatus) are necessary.
If possible, recharging should be located in an area away from work, storage and pedestrian
areas. Before the charger is disconnected from the battery or truck on charge, the current
should be switched off to reduce the risk of a spark, which could be sufficient to cause ignition. It is important to ensure that the charger and the connections used comply with the requirements of installation, connection and use of the Electricity at Work Regulations 1989,
which shall be covered in the next Element C8: Electrical Safety.
Those who are responsible for changing batteries should receive clear instructions and training on the hazards and precautions involved in such activities. This could include first aid and
spillage procedures in case of acid spills and splashes, and the importance of wearing suitable PPE, eye and hand protection. Eye wash stations should be provided. Assessments re-

quired under Regulation 6 of the Control of Substances Hazardous to Health Regulations

2002 (as amended) should be conducted.
To avoid hazards involved with the manual handling of lift truck batteries, lifting gear should
be provided.
Internal Combustion engine powered lift trucks.
Refuelling areas for petrol or diesel should be located outside buildings and smoking should
be prohibited. Notices to this effect should be clearly displayed. The cylinders of LPG trucks
should preferably be changed outside buildings.
Where this is not possible and space is restricted, ventilation should be adequate to remove
exhaust fumes. If forced ventilation is in operation, motors should be designed to be explosion proof. Engines should be switched off during refuelling, and refuelling should be conducted away from heat or other sources of ignition.
Due to the risk of causing fires or explosions, lift trucks should not be used in areas where
flammable gases, dusts or vapours are liable to be present unless they are suitably protected
for such use, e.g. electric lift trucks must be fitted with suitable flame-proof equipment.

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.

1.11 - Layout and Design.

Layout and Design.
To prevent accidents occurring, the movement of vehicles should be governed by stringent
rules which are enforced by management supervision and control. However, as direct supervision of site traffic is not always practicable and as many visiting drivers may be unfamiliar
with the site, the layout and design of traffic routes within sites is a particularly important consideration. Routes should not be used by vehicles which are inadequate or unsuitable. Restrictions on such usage should be clearly indicated.
Traffic routes should be wide enough to allow vehicles to pass oncoming or parked vehicles
without leaving the route. One-way systems or restrictions should be introduced where necessary. On traffic routes in existence before 1st January 1993, where it is not practical to
make the route wide enough, passing places or traffic management systems should be provided as necessary.
Traffic routes used by vehicles should not pass close to any edge or to anything likely to collapse, unless fenced and adequately protected.
The need for vehicles with poor rear visibility to reverse should be eliminated as far as possible, for example by the use of one-way systems.
Parking Areas.
The provision of lift truck parking areas must be suitable and sufficient and sited away from
the main work area. This will serve to reduce unauthorised use by other employees on the
site and ensure that trucks are not obstructing doorways, fire fighting equipment or preventing
other vehicles from manoeuvring.
Space is required to store returns, empties, pallets and other materials which tend to accumulate in loading areas unless specific provision is made for them.
Road junctions and road/rail crossings should be kept to a minimum. Site entrances and
gateways should be of sufficient width to accommodate vehicles stopped for checking without
causing obstructions on the public highway or on the site.
Physical protection of vulnerable plant and equipment such as storage tanks, pipework and
storage racking may be necessary. Such plant should be located away from roads but where
that is not possible, suitably constructed barriers should be provided for protection.
Road Construction and Maintenance.
All roads should be even, constructed of suitable materials with concrete or bituminous surfaces and well-drained. Excessive gradients, i.e. in excess of 1 in 10, should be avoided
where possible, although this is difficult in the vicinity of ramps which connect parts of the site
at different levels. The provision of lay-bys and sufficient forward visibility, particularly on constricted sites, can contribute to safe vehicle movements. Ground conditions should be improved, sharp or blind bends avoided where possible, or measures such as one-way systems
and mirrors considered. Maintenance of roads is particularly important, e.g. potholes should
not be allowed to develop, snow clearing and gritting may be necessary, and goods which fall
from vehicles should be retrieved as soon as possible.

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.

restricting reversing to places where it can be carried out safely;

keeping people on foot or in wheelchairs away;
providing suitable high visibility clothing for people who are permitted in the area;
fitting reversing alarms to alert, or with a detection device to warn the driver of an obstruction, or apply the brakes automatically; and
5. employing banksmen to supervise the safe movement of vehicles.
Whatever measures are adopted, a safe system of work should operate at all times. Account
should be taken of people with impaired sight or hearing.

1.13 - Employees Carried on Mobile Work Equipment.

Regulation 25 of the Provision and Use of Work Equipment Regulations 1998 states
that:
Every employer shall ensure that no employee is carried by mobile work equipment unless:
(a) it is suitable for carrying persons; and
(b) it incorporates features for reducing to as low as is reasonably practicable risks to their
safety, including risks from wheels or tracks.
Working platform attachments which are designed to lift/carry people can be fitted to certain
types of lift trucks, including reach and counterbalanced.
The two types, as described in Guidance Note PM28 Working platforms, are integrated
and non-integrated:

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.

During use, the following precautions are necessary:

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.

Mnemonic : Safety of Fork Lift Truck Platforms (FIT CLAWS)

F loor strong and non-slip
I nward opening gates
T oeboards and rails
C ontrols preferable
L ocking device to forks
A nchorage points for harness
W idth and weight less than fork lift truck
S creen from fork lift truck parts
Other attachments used on lift trucks.
Fork arm extensions: These may be simple box or channel sections which slip onto the forks
of the truck to give them extra length, or they may be special telescopic forks which replace
the normal forks. The telescopic types are usually hydraulically operated, and allow the load
to be moved forward or backward without moving the truck. This gives the facility for placing
loads into deep racks, or to reach loads on the far side of a lorry trailer
Fork positioner:
These units are mounted on the fork carriage and have forks which can be moved
hydraulically to change their lateral position. The truck operator is able to adjust the fork
centres for narrow or wide loads without leaving the driving seat. The addition of this
attachment moves the forks forward and therefore the load moment is increased. This,
together with the self-weight of the attachment, will reduce the capacity of the fork lift truck.
Rotator:
These units are usually mounted on the fork carriage and used in combination with another
attachment. They enable the attachment and load to be rotated through 180 degrees or 360
degrees. They may be provided with a secondary carriage on which a further attachment is

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.

1.14 - Safeguarding Cab Operators.

Cabs, operators' stations and work platforms, with suitable side, front and rear barriers or
guard rails can prevent people from falling from mobile work equipment when it is travelling.
Where provided, they should be properly designed and constructed. They can be fully
enclosed or may be open to the environment.

1.15 - Outline of Training of Lift Truck Operators.

Training Requirements.
As the safe use of lift trucks depends largely upon the skill of the driver, training is an essential first step in the reduction of injuries and damage caused by lift trucks.
The requirements for lift truck operator training are contained within:

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.

