Aerial Lift Training

AERIAL LIFT OPERATOR SAFETY TRAINING

INTRODUCTION ANATOMY STABILITY SAFE OPERATIONS HAZARDS

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Accountability

The material presented within this course is for educational and training purposes only. All parties involved in the development, distribution and maintenance of this course shall be held harmless from any incident resulting from misuse of the content beyond the guidelines and purposes herein stated. Before you begin you should understand that it is your responsibility to adhere to the laws and regulations presented within the following course and its corresponding materials. Likewise, it is your further responsibility to strictly follow any additional guidelines specific to your own workplace. Good Luck & Stay

Safe!


Note to Instructors: the first few slides in this presentation can be drawn upon as desired

and used to initiate dialog as to the importance of safety training and operator responsibility.

If you choose to skip these slides, the official presentation begins on slide 12.



Why Safety Training?

It’s required everywhere you go.


Why Safety Training?


1. Training reduces the risk of accidents and

injuries to you and those you work with

2. Training reduces operating costs (How?)

3. OSHA requires it – no matter who you are or

how long you’ve been operating.

It’s as easy as 1, 2, 3!


Intro_ 1_a: Welcome Welcome to the Hard Hat Training series. Today you will learn about the set-up and safe operation of aerial lifts. We will strive to provide information that will increase your knowledge and help to make you a better operator.

Welcome to the Hard Hat Training Series!



Intro_1_b: Aerial lifts are a common sight Aerial lift platforms are great tools to conduct work at heights and increase production efficiency. These machines lift personnel, along with tools and materials, from 10-12 feet in the air to as high as 100 feet.

Aerial lifts are a common sight INTRODUCTION



Intro_1_c: Equipment anatomy & inspections During this training we’ll take a look at the different types of lifts and their anatomy. We’ll also show you why it’s important to conduct a thorough pre-shift inspection each day before putting a lift into service.

INTRODUCTION Equipment anatomy & inspections



Intro_1_d: Stability of aerial lifts We will look at aerial lift stability and the importance of knowing the machine’s capacity.

Stability of aerial lifts INTRODUCTION



Intro_1_e: Safe operations We will emphasize the importance of planning each lift and setting up the machine properly so as to avoid hazards and obstacles around the worksite.

Safe operations INTRODUCTION



Intro_1_f: 6 most common hazards We will introduce the six most common hazards associated with aerial lift operation and show you how to recognize, avoid or minimize them.

6 most common hazards INTRODUCTION



Intro_1_g: Completion of course When you complete this training you should be familiar with the types of aerial lifts used by your company, have an increased knowledge of how to set up and safely operate them and be able to recognize and avoid the most common hazards associated with their use.

Completion of course INTRODUCTION



Intro_2_a: Types of lifts Aerial lifts have made it safer and easier to lift personnel and their tools to great heights. If used correctly, this equipment provides quick and safe access to work areas that at one time could only be reached from scaffolding or a crane’s man basket. Collectively, they’re called Aerial Work Platforms, but individually they have many different names. To avoid confusion we’ll define the four main types of lifts.

Types of lifts INTRODUCTION



Intro_2_b1: Bucket trucks Vehicle mounted aerial lifts are mounted on trucks or vans and are often referred to as bucket trucks, cherry pickers or boom trucks. They are most commonly used along public roads and highways by public works and road maintenance crews or utility companies.

Bucket trucks INTRODUCTION



Intro_2_c: Self propelled boom lifts Self-propelled aerial lifts can be either a straight boom or an articulating boom. They’re commonly used on construction sites and around industrial plants for maintenance personnel.

Self propelled boom lifts INTRODUCTION



Intro_2_d: Scissor lifts Self-propelled scaffolding are commonly called scissor lifts and can be used on smooth flat surfaces or rough terrain, depending upon the type. These are mostly used indoors, but there are models that can be used outdoors as well.

