Code of Practice

Safe Working Practice for Open Top Tipping Bodies

Produced by IRTE, a professional sector of SOE

SOE (Society of Operations Engineers) is a professional membership organisation representing some 17,000 individuals and companies in engineering. It supports and encourages members throughout their careers and is committed to their ongoing growth and personal development.

Through a network of trustees, industry partners and members, SOE promotes best practice in operational and health and safety initiatives. SOE offers members continuing professional development and support throughout their careers, providing definitive recognition for both achievement and status. The organisation is a Licensed Member of ECUK and can nominate members for ECUK registration at EngTech, IEng and CEng levels.

SOE represents the Professional Sectors IRTE, IPlantE and BES and developed the technician-licensing scheme, irtec.

IRTE (Institute of Road Transport Engineers), one of the most respected names in UK transport, has always been recognised as an impartial voice of the industry.

IRTE publishes an industry-leading technical journal, Transport Engineer, every month. Transport Engineer is renowned for its incisive coverage of key issues, authoritative reporting, news analysis and informed comment.

IRTE also hosts regular technical seminars and forums and works alongside the DfT to promote efficiency and best practice. Recent events include trips and falls from vehicles, truck operation, fuel efficiency and the Road Safety Act. IRTE’s technical committee also produces regular industry guidance on key topics.

Recent published guides include A Best Practice Guide towards Tachograph Systems Compliance, Roadworthiness: Industry Best Practice, Coupling or Uncoupling & Parking of Large Goods Vehicle Trailers and Tail Lift – Specification Guide for Road Vehicles.

IRTE members come from a wide variety of transport-related roles. These include workshop managers, fleet engineers, transport managers, company directors, apprentices and technicians in the light and heavy goods vehicle and bus and coach sectors.

If you are interested in becoming involved with the IRTE Technical Committee, please contact Ian Chisholm, Head of Membership and Technical Services, on 020 7630 1111

or email ian.chisholm@soe.org.uk.

This guide was first published by the SOE in August 2009ISBN 978-0-9555685-5-8

Editor: David Jones Design and Guide Coordinator: Sarah Prest© 2009 Society of Operations Engineers

Foreward

A typical tipper vehicle with raised body, suitably supported for repairs.

This code of practice is intended as a basis for individual operators to produce bespoke instructions to suit their own unique operations, for which a ‘Risk Assessment’ should be carried out.

The equipment operated, manufacturers instructions, loads transported, area of operation and the results of the ‘Risk Assessment’ will determine the content of any bespoke instructions.

Other specialist types of open top tipper exist; for example, three way, rise and tip, bulk discharge, etc each require dedicated and other safety considerations, all of which will become apparent when carrying out a ‘Risk Assessment’.

IRTE cannot accept any responsibility for the failure of this code of practice to cover all eventualities.

SECTION PAGE

Introduction 5The Law 6Accidents and damage to property 6Repair and maintenance 7Loading and outward journey 8At point of delivery 10Leaving the delivery point 12Good practice 13IRTE publications 14

Contents and appendices

Introduction

Accidents and dangerous situations occur all too often because drivers of tipping vehicles fail to follow safe operating procedures, which can result in the fatal or serious injury of the driver and/or others.

In addition to the potential danger to life, if safe working practices are not maintained, there is a high probability both the vehicle and surrounding property will be severely damaged in the event of an accident.

Driver awareness and understanding of the risks involved when loading and discharging a tipping vehicle, and the dangerous situations that may occur whilst carrying out routine tasks associated with tipping vehicles, is extremely important (see picture on page 3). Sometimes this awareness and understanding is severely lacking and the subject is often neglected at all levels, from the fleet operator down.

This Code of Practice is intended to be used as a management tool by all operators and users of tipping vehicles, from large or small fleet operators, their managers and drivers, to independent owners, self-employed drivers and driver training bodies.

This booklet provides guidance on the law, explains why accidents occur, and illustrates the need for procedures to ensure accidents involving tipping vehicles do not occur.

Different risks exist depending on the type of equipment being used. It is therefore important to identify the risks and implement a training regime to ensure drivers follow correct procedures. Equally, drivers must be aware of the potential consequences of their actions should they not adhere to procedures.

In addition, this guide contains safety rules that should be observed and a section concerning good practice.

The IRTE would like to thank the Health and Safety Executive (HSE) for the support and advice provided in the compilation of this Code of Practice.

The Law

If a driver fails to discharge a load or operate a tipping vehicle safely, both the operator and driver may be responsible for seriously injuring themselves or others, perhaps even fatally. Both the operator and driver could also be contravening health and safety law.