Further guidance on the selection of operators is detailed in HS(G)6: Safety in Working

with Lift Trucks, a summary of which follows.
Employers should be careful in selecting potential lift truck operators. The use of selection
tests can avoid wasteful attempts to train unsuitable trainees. It is advisable to conduct
medical examinations on potential operators, and at regular intervals throughout their
employment. Examination at age 40 and thereafter at five-yearly intervals up to the age of 65
is recommended.
Operating ability may be affected temporarily by some types of drugs and medical conditions
(Medical standards are covered in Appendix 5 of HS(G)6). Alcohol-dependent individuals or
drug abusers should not be employed as operators.
Operators should have normal agility and full movement of their trunk, neck and limbs,
although amputees may be re-employed following re-training. Safe operation of lift trucks
depends on good vision and judgement of space and distance, distant vision should not
normally be less than 6/12 with both eyes. Glasses should be worn if required. Good hearing
is essential to hear instructions and audible warning signals.
Training Providers.
The Health and Safety Executive (HSE) recognises five accrediting bodies which operate
schemes to accredit various training organisations or individuals (referred to as Approved
Training Providers or ATPs) who are deemed competent to provide or carry out a good
standard of training. These accrediting bodies are:

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.

1.16 - Video: Fork Lift Trucks.

http://www.sheilds-elearning.co.uk/file.php/4/videos/C7%20FLT.flv

1.17 - Rolling Over of Mobile Work Equipment.

The Provision and Use of Work Equipment Regulations, Regulation 26 states:
(1) Every employer shall ensure that where there is a risk to an employee riding on mobile
work equipment from its rolling over, it is minimised by;

stabilising the work equipment;

a structure which ensures that the work equipment does no more than fall on its side;
a structure giving sufficient clearance to anyone being carried if it overturns further
than that; or
a device giving comparable protection.

(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;

it would increase the overall risk to safety;

it would not be reasonably practicable to operate the mobile work equipment in consequence; or
in relation to an item of work equipment provided for use in the undertaking or establishment before 5th December 1998 it would not be reasonably practicable.

1.18 - The Application of Regulation 26 & Control Measures for Rollovers.

In addition to the more general requirements of regulation 25, regulation 26 covers the meas-

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.

1.19 - Operator Restraint Systems.

While safety cabs have dramatically reduced fatalities from machines overturning,
there are still many injuries which could be avoided by using seat restraints, eg:

drivers being thrown from machines with only a roll bar;

drivers or passengers being thrown through cab doors or windows, or injured by being
thrown around in the cab.

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:

using selfpropelled machines such as combine harvesters, selfpropelled sprayers,

sugar beet harvesters, forage harvesters or potato harvesters;
using ATV quad bikes because they have no rollover protection so seat restraints
would be dangerous;
using any machine which has no rollover protection fitted. (NB The mast on a forklift
ensures it can only turn over onto its side so seat restraints can be fitted to these machines without additional rollover protection.)

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

situations in which the machine is used.

Where a new seat is fitted ensure the seat mounting points can withstand the additional
stresses from a person being strapped to it during an overturn. Always ask the manufacturer's
advice on this point.
For passenger seats which have no mounting points for seat restraints it may be easier to
replace the seat, but again the seat mounting points must be strong enough so that the seat
will not become detached during an overturn.
NEVER drill or weld cab frames or roll bars to fit mounting points for seat restraints. This
could weaken the structure and invalidate its safety certification.
Mobile trailed and mounted machines.
On trailed or mounted machines the same requirements for operator protection apply, ie if
there is a rollover protection device fitted and there is a risk of employees being crushed
between the machine and the ground from overturning, then seat restraints should be fitted.
Duty to wear seat belts.
The following legal duties under the Health and Safety at Work etc Act 1974 apply to
employers, the self employed and employees:

Employers have a duty to ensure, so far as is reasonably practicable, the provision of

information, instruction, training and supervision to ensure the safety of their employees at work.
The self employed have a duty to conduct their undertaking so as not to expose
themselves to risk.
Employees have a duty to take reasonable care for their own health and safety.

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.

1.20 - Controlling Movement of Work Vehicles - Stopping & Braking.

Devices for stopping and braking.
All self-propelled mobile work equipment should have brakes to enable it to slow down and
stop in a safe distance and park safely. To this end, mobile work equipment should have
adequate braking capacity to enable it to be operated safely on the gradients on which it will
be used and its parking brakes should be capable of holding it stationary (where appropriate,
fully loaded) on the steepest incline that the mobile work equipment may be parked in use.
Other relevant product legislation exists which deals with braking systems on vehicles which
may be used on the road as well as at work, such as the Road Vehicles (Construction and
Use).
Regulations and Directive 76/432/EEC, as amended by Directive 96/63/EC, dealing with
tractor braking. Under normal circumstances, vehicles meeting these requirements would be
suitable for use at work.
Regulation 28(d).
Emergency braking and stopping facilities.
Where there are significant risks associated with failure of the main braking device, a secondary braking system is required. The secondary braking system may operate automatically
through spring applied brakes or through a dual circuit system on the service brakes. It may
also be operated through the parking brake system or other controls which are easily acces-

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.

1.21 - Driver's Field of Vision & Issues Concerning Visibility.

Driver's field of vision.
This regulation applies when mobile work equipment is about to move or while it is travelling
(including manoeuvring). Under these circumstances, where the driver's direct field of vision
is inadequate to ensure safety then visibility aids or other suitable devices should be provided
so far as is reasonably practicable. Regulation 17 requires that operators of mobile equipment should be able to see anyone who may be put at risk when any control is operated.
Therefore, if direct vision is impaired, then mirrors or more sophisticated visual or sensing facilities may be necessary. Regulation 28(e) requires, so far as is reasonably practicable, mobile work equipment to have adequate devices to improve the driver's field of vision where
this is otherwise inadequate. Such devices may include mirrors or closed-circuit television
(CCTV) and the provision of these devices can be used to meet the requirements of both
regulations.
Examples of devices which can aid the driver's vision include:
1.
2.
3.
4.

plane, angled and curved mirrors;

Fresnel lenses;
radar; and
CCTV 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.

1.22 - Carriage of Appropriate Fire-Fighting Appliances.

Where escape from self-propelled work equipment in the event of a fire could not be achieved
easily, you should ensure that fire-fighting appliances are carried on that equipment.
This regulation covers the risks to the operators of self-propelled work equipment if the
equipment itself or any load handled by it catches fire. If the operators cannot readily escape
from the equipment (such as from a tower crane), you will need to provide appropriate
equipment for extinguishing the fire. This will depend on the type of equipment and/or any
load it is intended to handle but could include appropriate extinguishers and fire blankets.
For self-propelled work equipment that is used on the public highways carrying a dangerous
load, it may need to carry suitable fire extinguishers under the requirements of the Carriage of
Dangerous Goods and Use of Transportable Pressure Equipment Regulations 2007.

1.23 - Safe Use of Agricultural Tractors.

