Element C7:

MECHANICAL HANDLING

Learning outcomes. On completion of this element, candidates should be able to: outline the factors which affect the stability of work vehicles; identify the main hazards associated with the use of lift trucks, lifting equipment, hoists, lifts and conveyor equipment and describe appropriate precautions to reduce the risks where possible; outline the specific hazards and safeguards associated with automated warehouses. Relevant statutory provisions: Workplace (Health, Safety and Welfare) Regulations 1992 Provision and Use of Work Equipment Regulations 1998 Lifting Operations and Lifting Equipment Regulations 1998 Minimum hours of tuition: 6 hours.

1 .State the requirements of Regulation 4 of the Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 in relation to Strength and Stability Every employer shall ensure thatA) 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; B) Every part of a load and anything attached to it and used in lifting it is of adequate strength.

2) (i) Identify the factors that can affect the stability of the lifting equipment. Factors contained in the guidance note to Regulation 4 of LOLER include: A) The strength of the ground or surface on which the lifting equipment is positioned or located, e.g. spreader plates may be needed so they can safely support the weight of the equipment and the maximum load to be lifted;

B) The stability of the surface under load conditions; e.g. if the lifting equipment is too close to an excavation the ground may slowly subside or collapse suddenly; C) Whether the surface on which the lifting equipment operates is on a slope and the angle of any slope this imposes horizontal as well as vertical forces; D) The size and nature of the load (eg whether the load itself is unstable); E) How the load is intended to be lifted; and F) The maximum wind loading that may occur

(ii)Identify methods that can be used to improve the stability of lifting equipment. Designing a suitable base on which to position the lifting equipment Using an anchorage system; Using counterbalancing weights; and Using ballast, outriggers or stabilisers

3 State the factors to be considered when selecting and

.

assessing the suitability of lifting tackles (accessories) to be used with a crane in a lifting operation

Carry out initial assessment of the load to be lifted and its weight in order to ensure that accessories are used within their safe working load. The assessment of the type of tackle to be selected would also have to consider: The shape, size and centre of gravity of the load to determine the choice of sling to ensure stability.

The fixing points on the load Any sharp edges, which might need packing to protect the sling and the environment in which the lifting operation is to be undertaken Those carrying out the operation would also have to satisfy themselves that the tackle selected is in good condition with its safe working load marked or indicated, is within the examination date and is fully compatible with the crane with which it is to be used.

4. Define `lifting equipment The Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 defines lifting equipment. "lifting equipment" means work equipment for lifting or lowering loads and includes its attachments used for anchoring, fixing or supporting it

5. State the requirements of Regulation 7 of the

Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 in relation to marking of lifting equipment. Marking of lifting equipment

7. Every employer shall ensure that (a) subject to sub-paragraph (b), machinery and accessories for lifting loads are clearly marked to indicate their safe working loads; (b) where the safe working load of machinery for lifting loads depends on its configuration (i) the machinery is clearly marked to indicate its safe working load for each configuration; or

ii) information which clearly indicates its safe working

load for each configuration is kept with the machinery; (c) accessories for lifting are also marked in such a way that it is possible to identify the characteristics necessary for their safe use; (d) lifting equipment which is designed for lifting persons is appropriately and clearly marked to this effect; and (e) lifting equipment which is not designed for lifting persons but which might be so used in error is appropriately and clearly marked to the effect that it is not designed for lifting persons.

6.replacement of fluorescent tubes in a workshop is to be carried out using a fork-lift truck to support a temporary working platform. (i) List the design features of the working platforms in order to ensure its suitability (ii) Outline a safe system of work for the task. (i) Design features include: The width of the platform not exceeding the width of the truck The platform floor to be of adequate strength and slip resistant The provision of toe boards and guard rails, and gates that open upwards, inwards or sideways The fitting or anchorage points for safety harnesses The provision of guards to afford protection against the moving parts of the fork-lift truck

- Pockets in the platform to take the forks of the truck with locking devices to fix them in place. -Fitting of controls on the platform Ensuring that: 1) The operations are carried out on the truck and the platform 2) Operations are carried out on firm and level ground 3) Pre-use checks are carried out on the truck and the platform 4) That the truck is correctly positioned and the parking brake applied 5) That safety harnesses are used if there is a need to reach beyond the limits of the platform 6) That the truck driver remains always at the controls of his machine and does not move the truck with the platform elevated 7) That barriers are positioned to protect against the possibilities of collision and passers-by being struck by falling materials