Employers, owners and managers have a responsibility to provide and maintain safe systems of work, and to take reasonable and practicable precautions to ensure the health and safety of all workers and members of the public who may be affected by their activities. They should ensure safe systems of work for discharging a load and operating tipping vehicles are understood, and procedures are in place to check they are followed.

All drivers, including the self-employed, have a responsibility for their own health and safety, and that of other people who could be affected by their actions.

Accidents and damage to property

Accidents caused by human error are avoidable.

All tipper drivers should be given appropriate training on the operation of the equipment they are expected to use and the application of established safe systems of work. An accident is likely to be either a result of inadequate training or failure of the driver to understand and implement their training. Records of training are important and should be signed and dated by the recipient to confirm the training has taken place and been understood.

Damage caused because of a tipping accident can be extensive, affecting both the vehicle itself and surrounding property. The two most common accidents involving damage occur because of the vehicle rolling over sideways or hitting an overhead obstruction. Both types of accident can also result in loss of life.

Repair and maintenance

The requirement for routine inspections and planned maintenance on commercial vehicles requiring an ‘Operators Licence’ is well understood, with the majority of operators either carrying out work in their own workshops or contracting the work to a commercial vehicle main dealer, authorised repairer, or independent garage. There is a risk that unless workshops are run by the operator, who has arranged specialist training in the maintenance and repair of the ancillary equipment fitted to their chassis’, it is possible other repairers will not have the ability to maintain the vehicle as a whole to the required standard, due to the lack of expertise and specialist equipment required. Obviously there will be exceptions to this generalisation, but it is important the extent of the work carried out on a contracted maintenance agreement is fully understood, and the operator is not left exposed due to the limitations of the agreement.

Vehicles not subject to an Operators Licence, such as vehicles up to 3500kg GVW and those operating off the public highway, must be maintained to the same standard.

When considering a tipping vehicle of any size, it is important the hydraulic system and integrity of the body and its attachments be correctly maintained.

The hydraulic system should be maintained as directed by the manufacturer. Any oil leaking from the system has the potential to create dangerous situations. For example, a tipped body may lower unexpectedly; high-pressure oil may cause personal injury; spilt oil is a contaminant that may cause an accident and will almost certainly be an environmental hazard.

The tipping body and its attachments are highly stressed pieces of equipment and fundamental to the safety and integrity of the vehicle, therefore any damage or excessive wear may adversely contribute to an already dangerous situation if the vehicle is unstable or unsafe. Typical examples of often overlooked problems affecting the integrity of the body include, damage to the structure caused by loading machines, and thinning of the floor due to the constant effect of the load acting as an abrasive whilst being discharged, or indeed abuse to the structure during operational stress.

A standard format inspection sheet that can accommodate variations in design should be developed and completed as part of each routine vehicle inspection.

Loading and outward journey

Due to the loading methods employed, and site conditions at the point of loading, it is important drivers understand their responsibilities regarding the vehicle and load which is to be taken onto the public highway. Many sites are run in a very professional manner with highly trained loading operatives using weighbridges and, if appropriate, washing facilities. However, some do not have these and as such additional responsibility is placed on the driver.

The type of material being transported and its flow capabilities must be considered before loading. Some loads, especially those that are wet, sticky or solid can have a tendency to move at different rates during the tipping operation, which can create a dangerous situation. Should the load at the rear or one side move unexpectedly, this could lead to the creation of an unbalanced vehicle and contribute to a roll over accident, as well of course as a potential axle overload situation.

The load should be evenly distributed along the length and across the width of the body. Failure to do this may result in an unstable vehicle that may be dangerous to drive and have axle and tyre overloads, which would render the vehicle illegal. It also has the potential to create a severe hazard during the tipping process. Many tippers have a high centre of gravity, therefore any uneven weight distribution is likely to increase problems encountered particularly when cornering, braking and on roads with excessive camber.

Dangerous tipping situations that can contribute to a vehicle roll over.

Low tyre pressure Uneven load Soft ground Sloping ground

Keep clear of excavation

Remain on compacted ground

Keep clear of excavation

Remain on compacted ground

Loading and outward journey

The driver is responsible for ensuring the vehicle does not exceed the gross plated weight or individual axle weights. As such, drivers must not proceed if there is any doubt regarding compliance with legislation. It should be remembered the density of individual loads can differ significantly, and many tipper bodies will accommodate more load than they can legally carry in weight. Therefore, it is important drivers are provided with training to identify the different types of materials they are expected to transport, and the weight of an individual load is known and documented.

When a vehicle has been loaded under off-road conditions, the driver should inspect all securing devices and locks, the tyres and any low mounted equipment for damage before leaving site.