On average ten people a year die in tractor accidents and there are many major injuries, including amputations and fractures. There are many more accidents which HSE never hears
about. Simple but essential safety steps would have prevented most of them.
Step 1 Before starting:
Before you start a tractor, you must know the basic safety procedures. These are safety
checks and safe stop.
Safety checks:

Am I wearing suitable clothing and footwear?

Have I read and understood the instruction manual?
How am I going to do this work?
Have I carried out pre-start checks of the machinery?
Do I know enough to work safely?

Safe stop:

Make sure the handbrake is fully applied.

Make sure all controls and equipment are left safe.
Stop the engine.
Remove the key.

Always use safe stop:

before leaving your seat; or

when anyone else approaches; or
when anyone else is working on the machine.

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.

1.24 - Tractors - Operator's Position.

Step 2 In position.
A tractor can only be safely operated from the driving seat. You must know how to get in and
get out safely, how to adjust seats and mirrors and how to recognise controls so you are al-

ways in control of your tractor.

Some tractors have controls mounted externally to aid hitching (normally on the rear mudguard) - you will need to take different precautions when operating these.
Key points.
Getting in and out:

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.

Visibility and seat adjustment:

Before carrying out adjustments ensure the tractor is in safe stop.

Check the seat position - can you operate all controls comfortably?
Adjust the seat suspension to your weight.
Make sure mirrors are properly adjusted.
When wearing a seat belt, doublecheck that you can still see clearly.
Make sure mirrors and windows are clean and give full visibility.

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.

1.25 - Checks to be Made Before Powering up the Tractor.

Step 3 Under power

This step is about getting the engine started and making sure it is safe to get on. This is the
time to check the brakes, the steering and other controls. Also check that no one else is in
danger from your tractor.
Key points:

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.

1.26 - Safe Tractor Driving Techniques.

Step 4 Driving.
This is not the last step. A safe tractor operator needs many more skills than the steps listed
so far. You need to be a competent driver before you can operate tractors and other machinery safely.
Above all, watch out for other people and keep your speed down.
Key points Step 4 Driving.
This is not the last step. A safe tractor operator needs many more skills than the steps listed
so far. You need to be a competent driver before you can operate tractors and other machinery safely.
Above all, watch out for other people and keep your speed down.
Key points:

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.

1.27 - Pedestrians & Bystanders Near Tractors.

Step 5 Other People.
Every time you use a tractor, look out for other people, wherever you are, as other workers
are often nearby. Always keep a look out for children.
Key points.
If you are an operator:

Check for bystanders before starting tractors or machines.

Check where assistants are working and make sure you can see them.
Agree a way to work safely and make sure everyone follows it.
Communicate clearly and make sure instructions can be heard and understood.
Only carry someone else if a proper passenger seat is fitted.
Use the horn to warn assistants that you are going to start.

If you are helping a tractor operator:

Agree a way to work safely - and follow it.

If you are using hand signals, agree their meaning beforehand.
Make sure the tractor operator can see you.
Never stand in the line of travel of a tractor or machine.
Find out the safe places to work or stand when near machines.
Listen to and follow instructions.
Do not operate any external controls unless you have been instructed to do so.

If children could be present:

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.

1.28 - Hitching Loads to Tractors.

Step 6 Hitching.
Accidents are common when hitching or unhitching tractor-mounted machines.
To prevent these accidents, remember:
1. Safe stop.
2. Operate controls from the correct position.
3. Never forget your assistants are also at risk.
Key points:

Make sure you use the right hitch system.

Only use controls from the operating position.
Take extra care when using external controls.
Never stand between the tractor and other machines, or behind them unless the trac-

tor is stationary and the driver is aware of your presence.

Never stand with your feet under, on or near drawbars.
Ensure that jacks, skids and other supports are used and maintained.
Communicate clearly if you get help with hitching.

1.29 - Attaching Other Machines & Trailers to Tractors.

Step 7 Other machines and trailers.
Unguarded power take-off (PTO) shafts, machine blockages and maintenance activities
cause many serious injuries.
Correct guarding is essential and you must remember safe stop - this is the most important
step to make sure you can operate other machinery safely.
Key points:
PTO shafts:

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.

Maintaining trailer brakes:

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.

1.30 - Overhead Power Lines & Use of Tractors.

Step 8 Overhead power lines.
Overhead power lines exist on many farms. This step is about dealing with the dangers they
present.
Key points:
Overhead power lines:

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.

1.31 - Dangers of Tractors Overturning.

Step 9 Overturning.
A tractor can overturn anywhere - on silage clamps, near field drains and even on the flat.
Most overturns happen on slopes. You must know and recognise the dangers of slopes.
Accidents happen because drivers misjudge slopes, ignore changing ground conditions and
forget the effect of loads on stability - do not drive on slopes until you are properly trained.
Key points:

Remember, overturning can happen on flat ground as well as on slopes.

Remember, although a tractor can be driven up a slope with a hard surface, it cannot
necessarily come down the same slope safely.
Always couple and use trailer and trailed equipment brakes.
Use seat belts if they are fitted. If they are not, get them fitted. You are at risk even if
you have a cab.
Make sure a safety cab is fitted - or a roll frame on older tractors (in which case a seat
belt must be fitted and used).
If in doubt, walk the ground before driving over it to check for hollows, hidden logs,
tree stumps, rock outcrops, rabbit holes etc.
Get yourself trained in slope safety.

A safe working system:

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.

Driving across and turning on slopes:

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.

Turning with rear-mounted equipment on a slope:

Add enough front ballast to counterbalance rear-mounted equipment, particularly

when working on slopes. But remember, using such ballast may reduce safety when
travelling downhill.
Remember when using rear-mounted fertiliser spreaders or sprayers, the tractor rearwheel grip reduces as the load is discharged.
Remember the steady weight reduction reduces traction and increases the possibility
of sliding, especially when coming down the slope.
The higher the mounted equipment is on the tractor's rear linkage, the less stable the
tractor becomes. Keep mounted equipment as low as possible (within the constraints
of effective use).
Select the correct gear for the ground conditions and turn slowly, so that the tractor is
under complete control during the manoeuvre.
Do not turn downhill on a slope.
Use a three-point turn on sharp corners.
Take extra care with offset-mounted machines. Turn slowly with the offset load on the
upslope side whenever possible.

Tractor with raised load on the front end:

Ensure enough ballast weight is fitted to the rear.

Make sure the loader is not overloaded (consult the manufacturer's handbook).

Whenever possible lower the loader for travel.

Do not drive at speed, make abrupt turns, or suddenly stop with the loader raised.
Plan fore-end loader work to minimise travel with the loader raised.

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.

Hitching chains or tow ropes:

Always hitch as low as possible.

Never hitch above the axle.
A chain or towrope hitched too high could cause rearward overturn of the towing tractor even on level ground.

Freeing a bogged-down tractor:

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.

Winching with tractor-mounted winches:

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.

Driving near a ditch or bank:

Keep away from banks and ditches, especially when turning.

