c7 presentation

8/6/2019 C7 Presentation

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Element C7:MECHANICAL

HANDLING


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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

LiftingOperations and Lifting Equipment Regulations 1998

Minimum hours of tuition: 6 hours.


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1 .State the requirements of Regulation 4 of

the Lifting Operations and Lifting EquipmentRegulations (LOLER) 1998 in relation to

Strength and Stability

Every employer shall ensure that-

A) Lifting equipment is ofadequate 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.


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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 platesmay be needed so they can safely support

the weight of the equipment and the

maximum load to be lifted;


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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 angleof any slope this imposes horizontal as well as

vertical forces;

D)T

he size and nature of the load (eg whetherthe load itself is unstable);

E) How the load is intended to be lifted; and

F) The maximum wind loading that may occur


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(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


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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 safeworking 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.


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The fixing points on the load

Any sharp edges, which might need

packing to protect the sling and theenvironment in which the lifting operation

is to be undertaken

Those carrying out the operation wouldalso have to satisfy themselves that the

tackle selected is in good condition with

its safe working load marked orindicated, is within the examination date

and is fully compatible with the crane

with which it is to be used.


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4. Define `lifting equipment

The Lifting Operations and LiftingEquipment 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


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5. State the requirements of Regulation 7 of theLifting 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), machineryand accessories for lifting loads are clearly

marked to indicate their safe working

loads;

(b) where the safe working load of machineryfor lifting loads depends on its configuration

(i) the machinery is clearly marked to indicate

its safe working load for each configuration; or


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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 liftingpersons but which might be so used in error is

appropriately and clearly marked to the effect that it

is not designed for lifting persons.


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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 oftoe boards and guard rails, and gates thatopen upwards, inwards or sideways

The fitting oranchorage points for safety harnesses

The provision of guards to afford protection against the moving

parts of the fork-lift truck


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- 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 brakeapplied

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


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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 EquipmentRegulations (LOLER) 1998 in relation to lifting

equipment for lifting persons


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5. - (1) Every employer shall ensure that lifting equipment

for lifting persons -

(a) subject to sub-paragraph (b), is such as to prevent aperson 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 preventthe 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.


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(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 suspensionrope 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)

AGVs 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.


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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 structuresc) Objects falling from vehicles

d) Instability arising from slippery floors

e) Gradients or damaged floorsf) Vehicles malfunctioning due to poor maintenance

g) Software errors that could results in a number of

effects, one being inadvertent movement of the AGV


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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 areasc) 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

AGVs in cases of emergency.


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11. List the factors affecting the likelihood of an

agricultural tractor from overturning

Factors include:

1) Angle of slope

2) Direction of travel on gradients

3) Uneven or soft ground

4) Speed on cornering5) Wheel width

6) Condition and pressure of tyres

7) The affects of trailers and other attachments


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12. List the measures that may be necessary to

minimise the risk, or mitigate the effects, of a tractor

overturn.

Measures include:

1) Seat restraints

2) Roll-over protection

3) Restricting the use of tractors on steep gradients

4) Fitting counterbalance weights

5) Maintenance of tyres

6) Training of drivers


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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 possibilitiesthat 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.


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Fork lift trucks (FLTs) 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


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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


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14. State the requirements of Regulation 8 of the

LiftingOperations 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.


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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 ofsupervision are determined by the nature of the work,

and the competence of those involved in using the

equipment and assisting with the lifting operation.


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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

LiftingOperations 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)


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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

LiftingOperations and Lifting Equipment Regulations (LOLER)

1998 state that suitable measures should be taken to

minimise the risks from lifting equipment due to its proximityto 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


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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 therequirement for planning contained within Regulation 8 of the

LiftingOperations and Lifting Equipment Regulations (LOLER)

1998. State the requirements of Regulation 4 of PUWER.


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Regulation 4 Suitability of Work Equipment

1) Every employer shall ensure that work equipment isso 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.


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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


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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.


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(ii)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 thewheelbase of the truck (This minimises the overall

working length and allows the aisle width to be

reduced), which increases stability. When theload 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.


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(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 leveland 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.


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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.


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Sudden braking.

Driving on slopes.

Driving with load elevated. Loss of load.

Insecure load.

Poor floor surface.

Other hazards associated with the use lift trucksinclude:

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.


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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 acidcan 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.

Vib ti C d b d f b dl i fl t d t d


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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, guardsshould 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).


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24. State the requirement of Regulation 25 of

the Provision and Use of Work Equipment

Regulations (PUWER) 1998 in relation toemployees carried on mobile work equipment.

Regulation 25 of the Provision and Use of WorkEquipment 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.


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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 controlledby 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 theplatform or move the truck. All movements are

controlled by the truck operator.


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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 gatesT oeboards and rails

C ontrols preferable

L ocking device to forksA nchorage points for harness

W idth and weight less than fork lift truck

S creen from fork lift truck parts


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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 beadopted 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 receivedadequate 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.


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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 thetraining organisation, or at the employers own premises (in-

house). If training is conducted on the employers premises, the

area must be large enough to allow for manoeuvring, and suitably

closed off from other employees and work activities.


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(ii). Specific Job Training.

This type of training should cover knowledge of theworkplace, 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.


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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

c7 presentation

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