Contd.., 8) That the electricity supply is isolated during the changing of the tubes Only competent personnel are used for the operation 7. State the requirements of Regulation 5 of The Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 in relation to lifting equipment for lifting persons

5. - (1) Every employer shall ensure that lifting equipment for lifting persons (a) subject to sub-paragraph (b), is such as to prevent a person using it being crushed, trapped or struck or falling from the carrier; (b) is such as 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; (c) subject to paragraph (2), has suitable devices to prevent the risk of a carrier falling; (d) is such that a person trapped in any carrier is not thereby exposed to danger and can be freed.

(2) Every employer shall ensure that if the risk described in paragraph (1)(c) cannot be prevented for reasons inherent in the site and height differences (a) the carrier has an enhanced safety coefficient suspension rope or chain; and (b) the rope or chain is inspected by a competent person every working day. (b) the rope or chain is inspected by a competent person every working day.

8. Outline the principles of operation of Automatic guided vehicles (AGVs) AGV s are unmanned vehicles with a low centre of gravity. They avoid collision via sensors and trip devices that cause them to slow or stop if they encounter an obstruction.

9. List the hazards associated with automatic guided vehicles (AGVs) used to transport palletised goods in an automated warehouse. a) Potential for collisions with pedestrians b) Trapping points between AGVs and stationary objects or fixed structures c) Objects falling from vehicles d) Instability arising from slippery floors e) Gradients or damaged floors f) Vehicles malfunctioning due to poor maintenance g) Software errors that could results in a number of effects, one being inadvertent movement of the AGV

10. Identify measures that should be taken to reduce the risk of accidents from the use of automatic guided vehicles Measures: a) The need to carry out risk assessments and put in place safe systems of work b) Segregation between operating areas c) Installation of safety devices such as ultrasonic or optical sensors d) Provision of information, instruction, training, supervision and maintenance e) Function of the machine to be automatically monitored to enable the main computer to take appropriate action to stop AGV s in cases of emergency.

11. List the factors affecting the likelihood of an agricultural tractor from overturning Factors include: 1) 2) 3) 4) 5) 6) 7) Angle of slope Direction of travel on gradients Uneven or soft ground Speed on cornering Wheel width Condition and pressure of tyres The affects of trailers and other attachments

12. List the measures that may be necessary to minimise the risk, or mitigate the effects, of a tractor overturn. Measures include: 1) 2) 3) 4) 5) 6) Seat restraints Roll-over protection Restricting the use of tractors on steep gradients Fitting counterbalance weights Maintenance of tyres Training of drivers

13. List the possible contributory factors that may have led to the collapse of racking within a cold store in which fork-lift trucks operate  Construction of racking  Possible collisions following on from use of fork lift trucks  Systems failures Construction/design issues include the possibilities that the racking was unsuitable for use in cold stores, that it was incorrectly assembled or that it was weakened by the loads placed upon it.

Fork lift trucks (FLT s) may have collided with the racking for a number of reasons that could include:

 Poor design of the cold store  Incorrect type of FLT (e.g. too large for size of cold store)  Poor lighting  Build up of ice  Inadequate floor maintenance  Driver error

Underlying systems failures that could have been identified include: Inadequate assessment of risk and equipment requirements  Lack of inspection and/or maintenance of racking Poor selection or training of FLT operators  Inadequate supervision, monitoring and reporting procedures  Excessive work demands

14. State the requirements of Regulation 8 of the Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 in relation to the organisation of lifting operations. Organisation of lifting operations 8. - (1) Every employer shall ensure that every lifting operation involving lifting equipment is (a) properly planned by a competent person; (b) appropriately supervised; and (c) carried out in a safe manner.

2. In this regulation "lifting operation" means an operation concerned with the lifting or lowering of a load. 15. Explain what is meant in Regulation 8 of the Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 by `appropriate supervision .

The guidance note to Regulation 8 of LOLER defines appropriate supervision as; `Appropriate supervision means that it should be proportionate to the risk and take into account the personnel involved in the particular lifting operation such as those with disabilities and the inexperienced. Levels of supervision are determined by the nature of the work, and the competence of those involved in using the equipment and assisting with the lifting operation.