If you cannot avoid driving near to ditches or banks take extreme care, particularly
where the surface is loose or wet or where the edge is concealed by undergrowth.
Make headlands wide enough for safe turning.

Using a tractor to stack or consolidate silage

This is a job for the experienced driver only:

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.

2 - Lifting equipment: hazards and control measures.

Safe Use Of Cranes.
To meet the requirements of our changing engineering and built environments, there is a
need for a variety of different cranes. Therefore, cranes come in a variety of sizes and lifting
capacities.
The capacity of a crane is its maximum lift in perfect conditions. If the working conditions are
not perfect, a competent person may increase the factor of safety, reducing the maximum
load capacity.
The stability of any crane is based on weight and geometry, The angle of the jib has a large
bearing on the maximum weight any crane can lift. With the jib of the crane at near vertical,
the crane can lift its maximum weight. With the jib reaching as far away from the crane, the
maximum weight is greatly reduced. All cranes come with load-radius charts, which give the
maximum load at specified radii from the crane.
No matter how large the capacity of the crane, it can only lift its maximum load if it is sited on
a suitable, level working area. It should always be remembered that the capacity of any lifting
appliance is the safe working load (SWL) of its weakest link. Crane stability depends upon
setting up a system of work, which minimises the risk of overturning or other failure.
The safe system will include:
1.
2.
3.
4.
5.
6.

Planning the lift.

Selection of correct crane.
Selection of correct lifting accessories.
Selection and provision of trained and certificated staff.
Ensuring test certificates, etc., available and in order.
Controls to prevent unplanned lifts or movements.

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:

Weight and dimensions of loads.

Heights of lifts and distances/areas of movement of loads.
Number and frequency of lifts.
Length of time the crane will be required.
Site ground conditions.
Space available for crane access, erection, operation and dismantling.
Other special operational requirements (e.g. adjacent operations).

2.1 - Crane Types.

The main types of crane in regular use are as follows:
Lorry-mounted hydraulic cranes.

Figure 1. Lorry-mounted Hiab.

These cranes have the arm mounted behind the cab, or the mounting is along the lorry bed,
and has sufficient reach across the bed of the lorry to load and unload goods. Often known by
the trade name of 'HIAB'. This type of Hiab crane is very versatile and can also be fitted with
many different attachments. Dependant upon the lorry use, these include pallet forks and
gravity clamps.

Figure 2. Wheel Mounted Crane.

As one of the most versatile and easily-manoeuvred cranes, the wheeled mounted crane is
seen in numerous environments. Rough terrain wheeled cranes are usually fitted with a telescopic jib. These are very mobile and suitable for repetitive small lifts, making them useful
around a construction site. With this flexibility in mind, it must be remembered that this type of
crane can be easily abused and therefore additional supervision may be required.
The majority of large lifts are completed by contractors who specialise in heavy lifts. Most of
the bigger road mobile cranes have a large chassis and either a lattice or a telescopic jib, and
are owned by this type of contractor. It is not unusual that for a single large lift, the erection
and dismantling time is often far longer than the lift time itself.
Road mobiles normally have outriggers fitted. They extend from the chassis of the crane and
are used to support the weight of both the crane and the load, lifting the running wheels clear
of the ground. When using the outriggers, it is important to realise that whilst their use can
increase the capacity of the crane, they increase its size. The outriggers must be on firm
foundations such as solid timber packing, steel plates or even specially-cast concrete pads.

Figure 3. Extended Outrigger.

Crawler or tracked type cranes.

Figure 4. Crawler Mounted Crane.

These are used where ground conditions are poor. They use a lattice jib, which can be ex-

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.

Figure 5. Watson Piling Attachment.

Tower Cranes.

Figure 6. Tower Crane.

These cranes consist of a tall, slender lattice mast with a jib unit at the top. They are used on
long duration work on construction sites, where large areas of access are required to be covered with the loads. Various types are available for special situations. They are normally fixed
to one location, which will give it a higher maximum capacity, but can also be mounted on
rails, which would reduce the load capacity.
Gantry cranes.

Figure 7. Gantry Cranes.

Gantry cranes consist of a framework of two vertical supports connected with a horizontal
beam or lattice, along which a trolley moves. The bases of the upright have wheels fitted
which run on railway tracks, allowing the gantry to move backwards and forwards.
The area, which can be covered, is the full length of the gantry rails and the width between,
but whilst giving great flexibility within the area, they cannot provide lifting capability outside.
Some are fitted with rubber wheels, which can steer and drive the gantry and they are used

extensively for handling freight containers.

Overhead cranes.

Figure 8. Overhead Crane.

A version of gantry cranes used generally within buildings, although they can be found in outside situations. The verticals of the frame are omitted, the rails being attached to the structural steel framework of the building or on columns outside at a high level. They are common
in engineering works and plants where lifting access for conventional cranes is difficult due to
the layout (e.g. in power stations, to lift out turbines for maintenance). Capacity can be very
high (200 tons is not unusual) and they are usually designed for a specific location.
Derrick cranes.

Figure 9. Derricking crane with limited area of swing.

2.2 - Description of Hazards Associated with Cranes & Lifting Operations.

Associated hazards when using any lifting equipment are:
Unstable ground.
Is the ground the lifting appliance standing on capable of withstanding the load, are there any
underground service i.e. caverns or cellars?
Exceeding the safe working load.
Is the lifting appliances Safe Working Load sufficient for the load to be lifted at the correct radii?
Overhead Obstructions.
Are there any overhead Electricity cables in the vicinity of the lift or the slewing radius?
Other overhead obstructions could also include aircraft etc.
Weather Conditions.
Have weather conditions been taken into consideration i.e. wind speed?
Working condition of Lifting Appliance.

Has the lifting appliance received the following inspections for safe working:

Test certificate (if required).

12-month inspection.
6-month inspection of lifting accessories.
operator weekly inspections.
operator daily inspections (visual checks, lubrication levels and tyre pressures etc).

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.

Figure 1. Lucky Crane Driver.

Crane incident Fig. 2.

Crane incident fig. 3.

Crane incident fig. 4.

Crane incident fig. 5.

Crane incident fig. 6.

Crane incident fig. 7.

Crane incident fig. 8.

This is a reminder to take all "lifts" seriously, from the lightest and least complex to the
heaviest and most complex. Proper rigging and securing of loads SAVES LIVES.
Amazingly (and thankfully), the operator suffered only minor scratches in one leg.

2.3 - Description of Precautions in Use of Cranes.

Site Conditions.

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.

Planning the Lift.

When planning any lift, a number of key items have to be considered:

The correct crane has been arranged and supplied.

