Manually and Mechanically Operated Load Handling Equipment There are many different types of lifting and moving equipment such as manually operated trucks and hoists and mechanically operated forklift trucks, lifts, hoists, conveyors and cranes. Typical hazards associated with lifting and moving equipment are: Collapse or toppling of the equipment. Falls from height. Falling objects. Being struck by the equipment or the load during movement. General precautions for safe use include ensuring that the equipment is: Suitable in terms of strength and stability. Correctly positioned and installed. Visibly marked with the safe working load. Used by competent operators under appropriate competent supervision. Maintained in a safe working condition. Only used for carrying people if it has been designed for that purpose and all additional safety requirements have been implemented. Lifting equipment should be routinely inspected and subjected to a statutory thorough examination by a competent engineer as required by local law. Loads are frequently moved around the workplace using lifting and moving equipment. This equipment may rely on some form of manual effort (such as a trolley, sack truck or pallet truck) or it may be fully mechanised (such as a forklift truck, hoist, conveyor or crane). Though these devices are useful in minimising the risks associated with manual handling, they do present their own hazards. The hazards and safety precautions of various types of lifting and moving equipment now follow. Pedestrian (Manually) Operated Load Handling Equipment There are many different types of pedestrian operated load handling aids and equipment, such as trolleys, sack trucks and pallet trucks. The hazards associated with this type of equipment include: Manual handling risk associated with pushing or pulling the truck. Instability of the load causing the load to fall. Moving up, down or across slopes causing loss of control. Poor parking of the truck causing obstruction in a traffic route. Other pedestrians may be struck during manoeuvring. Trapped feet under the wheels or when lowering the load. Precautions for safe use of manually operated equipment include: Avoidance of uneven ground and slopes. Use of ramps over steps. Observing the safe working load limits of the truck. Securing the load if necessary. Using the brakes (if fitted) whenever the truck is stationary. Care when moving or lowering the load. Safe parking and storage to avoid obstruction. Routine inspection and maintenance. Use of safety shoes or boots to avoid crush injuries. Unit IGC2 Element 3 3-12 RRC Training
Lifts and Hoists A wide variety of items can be included in the phrase lifts and hoists : from a simple manually-operated chain hoist to a passenger lift in a multi-storey building. We will look at larger hoists later. People Hoists and Handling Aids In some sectors workers may have to move people, such as hospital patients and those needing assistance with living requirements in the home. There are a variety of moving and handling aids available which include: Patient hoists can be manual (where the hoist is lifted by operating a manual crank handle) or powered, and may be mobile or permanently mounted in a ceiling track. Hoists should only be used by trained personnel and the safe working load of the hoist should not be exceeded. The suitability of the equipment for the working environment must also be considered, e.g. pushing a mobile hoist on a carpet or over rugs may be difficult. Lifting equipment of this type should be inspected regularly to ensure it remains in good working order. Small handling aids such as slide sheets and transfer boards used to assist the transfer of patients, e.g. from bed to trolley in a hospital. The slide sheet is placed beneath the patient and the person is pulled over the slide onto the bed. This allows for the rapid transfer of the patient without lifting them and is again for use by trained persons. Wheelchairs a form of handling aid, wheelchairs help in the movement of people. Though they can be powered, most wheelchairs used to transfer patients are simply pushed. To make sure that workers are competent to use mobility assistance equipment training in handling techniques should include instruction in the: Different types of equipment available, and their appropriate use. Safe use of hoists and their slings. Recharging of electric hoists. Safe use of the smaller aids, such as handling belts, transfer boards. Identification of possible faults and safety checks that should be made each time before use. Procedures to follow when equipment is damaged and unsafe to use, or if it fails during use. A manual, mobile hoist used to lift patients (Source: http://www.hse.gov.uk/pubns/books/hsg225.htm) RRC Training Unit igc2 Element 3 3-13
Summary of handling options available http://www.hse.gov.uk/pubns/indg398.pdf Mechanically Operated Load Handling Equipment There are several general requirements for safe lifting operations: The equipment should be strong enough for the lifting task (rated for the load to be lifted) and suitable for the operation (e.g. forklift trucks must only carry people if a suitable attachment has been installed, such as a man-rider cage and if the truck has been subjected to any necessary inspections in order to allow the lifting of people). The equipment should be stable and secure, e.g. mobile cranes with outriggers must be located on firm, level ground to avoid the outriggers sinking and the crane tipping. Lifting equipment should be visibly marked with the safe working load (SWL), the maximum load that the device is permitted to lift. Lifting operations should be planned, carried out and supervised by competent persons. For example, though it is possible to hire a crane and a driver, the lift should also be planned and supervised throughout it is common practice to carry out a contract lift whereby the planning and execution of the entire lifting process is contracted out to the hire company. Equipment that is used to lift people may be subject to additional regulatory inspections. Unit IGC2 Element 3 3-14 RRC Training