An appropriate sheet or net to retain the load and any debris should be used and adequately secured. N.B. Local planning regulations may make the use of sheeting systems compulsory.

Unfortunately, some tipper operators do not have a particularly good image with the public at large due to the mud and clay deposits left behind on the road by some operators when leaving site. There is also a perception tippers are more likely to cause damage from flying stones and other loose material. Therefore, it is the drivers’ responsibility to ensure excess debris is removed and any rocks/stones removed from between twin tyres.

The driver should always check the condition of the lamps, reflective marker boards and number plates before leaving site - as depending on the ground conditions, they may have become obscured by mud and grime.

As the majority of tipper bodies are not water tight, the driver should allow excess water from a wet load to drain from the body prior to leaving site.

At point of delivery

On arrival at site, the driver must moderate the vehicle’s speed to suit the conditions. If travelling off the public highway, the driver must be mindful of the surface conditions, stay on compacted roadways, keep well clear of any excavations and look for overhead cables and other obstructions.

Prior to discharging the load, the driver must position the vehicle on flat firm ground. If a slope cannot be avoided then it should run from end to end of the vehicle, not across the width as this creates instability. If the vehicle is articulated, the tractor unit and trailer must be in a straight line otherwise another unstable condition is produced.

In many instances, it is beneficial for the vehicle to be equipped with a rearward facing camera to provide the operator with a clear view of the area immediately behind the vehicle, whilst it is reversing or the driver operating the tipping gear. This equipment is now mandatory when working on many sites.

Before discharging the load, the driver must check the area in which the load is to be deposited is clear of personnel and obstructions.

The driver should not leave the cab unless suitably equipped with Personal Protection Equipment ( PPE ), consisting of a hard hat, gloves, safety boots and a high visibility vest or jacket, plus when appropriate eye and ear protection, and the handbrake applied.

If the body is not straight do not tip, but lower in a controlled manner.

If the body is equipped with a manual locking system, to secure the tailboard the driver must take care that the pressure of the load against the tailboard does not place them or others in danger.

Do not allow any person to stand adjacent to the vehicle whilst tipping as this is a place of danger. An accident involving a person standing adjacent to a tipper is most likely to be caused by one of three things, all of which can have fatal consequences. A swinging tailboard is liable to cause injury if someone is standing behind it when tipping takes place or between it and the body when lowering. A load that moves suddenly, or is discharged at speed, can also cause injury to persons standing at the rear of the vehicle and even those standing at the sides, as the load spills outwards. Standing at the side of a tipper is often considered a safe place by the uninitiated. This is not the case. Should a tipper roll over, it is unlikely that people standing at the side will recognise the warning signs and be able to run clear quickly enough to avoid potentially fatal injury. The driver has a responsibility of safety to ensure his actions do not endanger others and should maintain an exclusion zone around the vehicle whilst tipping.

To ensure control of the load is maintained during tipping, the flow rate properties of the material being carried should be considered beforehand. The body should be tipped in an appropriate manner to suit the materials being discharged, maintaining a smooth operation and avoiding sudden shocks caused by rapid tipping and lowering or sudden stops. Care should be taken to ensure a free flowing load does not exit with excessive speed, and wet or sticky loads do not create a dangerous situation if they do not move. The higher the angle of tip, the more unstable the vehicle becomes. Depending on the design of the body, if appropriate the tailboard should be periodically checked to ensure it is not likely to hit an obstruction or become buried in the load.

Drivers should remain in the cab at all times during the tipping process and look to the rear of the vehicle using the mirrors to monitor and adjust the rate of discharge. If the driver has any concerns regarding the safety of the tipping process, whether they are ground or site conditions, the load itself, vehicle and ancillary equipment or the proximity to people, tipping should immediately stop and the body slowly lowered until the risk has been removed.

If load discharge is restricted by previously tipped material, it is permissible to slowly move the vehicle forward. Before moving, the driver must consider if it is safe to do so with the body at its current tipping angle and, if appropriate, either partially or fully lower the body before moving. All movements must be carried out smoothly, in a slow controlled manner. If the vehicle is fitted with air suspension, the release of the brakes can cause a sudden movement and result in instability. Therefore, the body must be lowered prior to releasing the brakes. Having moved, the driver should then reassess the situation before recommencing tipping.

When the load is fully discharged, lower the body to approximately 10º and slowly pull the vehicle clear of the load to a safe area. At this point, the driver should clear the rear bearer and tailboard of debris to allow the tailgate to close correctly. Fully lower the body and secure the tailboard.

At point of delivery

Leaving the delivery point

A vehicle leaving site after delivery of the load should be subjected to the same basic damage and cleanliness checks as when leaving the loading point. If the vehicle has operated in ‘off road’ conditions and if there is any likelihood of debris blowing out of the body, it should be adequately sheeted. The rear lamps and reflective marker boards should be checked for cleanliness and damage.