Crane access, egress and movement space is adequate.
Ground conditions are capable of taking the load.
The crane is level.
Any underground services are protected (from the load, if it is to be placed on the
ground).
There are no overhead or side obstructions (at least 600 mm clearance is required).
Any overhead power cables are isolated.
The area around the lift is demarcated and only necessary persons are within it during
the lift (it may be necessary to plan a viewing area if visitors are expected to watch the
lift).
Load(s) to be lifted are determined reasonably accurately (to include the weight of the
lifting accessories).
The load is within the load radius capacity of the crane.
The load is free to be lifted (it is quite common when lifting out an existing component
to find unknown fastenings still holding, which increases the load the crane is trying to
lift).
Location of lifting points ensures that the lift is level and does not tilt because it is out
of balance.
Lifting points sufficiently strong to take the load.
There are no persons under the load AT ANY TIME.
The crane driver is given clear instruction by the banksman, either by hand signal or
by radio.
All involved understand their role in the lifting operation and are competent to undertake it.
All checks on crane and operator documentation are made and the documentation is
correct.

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.

2.4 - Outline of Types of Lifting Equipment, Factors Influencing Choice, Limitation of

Various Types.
Other Lifting Equipment.
There are a number of types of lifting equipment other than cranes, which are used in specific
locations for the raising, and lowering of loads. Whilst cranes, forklift trucks, etc, may seem
an obvious first choice, the other types of lifting equipment and their areas of use and
limitations should be known and understood.
Teagles.
The term teagle is a variation of the term tackle. Warehouses or tall buildings frequently use
teagle-lifting systems for raising loads to various floor levels, where access is gained through

a doorway called a teagle opening.

The teagle can be a simple system using a heavy protruding beam, which should show a safe
working load, with a gin wheel manually operated, or more sophisticated with equipment
which is mechanically operated. A continuing hazard in the use of teagles arises from people
falling from the teagle opening, which must be securely fenced; inexpensive gates or fixed
bars are available for this purpose.
Blocks and Tackle.

Figure 1.Block and Tackle.

Two Fall Block.
Blocks are usually made of metal but wooden blocks may still be found in use. The sheaves
of the block are grooves to take the rope. The diameter of the sheave is made to suit the size
of the rope used in the tackle. Each block must be clearly marked for identification and its
SWL shown. If exposed to conditions causing deterioration, they should be inspected at least
every 12 months, if used for goods, and after every exceptional circumstance liable to stress
the equipment.
Jacks.
Jacks are commonly used in lifting operations. There are no statutory requirements relating to
their design, capacity, testing, examination or use, but to ensure safe working they must be
treated as other lifting equipment in terms of their safety and safe use. There are three main
types of jack in use: screw (bottle), ratchet and hydraulic.

Figure 2 - 4. Screw Type, Ratchet Type, Hydraulic Type.

Winches.
A winch may be defined as a hauling apparatus consisting essentially of a revolving
horizontal drum onto which wire ropes or chains may be wound. It may be operated manually
by a crank or have a power drive.

Figure 5. Hydraulic Winch.

2.5 - Description of Maintenance, Inspection & Statutory Examination of Cranes &

Lifting Equipment.
Lifting Operations and Lifting Equipment Regulations 1998 (LOLER 98).
These regulations came into force 5th December 1998.
They implement the Lifting provisions of the Amending Directive to the Use of Work Equipment Directive (AUWED, 95/63/EC). The Regulations apply in all premises and work situations subject to the HSW Act and build on the requirements of the Provisions and Use of
Work Equipment Regulations 1998 (PUWER).
There is an Approved Code of Practice approved by the Health and Safety Commission
(available from HSE Books - ISBN 0 7176 1628 2 - ref: L113).
Those persons who hold responsibilities are:

those in control of equipment,

employers and,
employees.

Overall scope covers.

The initial integrity of equipment.

The planning of lifting operations - all operations to be assessed for risk.
Safe operation of equipment - need to be recorded in a procedure.
Continuing integrity of equipment - appropriate checking.
Regulation 2 (1) - defines 'lifting equipment' as 'work equipment for lifting or lowering
loads and includes its attachments used for anchoring, fixing or supporting it'.

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:

A passenger lift in an office block.

A rope and pulley used to raise a bucket of cement on a building site.
A dumb waiter in a restaurant or hotel.
A vacuum lifting crane.
A vehicle inspection hoist.
A scissors lift.

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,

particularly if they erect the crane.

The user has the duty to manage the subsequent lifting operations in a safe manner. The
user (as an employer or a self-employed person) also has the duty to ensure that periodic,
thorough examinations are undertaken at the frequencies laid down in LOLER or the
examination scheme, if there is one. The user may well come to an arrangement with the
hirer under which the hirer carries out the thorough examinations, but that does not alter the
user's duty to make sure they are done.
Crane for hire for contract lifting operations.
This refers to the situation where an organisation enters into a contract with a third party who
will undertake the lifting operation on their behalf, i.e. the third party provides the crane and
the operator. In these circumstances, the crane owner has the duty to ensure that the crane is
properly maintained, examined and safe to use and that the lifting operation is carried out
safely.
Further advice on contract lifting operations is given in BS7121.

Figure 1. Refuse collection vehicle.

Refuse collection vehicle.
The mechanism on the rear of a refuse collection vehicle for raising the bins to empty the
rubbish into the compactor is lifting equipment and is covered by LOLER.

Figure 2. Patient hoists.

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:

How often the lifting equipment will be used.

Where the lifting equipment will be used.
The nature and characteristics of the load that the lifting equipment will lift.
Any limitations on use specified by the manufacturer or supplier.It must cover means
of access, ergonomic risks, weather conditions in open-air operations, etc.

Strength and Stability (Regulation 4)

Every employer shall ensure that:

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:

Defective Part Identification

Address of examination
Recommended remedies
Name and address of employer
Equipment Description
Deadline of next examination
Previous exam dates
Report date
Examination date
Competent persons date
Authenticator's details
Safe to operate
Test details
Safe working load

Reports and Defects (Regulation 10).

A person making a thorough examination for an employer under Regulation 9 must:
1. notify the employer of any defect in the lifting equipment which in his opinion is or
could become a danger to persons;(

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.

Lifting Accessories (Previously known as lifting tackle).

Ropes, wires, chains (lifting accessories) used on mechanical lifting equipment provide the
linking systems between the apparatus generating mechanical advantage and the loads
being moved or supported. The term "lifting accessories" covers such things as chain and
rope slings, rings, hooks, shackles and swivels, i.e. connecting units.
The main requirements relating to lifting accessories are as follows:

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.

Figure 3. Fibre Ropes

Fibre Ropes
The term "fibre rope" is a general expression, which covers natural or man-made fibre ropes.

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.

Figure 4. Natural Fibre Ropes.

Natural Sisal
The use of ropes made from natural fibres goes a long way back into history. Pulling heavy
objects over rollers with ropes was one of the earliest methods for moving loads. In
conjunction with inclined planes, the Egyptians used the technique for building the pyramids.
Manilla and sisal ropes are mainly used for lifting purposes and have superseded hemp
ropes.
Size for size, best grade manilla rope is superior to sisal rope.
Problems with Fibre Ropes.
Natural fibre ropes shrink when wet (a problem well-known to campers) and often have
reduced strength owing to uneven distortion of the rope structure. In freezing conditions this
problem can be exaggerated and it is important never to use a frozen natural fibre rope; it
must be thawed out first (and dried if possible). Natural ropes can be degraded by attack from
chemicals, fungal growths and weathering; i.e. sunlight, wet, hot and cold conditions.
Man-made Fibre Ropes.