Forklift Trucks There are many different types of forklift truck, but they share a range of common hazards and safety precautions. The hazards associated with forklift trucks are: Overturn of the truck the narrow and short wheelbase of the truck makes it unstable so it can fall over sideways or tip forwards or backwards very easily. We covered some of the poor practices that might cause a forklift truck to fall over in Element 2. Fall of the load the load may fall from the forks of the truck on to the driver or others standing nearby during a lifting operation. Striking of pedestrians - like all vehicles, a forklift will cause serious injury if it hits a pedestrian. Fall or entrapment of a person riding on the forks workers often use the forks of a forklift as a working platform. This practice may result in a fall from height or the worker becoming trapped between the mast of the forklift and fixed structures. Fall from loading dock another common accident, where the forklift truck either falls through or off the loading dock that it was driving over to access the back of a lorry. The engine type of the forklift truck is also a source of concern: Battery-powered trucks are commonly used in indoor workplaces. Batteries present several hazards in their own right: Charging batteries emit hydrogen gas which is explosive. Batteries contain dilute sulphuric acid which is corrosive. Batteries are extremely heavy and present a manual handling risk if they have to be changed for charging purposes. The electricity can cause arcing, shock, burns or fire. Battery contents are an environmental hazard requiring appropriate disposal. Battery-powered vehicles can be very quiet or almost silent, increasing the risk of collision with pedestrians. Battery leads can short and result in burns and electric shock. Diesel-powered trucks are commonly used outdoors. Hazards include: Dermatitis caused by contact of diesel with the skin. Diesel spills are a significant slip hazard. Large spills might pollute the environment. Exhaust fumes are toxic. Those hazards associated with the bulk storage of diesel. Liquid Petroleum Gas (LPG)-powered trucks have the following hazards: LPG is an explosive gas. Exhaust fumes are toxic. LPG cylinders are heavy and present a manual handling risk during changing. Those hazards associated with the storage of replacement cylinders or bulk storage of LPG. The precautions for safe use of forklift trucks include: Restricting use to trained operators only. Routine visual inspection of the truck before use. Routine maintenance of the truck in accordance with the manufacturer s recommendations. Never using the forklift to lift people unless a proper working platform is attached. Ensuring that the load on the forks is secure and stable. Ensuring that the safe working load limits of the truck are not exceeded. Observing site speed limits. Never travelling with the forks raised. Never travelling with obstructed vision. Highlight sections of the text to make key ideas stand out. This will be very useful when you start your revision. RRC Training Unit igc2 Element 3 3-15
Forklift trucks powered by different types of fuel require different precautions: Battery-powered trucks: Batteries must be charged in well-ventilated areas only, away from ignition sources. Sulphuric acid should only be handled when wearing appropriate PPE (gloves, apron and eye/ face protection). Battery handling should be mechanised. The electrical risk may require the use of insulated tools and gloves. Diesel-powered trucks: Should only be used in a well-ventilated area. Spill kits should be available. Gloves should be worn when handling diesel. LPG-powered trucks: Should only be used in a well-ventilated area. LPG cylinder handling should be mechanised. Spare cylinders must be stored in a secure, safe, well-ventilated location. Hoists We looked at smaller, manually operated people hoists earlier here we consider the larger hoists in use, from passenger lifts to construction site hoists. The main hazards associated with hoists are: Falling objects such as the load falling from the hoist, or the hoist itself falling due to structural failure. Being struck by the load during a lifting operation. Becoming entangled in moving parts. Additional hazards exist when the equipment is used to carry people, such as with a passenger lift: Falls from height from a landing level or from the platform of the lift itself. Being struck by landing levels, parts of any enclosure or other projections while riding on the platform of the lift. Precautions for safe use of hoists and lifts include: Ensuring that the hoist or lift is suitable for its intended use in particular people should only be carried on equipment specifically designed for that purpose. Preventing people from getting underneath the hoist or lift platform or the load during a lifting operation by enclosing the base of the lift or hoist with a fence. Preventing people from gaining access to an unprotected landing edge with a passenger lift, having safety interlocks fitted on the doors at each landing. Preventing people being carried on the lift platform from being struck by landings or other obstructions as the lift moves by constructing an enclosure around the lift platform. Observing the maximum safe working load of the lift or hoist which should be clearly displayed. Ensuring that all safety devices such as brakes, freefall brakes and interlocks are in full working order. Restricting the use of the hoist or lift where necessary to trained, competent people only. Providing information, instruction and training as required. Routine maintenance by competent engineers. Routine inspection and thorough examination as required. A hoist Unit IGC2 Element 3 3-16 RRC Training