16. Outline a simple plan for routine use of an overhead travelling crane
This information is contained within the guidance notes to Regulation 8 of the Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 and includes the following principles:  Assess the weight of the load

 Choose the right accessory for lifting, e.g. depending upon the nature and weight of the load and the environment in which it is to be used;  Check the anticipated path of the load to make sure that it is not obstructed  Prepare a suitable place to set down the load  Fit the sling to the load (using an appropriate method of slinging)  Make the lift (a trial lift may be necessary to confirm the centre of gravity of the load; tag lines may be necessary to stop the load swinging)

 Release the slings (boards or similar may be necessary to prevent trapping of the sling); and Clear up. 17. The Approved Code of Practice to Regulation 8 of the Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 state that suitable measures should be taken to minimise the risks from lifting equipment due to its proximity to other objects. Identify eight possible proximity hazards: 1) Coming into contact with overhead power lines 2) Coming into contact with other work equipment or structures 3) Trench work and excavations 4) Other lifting operations in the vicinity 5) Low bridges

6) Speed retarders 7) Warehouse racking; and 8) Underground services such as drains or sewers 18. Regulation 4 of the Provision and Use of Work Equipment (PUWER) 1998 requires suitable work equipment to be provided for the task and is therefore closely related to the requirement for planning contained within Regulation 8 of the Lifting Operations and Lifting Equipment Regulations (LOLER) 1998. State the requirements of Regulation 4 of PUWER.

Regulation 4 Suitability of Work Equipment 1) Every employer shall ensure that work equipment is so constructed or adapted as to be suitable for the purpose for which it is used or provided. 2) In selecting work equipment, every employer shall have regard to the working conditions and to the risks to the health and safety of persons which exist in the premises or undertaking in which that work equipment is to be used and any additional risk posed by the use of that work equipment.

19. List the three aspects that should be considered in the selection of suitable work equipment 1) Its initial integrity 2) The place where it will be used; and 3) The purpose for which it will be used 20. List three factors that should be considered in an examination scheme for lifting equipment 1) Its condition 2) The environment in which it is to be used; and 3) The number of lifting operations and the loads lifted

21. Outline the characteristics of the following types of lift truck: 1) Counterbalance lift truck 2) Reach lift truck 3) Rough terrain lift truck (i)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 overloaded, 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.

(ii) Reach lift truck

When the forks are extended, the reach truck behaves in a similar manner to the counterbalanced 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.

(ii)Reach lift truck When the forks are extended, the reach truck behaves in a similar manner to the counterbalanced 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.

(iii)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.

22. Identify the hazards that can be associated with the use of lift trucks
 Collision.  With buildings, other vehicles and pedestrians; these can cause property and machinery damage, and serious injury.  Falls.  Falls from height resulting from using the forks of a lift truck to lift passengers.  Falling out of the cab.  Overturning.  Driving too fast.  Manoeuvring at too high a speed.

 Sudden braking. Driving on slopes. Driving with load elevated. Loss of load. Insecure load. Poor floor surface. Other hazards associated with the use lift trucks include:  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 leadacid 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.

23. Identify the three main factors when considering the precautions taken to reduce the hazards associated with the use of fork lift trucks
Operator (Safe Driver). Equipment (Safe Vehicle). Environment (Safe Site).

24. State the requirement of Regulation 25 of the Provision and Use of Work Equipment Regulations (PUWER) 1998 in relation to 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.

25. Outline the two types of working platform as described in Guidance Note PM28 Working platforms: (i)integrated (ii) non-integrated: (i)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. (ii)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.

26. List the mnemonic for the safety of fork lift truck platforms (FIT CLAWS) Mnemonic for fork lift truck platforms: 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

27. State the requirements for training under Regulation 9 of the Provision and Use of Work Equipment Regulations (PUWER) 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.

28. Outline the three stages of training required for those wishing to operate lift trucks. (i)Basic Training (ii) Specific Job Training (iii) Familiarisation Training (i) 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.

(ii). 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 off-the-job and is often combined or integrated with basic training. (iii) 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.

29. Identify six factors to be included in a safe system of work for crane operations. 1. Planning the lift. 2. Selection of correct crane. 3. Selection of correct lifting accessories. 4. Selection and provision of trained and certificated staff. 5. Ensuring test certificates, etc., available and in order. 6. Controls to prevent unplanned lifts or movements. 30. Outline the characteristics of the following types of cranes: (i) gantry cranes (ii) tower cranes