Man-made fibre ropes consist of the following types of material:

Nylon or polyamide.
Terylene or polyester.
Polypropene (polypropylene) and polythene (polyethylene).

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.

Figure 5. Nylon Rope

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

Sisal and manilla grade 2

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.

Figure 6. Wire Rope Cores

6 x 19 Rope
The flexibility of a wire rope is mainly dependent upon the number of wires in the strand;
therefore the greater the number of wires, the greater the flexibility. Wire ropes can have a
fibre rope core, but sometimes wire cores are used although they reduce the flexibility of a
rope. The wire rope lay can have a tendency to unwind in use, but pre-formed wire ropes are
available that resist this effect.

Figure 7. Kinking of wire rope

Wire Rope Safety.
A good guide to the safe condition of a wire rope is the number of broken wires which are
visible. In a length of rope ten diameters long, there should be no more than 5% of the total
number of wires broken.
Example:
Consider a 1.3 cm diameter 6x19 wire rope. 10 diameters gives a length of 13 cm with 114
wires.
5% of 114 = 6, therefore in 13 cm of this rope, there should not be more than 6 wires broken.
The factor of safety for wire ropes used in factories is 6, derived from:

= Safe Working Load

Breaking Load
6

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.

Figure 8. Wire Rope Grips (Bulldog Clips).

Chains.
Chains of mild steel, high tensile steel and grade 60 alloy steel are each joined by using
connector links made of the corresponding material, and these are secured by welding, using
the atomic hydrogen process. After welding, either the links must be heat-treated individually
or the whole chain must be re-treated.
Grade 80 alloy steel chain is joined using mechanical joints which do not have to be welded,
thus avoiding the need for heat treatment. Two systems are available in the United Kingdom:
Rammerlock by Wheway Watson.
Kuplex by Parsons Chain Company Limited.
Each joining component must be individually tested and have its own test certificate. A
completed sling does not require testing, but any test certificate must include the details of
the component test certificate.

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:

Figure 9. Sling Angle Factor

You will appreciate that with the various slinging systems it is possible that a variety of sling
angles can be formed. It is considered good safety practice to operate sling angles at a
maximum of 90 where slings hang from a hook or ring, as illustrated below.

Figure 10. Angle between legs.

Storage of Ropes, Wires, Chains and Lifting Accessories.
The storage of ropes, wires, chains and lifting accessories is a very important aspect of safety
control of such equipment. Apart from the statutory obligations which require equipment to be
marked for identification and to indicate, where applicable, the safe working load, and that
registers and maintenance records are kept, there is superimposed upon those a wider
problem of administrative control. This requires the provision of suitable storage facilities, the
running of an efficient stores system by trained storemen, clear lines of supervisory
responsibility when equipment has left storage, temporary storage while in use, and safe
return of equipment together with a fault or damage report if required. All this requires an
efficient service administration, which will cost money.
It will be the lot of the safety worker to show that care for equipment is in the long run a

"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.

2.6 - Hoists & Lifts.

A lift or hoist is a lifting device which has a platform or cage and where the direction of
movement is restricted by a guide or guides. In practice, a lift will have some form of cage
around the platform, whilst a hoist is open. For the movement of loads vertically, hoists and
lifts are frequently selected.
The styles and types vary according to the work and the work environment. The simplest form
of hoists is the cantilever type used on construction sites.
Gin Wheels.

Figure 1. Gin Wheel.

A gin wheel is a single pulley block. It is very important that the gin wheel is securely attached
to its support, that it does not move about on the support and the support is able to carry the
total weight of the system. A safe working platform should be available for the loading and
unloading of items. Checks should be made to ensure the free-running of wheels and ensure
that they have not rusted up.
Hoist/lift for passenger and goods (including construction site platform).
Hoists and Lifts.
The drive systems utilised are:

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.

The hoist/lift may overturn or collapse.

The hoist/lift can strike persons who may be near or under the platform or cage during
normal operations.
The supporting ropes may fail and the platform/cage may fall to the ground.
The hoist/lift may fail in a high position.
If the hoist/lift fails the person being carried may become stranded.

Safe use and maintenance.

The legal requirements for hoists and lifts were largely contained within Sections 22, 23 and
25 of the Factories Act 1961 (for factories) and the Construction (Lifting Operations)
Regulations 1961 (for construction sites). These sector-specific laws have been replaced by
industry-wide legislation - PUWER 98 and LOLER.
As regards hoists and lifts, the key points from the regulations and guidance are:

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.

Mobile Elevating Work Platform (MEWP).

Mobile Elevating Work Platforms (MEWPs) are classified as lifting equipment for lifting
persons. They can provide excellent safe access to high level work but are particularly suited
to tasks of a short duration.
Hazards.
The primary hazards associated with the use of MEWPs are:

Collapse or overturning of the MEWP.

People falling or being thrown from the carrier or basket.
People in the carrier being trapped against fixed structures.

Factors in collapse or overturning incidents typically include:

MEWP being struck by a vehicle or other mobile plant.

Overloading a carrier.
Carrier struck by a load.
Equipment failure.
Ground Conditions.
Outriggers not being used or faulty.

Factors in people falling or being thrown from the carrier typically include:

Overreaching from the carrier.

Climbing in or out of an elevated carrier.
Sudden movements caused by an impact.
Ground movement.

Precautions.

Whoever is operating it is fully trained and competent.

The work platform is fitted with guard rails and toe boards.
It is used on suitable firm and level ground. The ground may have to be prepared in
advance.
Tyres are properly inflated.
The work area is cordoned off to prevent access below the work platform.
That it is well lit if being used on a public highway in poor lighting.
Outriggers are extended and chocked as necessary before raising the platform.
All involved know what to do if the machine fails with the platform in the raised posi-

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

2.7 - Safe Use of Conveyors.

Conveyors are designed to transport goods and materials between stages of a process and
to minimise the amount of manual handling of loads. The most common types of conveyor in
use are belt, roller, plate, screw and monorail. The main hazards associated with them are
trapping points at in-running nips, entanglement points at rollers and drive mechanisms, contact points with moving parts such as in screw conveyors, and materials falling from the
transporting surface. They can contribute to musculoskeletal disorders, if they are not designed and selected with the task and users in mind.

2.8 - Belt Conveyors.

A belt conveyor transports materials by means of a moving belt. This type of conveyor can be
used for horizontal and incline travel.
Guards are required at the trapping points where in-running nips are created between the belt
and rotating drums. In some cases guards or trip devices will be required along the complete
length of the conveyor and at areas where belts change direction. Belt conveyors should be

fitted with emergency trip wires or stop buttons which must be fully operative at all times.