Conveyors Conveyors use belts, rollers or screws to move articles or material around and are frequently used in manufacturing and distribution. Cranes Many different types of crane are used in workplaces, from small derricks bolted to the floor at the edge of a loading bay, to large tower cranes positioned at the top of sky-scrapers during construction. We will use a mobile crane as a typical example. A belt conveyor The main hazards associated with conveyors are: In-running nip points - where fingers might be drawn into moving parts. Entanglement where loose clothing might become entangled with rotating parts. Falling objects from overhead conveyor systems. The precautions for safe use of conveyors include: Warning alarms or sirens to alert people that the belt is about to start moving. Guarding of moving parts to prevent drawing in and entanglement as far as is possible. Ensuring that emergency stop buttons or pull-cords are fitted and available for use. Barriers to exclude people from the area (protects also from falling objects). Fitting guards underneath overhead conveyors to catch falling objects. Information, instruction and training for operators. Controlling loose clothing and long hair, e.g. by the use of overalls and hairnets in the workplace. Maintenance by authorised persons only to ensure safe running. Provision of a defect reporting system. Mobile crane The main hazards associated with a mobile crane are: The crane collapsing or toppling over. The arm (jib) of the crane striking against other structures during movement. The load (or part of it) falling. The load striking against objects or people while being manoeuvred. Contact with live overhead cables. RRC Training Unit igc2 Element 3 3-17
Factors that might make a mobile crane unstable and topple over: Overloading the crane beyond its lifting capacity. Siting the crane on uneven or unstable ground. Failure to use the outriggers (legs) correctly. Using the crane in high winds. Extending the jib of the crane too far out for the weight being lifted. Structural failure of parts (perhaps due to lack of maintenance). Using the outriggers correctly. Checking that the crane has been maintained and has a certificate of thorough examination in accordance with local laws. Restricting use of the crane to trained and competent operators only. Ensuring that each lift is planned and supervised by a competent person and that the driver and slinger are competent. Providing a banksman to give directions to the crane operator with good means of communication between driver and other operators. Ensuring that safety devices such as overload indicators are operational and are used correctly these devices are frequently disabled or ignored by the crane operator. Checking that there are no obstructions such as buildings or overhead lines in the vicinity of the lift. Checking weather conditions and obeying any manufacturer s recommendations about maximum wind speed. Lifting the load as close to the ground as possible; never lifting the load directly over a person. Using PPE such hard hats, steel toe-cap boots and hi vis clothing. Using signs to warn of the operations and exclusion of personnel from the area. Slinger The competent person responsible for preparing and slinging a load in readiness for a crane lift, and for attaching or detaching load slings from the crane hook. Unstable load Typical precautions for the safe use of a mobile crane include: Ensuring that the load to be lifted is within the safe lifting capacity of the crane safe lifting capacity will vary with the length of the jib and the distance away from the crane that the jib is positioned to (radius), so capacity can vary from one lift to the next. Carefully siting the crane on even, stable ground in a safe position away from structures or overheads that might be struck during the lifting operation. It is also important to consider the lifting accessories that are used to attach the load to the crane: items such as chains, wire ropes, nylon slings or eye-bolts and shackles. These must be fitted to the load by competent people and be in good condition. They should be regularly checked by pre-use visual inspection and subjected to thorough examination as dictated by local law. Unit IGC2 Element 3 3-18 RRC Training
http://www.hse.gov.uk/pubns/indg398.pdf Crane lift being supervised Periodic Examination and Testing of Lifting Equipment Lifting equipment is placed under a great deal of strain. If it is not maintained in good working order it can fail catastrophically. This will almost certainly happen under load, when the maximum damage will be done. Fatalities frequently occur as a result of catastrophic lifting equipment failures. There are, therefore, legal requirements about the thorough examination and testing of lifting equipment to ensure strength and stability. The legal requirements vary depending on region and type of equipment. In general, lifting equipment should be thoroughly examined: Before it is used for the first time (unless it has an in-date certificate of thorough examination from the manufacturer or previous owner). Before it is used for the first time where the way that it has been installed will make a difference to its strength and stability. Periodically. After an event that may have affected its strength and stability. The frequency of periodic thorough examination will typically be: Every 12 months where it is not used to carry people. Every six months where it is used to carry people. Every six months for lifting accessories. This examination and testing must be carried out by a competent engineer. Revision Questions 11. What are the most common hazards associated with the following lifting/moving equipment? (a) Fork-lift trucks. (b) Sack trucks. (c) Lifts and hoists. (d) Cranes. 12. What personal protective equipment might be appropriate for working with the following lifting/moving equipment? (a) (b) Pallet trucks. Cranes. 13. What are the typical safety precautions for safe use of a mobile crane? (Suggested Answers are at the end of Unit IGC2.) RRC Training Unit igc2 Element 3 3-19