A sheeted and clean vehicle gives the right image.

Good practice

Ensure:

The load is evenly distributedThe load does not exceed the carrying capacity of the vehicle or axel loadingsTyres and low-level equipment have not been damaged when going off roadMud and stones are not deposited on the public highwayThere are no stones, bricks, etc trapped between tyres that could become a hazard to other road users or pedestriansSheets or nets adequately contain the loadLights, reflective marker boards and number plates are undamaged, clean and operational Wet loads are adequately drainedPersonal Protection Equipment (PPE) including a hard hat, gloves, safety boots and a high visibility vest or jacket and if appropriate eye and ear protection are available and worn at all times when outside the cabTyre pressures are checked regularlyThe driving technique is adjusted to suit the vehicle and load centre of gravity as excessive speed effects stabilityThe vehicle is on firm level ground at all timesThe area around the point of discharge is clear of personnel and obstructions.All personnel are well clear of a swinging tailboardAccess into the body is only by an approved methodOverhead cables and other obstructions are well clear of your vehicle at all times and do not put you or others at riskA check is always made for overhead obstructions before tippingSite rules are known, understood and observedThe manufacturers operating instructions and safety rules are known, understood and implementedAn exclusion zone is maintained around the vehicle during the tipping process.

Do Not:

Discharge the load if the vehicle is leaning sideways or on unstable groundDo not continue to discharge if the vehicle begins to lean sideways whilst tipping Discharge the load from an articulated vehicle if the tractor unit is not in line with the trailerDrive with the body raised (other than the 10% to check/clear tailgate)Allow personnel to stand adjacent to a tipping bodyDrive onto soft ground or close to excavationsGo under an un-propped body or tailboardAllow other persons to go under an un-propped body or tailboardEnter body when tipped or tippingUse violent movements to release a ‘sticky’ loadDrive with the ‘Power Take Off’ engaged.

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IRTE publications

Coupling or Uncoupling and Parking of Large Goods Vehicle Trailers

The IRTE code of practice is aimed at managers, supervisors and trainers but has good advice for everyone who has responsibility for the safety of large goods vehicle and drivers.

IRTE Guide to Tipper Stability

Essential guidance for those wishing to implement best practice when operating tipping vehicles or tipper trailers.

To order any of these publications visit www.soe.org.uk to download a copy or contact the technical services department at technical@soe.org.uk or telephone 020 7630 1111.

A Best Practice Guide towards

Tachograph Systems

Compliance

Tachograph Systems Compliance

In this indispensable guide, Senior Tachograph Consultant, Gordon J F Humphreys, explains what firms need to do to protect their Operator’s Licence.

Tail Lift - Specification Guide for Road Vehicles

Guidance for manufacturers, specifiers, installers, suppliers and users of tail lifts as to the safety issues associated with tail lift installations.

Preventing Falls and Falling Loads from Tail Lifts

Produced by the members of a Tail Lift Users Group, which included tail lift operators, manufacturers and HSE, to provide guidance for the prevention of falls and falling loads from tail lifts.

Roadworthiness Guide

This guide is intended to assist vehicle operators and managers, regardless of fleet size to improve their vehicle maintenance controls and standards.

Maintenance Supplier Assessment

The IRTE’s maintenance supplier assessment guide is aimed at those who contract out the maintenance of their fleet. It advises on best practice procedures to ensure the maintenance facilities of workshops used are adequate for the type and number of vehicles undergoing work.

IRTE publications

‘Wheel Loss - No Longer a Mystery’ booklet

This guide explains the mechanisms of wheel loss and provides helpful best practice guidance to assist those specifying and maintaining commercial vehicles to reduce wheel loss incidents.

A simple guide for Tail Lift Operators

This guide provides some basic information and highlights the user’s legal responsibilities in the use, maintenance and examination of tail lifts.

Roadworthiness: Industry Best Practice for PCV (Passenger Carrying Vehicles)

Produced with leading industry bodies, this guide gives advice on best practice so all passenger carrying vehicle operators can improve their vehicle maintenance controls and standards.

SOE, IRTE Professional Sector,22 Greencoat Place, London SW1P 1PRTel: 020 7630 1111 Fax: 020 7630 6677Website: www.soe.org.uk Email: soe@soe.org.uk

Registered Charity No. 1081753Registered in England Company No. 3667147

IRTE would like to thank in particular John Holland for his invaluable contribution to the production of this guide as well as the IRTE Technical Committee for their support.

5685587809559

ISBN 978-0-9555685-5-8