2.9 - Roller Conveyors.

The rollers of these conveyors may be power-driven or free-running and can also be used for
horizontal and incline travel. Dangerous parts, such as power drives and in-running nips,
should be guarded.
The main hazards associated with belt and/or roller conveyors are:
(a) In-running nips:

Between the belt and head and tail pulleys.

Between the belt and idler rollers.
Between rollers of a roller conveyor.

(b)Trapping:

Or entanglement with transmission machinery e.g. rotating shafts, couplings, chains

etc.
At transfer point between belt conveyor and a roller conveyor and a roller conveyor.
Between the load being carried and a fixed structure.

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:

All rollers should be power-driven.

Suitable emergency stops should be installed.
Safe system of work should be adopted for long conveyor systems.

2.10 - Screw Conveyors.

Materials are moved by means of a rotating screw which pushes the material forward. Access
to screw conveyors should be prevented at all times by the provision of guards or covers,
which should not be removed unless the conveyor is locked off.
Monorails involve the use of a single rail and generally this is elevated with the carrier
mounted below. These are primarily used for moving bulky material, such as extracted minerals around from two fixed locations. Many factories and workshops use the principle of the
monorail where lifting chains can be found mounted on a wheeled trolley that runs on the bottom flange of an "I" beam. The disadvantage of monorails is that jobs can only travel along
the rail at set speeds and the whole conveyor does have to be halted if one is to be removed.
People should be prevented from walking under or between objects carried on a monorail as

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.

2.11 - Plate Conveyor.

These vary depending on the application but are used for carrying heavy weights and difficult
items.

2.12 - Safe Use of Automated Warehousing Systems.

What is an automated warehousing system (AWS)?
An automated warehousing system is designed to increase the efficiency of warehousing operations, i.e. the handling, movement and storage of goods with the use of automatic vehicles
controlled by computer software. In reducing the human element and the need for manual
handling, injuries sustained through such activities can be minimised.
Storage of Goods.
Goods arrive at 'Goods in' usually on pallets where they are off-loaded by mechanical handling devices; lift trucks and conveyors. This palletised load is transferred from these mechanical handling devices to the automated guided vehicles, usually via an opening in the
perimeter fence surrounding the storage area. Automatic guided vehicles move goods from
the transfer point, where they are transferred onto a stacking machine, and then placed into
storage racking. During this process, the information relating to the item contained within the
bar code is scanned and held on a database as stock information.
Retrieval of Goods.
When goods are to be retrieved, they are removed from the storage racking by an automated
order picking machine, and again the information on the barcode is scanned and the stock
information updated. The goods are taken by a goods retrieval machine to the transfer point,
ready for mechanical handling at the despatch through to the 'goods out' area. The following
schematic illustrates how the goods flow through the system.

Source: HS(G)76 Health and Safety in Retail and Wholesale Warehouses

Hazards in the use of Automated Guided Vehicles.
Control system hazards.
Software can become attacked by viruses which may cause automated guided vehicles to
function differently from their intended programming. If they do malfunction, this could cause
damage to racking and other equipment operating in the vicinity, and cause disruption to the
whole system and system failure.
Hazards at transfer points include:

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.

Hazards with the use of Automated Guided Vehicles (AGVs) include:

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.

Hazards in an automated storage area include:

being struck by an automated storage and retrieval machine;

being caught in trapping points between automated storage and retrieval machines
and racking.
trapping points at transfer points for goods and between dangerous moving parts of
the automated storage and retrieval machine;
collapse of an automated storage and retrieval machine or fall of load;
overrun of automated storage machine in horizontal or vertical travel;

inadvertent movement of an automated storage and retrieval machine.

Control System Precautions.

Software must be evaluated and protected from viruses. It is also important that safeguards
are built into the software to prevent a movement of inappropriate material to the workplace.
Precautions at Transfer Points.
Transfer points should be designed to allow the passage of goods, but not people. The size of
openings should be kept to a minimum for these purposes.
Trapping points and dangerous moving parts on machinery should be suitably guarded
following the hierarchy of machine guarding detailed in Regulation 11 of the Provision and
Use of Work Equipment Regulations (PUWER) 1998. (Refer to Element C6)
Precautions in the use of Automated Guided Vehicles.
Pedestrians should be segregated from areas where AGVs operate. You will remember
Regulation 17 of the Workplace, (Health, Safety and Welfare) Regulations 1992, stated the
requirement for the segregation of vehicles and pedestrians.
Computer monitoring of the condition of the AGVs could ensure that when faults are detected
by software such as faulty sensors, the vehicle is automatically stopped.
Trip devices fitted to the front and rear bumpers of the vehicle and trip whiskers, optical
devices or probes will stop the vehicles when activated and prevent collision with pedestrians,
vehicles or storage racking.
The installation of emergency stop buttons which are accessible from all sides can be
activated when necessary.
Fitting of speed control devices which automatically reduce the speed of the AGV when
obstacles are put in its path could prevent collision.
Signals both audible and visual can warn people that the vehicle is moving or about to move,
or that an obstacle has been detected.
Precautions in Storage areas include:

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.

Element C7: Summary.

Where automation of the process of handling loads is not appropriate, suitable mechanical
handling aids can be used to reduce the amount of manual handling necessary, although they
often have risks associated with them. The most widespread mechanical aids are cranes,
powered industrial trucks, fork lifts and conveyors. The basic principles that the equipment

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:

atomic guidance vehicles

Response 1:
Jump 1:

This page

Answer 2:

automatic guided vehicles

Response 2:
Jump 2:

Next page

Answer 3:

associated goods vehicles

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).

3.1 - Mobile Elevated Working Platforms.

Mobile elevating work platforms (MEWPs) can provide a safe way of working at height.
They:

Allow the worker to reach the task quickly and easily.

Have guard rails and toe boards which prevent a person falling.
Can be used in-doors or out.

MEWPs include cherry pickers, scissor lifts and vehicle-mounted booms. A familiarity
with them will enable you to:

choose the right MEWP for the job.

identify and manage the risks involved with working from MEWPs.

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?

3.2 - Control and Safety Measures for the use of MEWPs.

Accidents from mobile elevated work platforms (M.E.W.P.s) primarily come from:

Failure of critical mechanical parts of the M.E.W.P.

Unsuitable ground conditions.
Serious falls from the M.E.W.P.
Contact with a vehicle.

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:

General visual inspection of machine.

Check all bolts, screws and hoses fit tightly and that there are no oil leaks.
Check the arms, boon, jib and platform for visible damage or wear.
Check cylinder rods for leaks, wear and scratches.
Check wheel-reducing gears for leaks.
Check wheel nuts and tyre wear.
Check battery terminals are clean and tight.
Check fluid levels in battery and top up if necessary.
Check main control panel power cable is in good condition.
Check emergency stop works.
Check air filter is clean.
Check levels of motor oil, hydraulic oil and diesel level and top up if necessary.
Check the hydraulic filter-clogging indicator.
Check the tilt detector is functioning by tilting spirit level- alarm should sound beyond
5 degree angle.