Scissor lifts INTRODUCTION



Intro_3_a1: Standards These are the main OSHA and ANSI standards concerning aerial lifts. Many states have additional standards as do some industries such as Maritime, Mining and Offshore oil platforms. It’s your responsibility to know all federal, state and local rules that apply to your machine and jobsite. If you are not sure, ask your supervisor or safety coordinator.

Standards INTRODUCTION



Load tests INTRODUCTION

Intro_4_c: Load tests Load tests of aerial lifts should be performed on a regular basis, especially if there have been any structural repairs. Load tests will determine whether the lift can handle its capacity through all of its functions. For boom-supported lifts, these will test its stability and show the condition of the hydraulic components including the lift cylinders and extension cylinders.



Anat_1_a: Lift components and anatomy In this section we’ll look at components and anatomy of the self-propelled aerial lift and give a general description of each. We’ll go over general things to look for while performing a pre-shift inspection of the lift, but there are so many different types and models that it’s impossible to describe them all in detail. That’s why it’s important to be familiar with the operator’s manual for each type of machine you operate.

ANATOMY • Lift Components

• Visual inspection • Engine, refueling & chassis • Turret section and boom • Scissor and mast sections • Lift controls and platform

Lift components and anatomy



Anat_1_b: Self-propelled, boom-supported aerial lifts A typical self-propelled, boom-supported, aerial lift has either a straight or articulating hydraulic boom that is mounted on a counter-weighted chassis.

Self-propelled, boom-supported aerial lifts ANATOMY • Lift Components

• Visual inspection • Engine, refueling & chassis • Turret section and boom • Scissor and mast sections • Lift controls and platform



Visual inspection

Anat_2_a: Visual inspection Every machine is required to have operating instructions on the machine at all times. These can be found in the operator’s manual and on warning labels and decals.


• Visual inspection

• Engine, refueling & chassis • Turret section and boom • Scissor and mast sections • Lift controls and platform



Anat_2_d1: Decals & warning labels All nameplates and markings should be in place and in readable condition. Most operators’ manuals will have a list of the decals and labels that should be on the machine and a way of ordering replacements.

Decals & warning labels



• Visual inspection

• Engine, refueling & chassis • Turret section and boom • Scissor and mast sections • Lift controls and platform


Anat_3_a: Engine, hydraulics & chassis In this section we will cover the inspection of the engine, hydraulics, and lift chassis, and discuss the importance of their maintenance.

Engine, refueling & chassis ANATOMY • Lift Components • Visual inspection

• Engine, refueling & chassis

• Turret section and boom • Scissor and mast sections • Lift controls and platform



Anat_3_b2: Refueling Never refuel the machine with the engine running and only in an open, well-ventilated area away from sparks. Never start the engine if you smell or detect propane, gasoline, diesel or any other explosive substance. Use a soapy solution in a spray bottle to check for propane leaks. Never use a match or a lighter.

Refueling


ANATOMY • Lift Components • Visual inspection




Anat_3_b4: Battery condition Proper battery condition is essential for good engine performance and operational safety. Always use protective clothing and eyewear when working with batteries. Batteries contain acid, which should be neutralized with baking soda and water in the event of a spill. Avoid contact with electrical terminals.

Battery condition


ANATOMY • Lift Components • Visual inspection




Anat_4_b2: Fasteners The fasteners that bolt the turret to the chassis should be checked to see if they are loose or if they’ve been stretched.

Fasteners


ANATOMY • Lift Components • Visual inspection • Engine, refueling & chassis

• Turret section and boom

• Scissor and mast sections • Lift controls and platform


Anat_6_a: Lift Controls In this section we will cover the lift controls on the ground and in the platform.

Lift Controls ANATOMY • Lift Components • Visual inspection • Engine, refueling & chassis

• Turret section and boom • Scissor and mast sections

• Lift controls and platform



Stab_1_a1: Balance and leverage Stability of the machine is based upon the principle of balance and leverage. The concept of the teeter-totter is a good way to explain stability. When a teeter-totter is in perfect balance, the torque created by the weight times the length of the lever arm on one side of the pivot point must equal the torque created by the weight times the lever arm length on the other side.