Serious falls from the M.E.W.P.

Always use a fall protection system attached to the appropriate anchorage point inside the
cage:

Hold the guardrail firmly when operating or driving

Remove any traces of oil or grease from the platform steps, guardrails or floor
Wear personal protective equipment
Never disable safety switches or safety devices
Risks of jerky movements are high when:
Sudden action on the controls
Overloading the platform
Do not take stepladders in the cradle to increase working height
Never use the guardrails to climb on to increase working height
Uneven ground, especially when moving whilst at height
Gusts of wind
Always close the safety gate to the cradle

Suitable ground conditions:

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:

On soft unstable ground.

On ground slopes of 5 degrees and over.
In winds greater than permissible limit.
Near power lines.
In temperatures less than 15 degrees centigrade.
In poorly ventilated areas.
During storms (risk of lightning strike).
In the dark (unless floodlit).
With a load exceeding maximum load.
With more than the maximum number of operatives in the cradle.

Contact with a vehicle.

To limit the risks involved in contact with a vehicle appropriate barriers to separate the work
area from all traffic must be put in place. Also, to prevent pedestrians from entering the
workspace, signs must be in place. The operative must be familiar with the machines controls
and have been trained to use the M.E.W.P.

3.3 - Falls from MEWPs - Control Measures.

Background.
Between 1995/96 and 2001/02 five fatal accidents involving MEWPs were reported to HSE' s
Field Operations Directorate (FOD). The MEWPs involved had been struck by vehicles, suf
fered a failure or the ground had given way.
An analysis was made of incidents relating to:

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).

The following primary causes were identified:

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)?

Controlling the risk.

Firstly assess whether risks can be eliminated, for example:

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.

Ensure competent personnel undertake planned maintenance in accordance with the

manufacturer's instructions. These are complex pieces of work equipment that need to
be maintained. In particular, inadequate lubrication and electrical repairs have caused
problems (e.g. a fault from an electrical repair has caused outriggers to raise while in
use).
After a hydraulic levelling system hose failure, establish whether the carrier tilt will lock
when it is brought back to ground level. If it does, people are at risk of being tipped
out.

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)?

Use of fall protection.

If there is still a residual risk of impact or persons falling after you have assessed the
risks and put the control measures in place, then the use of fall protection equipment
should be considered, for example:

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.

Work restraint system.

A work restraint system for use on a MEWP should normally be a combination of a full body
harness (BS EN 3612) and a lanyard (BS EN 3543). It does not normally have
shockabsorbing capability.
It is becoming a common practice to use retractable lanyards to provide the occupants with
maximum freedom of movement, together with immediate restraint in the event of impact or
levelling system failure. The use of retractable lanyards for this purpose should only be

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:

Provision and Use of Work Equipment Regulations 1998;

Lifting Operations and Lifting Equipment Regulations 1998;
Personal Protective Equipment at Work Regulations 1992;
Construction (Design and Management Regulations) 1994;
Construction (Health, Safety and Welfare) Regulations 1996;
Workplace (Health, Safety and Welfare) Regulations 1992;
The Work at Height Regulations.

3.4 - Trapping and Crushing Injuries to users of MEWPs.

The Trapping/Crushing Risk.
MEWPs are acknowledged to be the safest and most efficient means of providing temporary
access at height for many work activities. In some work situations, however, MEWP
operators, particularly of boomtype MEWPs, have been trapped/crushed between the MEWP
platform/basket and an overhead obstruction. This has resulted in a significant number of
serious accidents, including several deaths, in the UK in recent years. In some of these
accidents, the operator's body was trapped/crushed over the control panel, trapping the
controls in the "on position" and making the crushing worse.
Common reasons for accidents include any of the following while operating a MEWP
close to an overhead obstruction:

Reversing, Slewing or Elevating into an obstruction.

Unexpected movement of the boom near to an obstruction.

What factors increase the risk?

The factors listed below may increase risk when operating a MEWP close to an
overhead obstruction.

Poor MEWP route planning.

Poor MEWP selection.
Insufficient MEWP familiarisation.
Uneven ground.
Poor visibility at height.
Distractions when operating MEWP.
Objects placed on the control panel.
High drive speeds, or lack of care.
Overriding MEWP controls.
Using faulty or poorly maintained MEWPs.

Note: MEWPs should only be operated by trained operators.

Common Rescue Problems.
Once trapped, rescue can often be hampered because:

No-one knows the person is trapped.

No emergency rescue plan.
No key in ground level controls (this limts the ability to use ground level controls in an
emergency).
Lack of familiarity with ground / emergency descent controls (ground operatives who
have never practised using the ground/rescue controls, and cannot therefore safely
bring the basket down in an emergency).
Overload cell has been activated (this can affect the operation of the controls).
Emergency stop has been activated (this can restrict the ability of the operator to be
rescued).
Complicated boom manoeuvre.

Rehearse rescue procedure.

The following points should have been considered before using the MEWP. In extreme cases,
and/or where an operation involves repeatedly working close to an obstruction, an observed
"dry run" could be appropriate, to look for potential entrapment risks that could result in a
rescue being required.
Ensure ground key available:

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.

Appoint a ground rescue person:

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.

Consider how to raise the alarm:

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.

The order of priority should be:

1) Operator: the operator, or other competent people in the basket, should try to rescue
themselves by re-tracing the steps they took in reverse order.
2) Ground staff: if visibility and understanding of situation from the ground are good, ground
staff should effect a rescue using the ground controls in the following order:

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.

3.5 - Hold to Run Controls.

Machines and plant which of necessity need to be run with the guards open to
facilitate adjustment and setting should be provided with special hold-to-run controls
whose essential features are:

Only one hold-to-run control to a machine.

When the hold-to-run control is selected, all other controls are isolated.
Movement of the machine will occur only when the control button is depressed.
On release of the control button, the machine stops.
The speed of movement of the machine is the minimum possible to carry out the setting or adjustment (about 10% of maximum speed).
On large or long machines, the control can be on a single wander lead covering the
length of the machine; or
The device can be plugged into one of a number of local sockets when all the other
local sockets must automatically become inactive; or
Local hold-to-run control panels can be positioned around the machine where selection of any one isolates all others.
Emergency stop switches should override the hold to run control.

3.6 - Tilt Sensors & Controls.

Mobile Working Platforms often come equipped with a variety of tilt sensors. The most
commonly activated sensor (especially with two people on a lift), will cause the machine to
refuse to raise the platform beyond a certain height. Sensors within the machine detect that
weight on the platform is off balance to such a point as to risk a possible tip-over if the
platform is raised further. Another sensor will refuse to extend the platform if the machine is

on a significant incline. Some models additionally feature counterweights, which extend in

order to offset the danger of tipping the machine inherent in extending items like booms or
bridges. Some lifts are also fitted with sensors which will prevent operation if the weight on
the platform exceeds the safe working load.