(A video clip for this image is available in the Other Video Clips folder within the Poster, Other folder.)


Balance and leverage

500 lbs

250 lbs

20 ft 10 ft

500 lbs X 10 ft

= 5,000 ft lbs

250 lbs X 20 ft

= 5,000 ft lbs


Stab_1_a2: Lift’s leverage For all aerial lifts, the torque on the side of the machine must always be greater or the lift will tip over. The lift’s torque or leverage is the effective weight of the machine times the distance from the center of rotation to the wheel or outrigger.



Lift’s leverage

Tipping point

Center of Rotation


Stab_1_a4: Ground pressure The pressure applied to the ground is the greatest when the boom is located directly over the outrigger or wheel, because this one outrigger or wheel is supporting most of the load. When working on soft soils it’s wise to set up on firm ground or on pads. Otherwise, there’s a chance the wheel or outrigger could sink into the ground and tip the lift over.



Ground pressure


SAFE OPERATIONS

Safety meetings

Oper_1_a2: Safety meetings Safety meetings are ideal for planning safe lifts. These meetings can be extensive or informal gatherings to make sure everyone is on the same page and all of the hazards have been identified. Often, the biggest hazard in aerial lift operation is lack of planning and then trying to make-do with undersized or inadequate equipment.



Demonstration of ability SAFE OPERATIONS

Oper_1_b2: Demonstration of ability Before anyone is allowed to operate an aerial lift on their own they should be able to demonstrate they are familiar with all operational and safety devices on the machine, including:



STABILITY SAFE OPERATION HAZARDS ANATOMY

Be trained and authorized Power line contact

Haz_2_b1: Power line contact Power line contact is the accidental contact of any metal part of an aerial lift with a high-voltage power line. A single contact can result in multiple deaths and crippling injuries. Each year roughly 150 people are killed by power line contact. About three times that number are seriously injured.

AERIAL LIFT HAZARDS

• Aerial lift hazards

• Power line contact

• Falls from tipover • Falls from platform • Struck or crushed by lift • Maintenance related accidents • Other hazards



Accident profiles from OSHA website

Haz_2_c: Accident profiles from OSHA website The following accident profiles will show just how quickly things can go wrong when an aerial lift is used for a job or purpose it was not intended for. Add to that a few safety procedures that were ignored and fatalities or injuries are the result. These profiles are taken from the OSHA website. Only the names of the companies and the manufacturer of the equipment have been withheld.


AERIAL LIFT HAZARDS





Accident profile #1

Haz_2_d: Accident profile #1 An employee had been assigned to paint a metal utility pole with a spray gun. He was working from an aerial lift and had painted one side of the pole. As he was rotating the bucket of the aerial lift so that he could paint the other side of the pole, he leaned back in the bucket, and the back of his neck contacted a 7960-volt overhead power line. The employee received an electric shock, which knocked him out of the bucket and into the bed of the aerial lift truck. Two coworkers broke his fall and administered cardio-pulmonary resuscitation. Unfortunately, the injured employee had no heartbeat and was not breathing when the emergency medical team arrived. He had been electrocuted.


AERIAL LIFT HAZARDS





Inspect wire rope Conclusion

Haz_2_g1: Conclusion In conclusion: Never attempt to rescue someone who has been shocked and is unconscious. Wait until the lines have been de-energized. Never be fooled into thinking the lines have been de-energized without confirmation from the electric company. Sometimes the breaker will reset itself. Never try to use a pole or board to knock an unconscious person away from the lift. The pole or board could conduct the electricity also.


AERIAL LIFT HAZARDS





Falls from tip over

Haz_3_a: Falls from tip over Falls from tip over is the next most common hazard associated with aerial lifts. There are lots of ways this can happen – it’s not always because of overloading. The most common cause of tip over is working on a slope or incline. Many machines now have tilt control sensors to prevent them from being raised into an unstable position or bubble levels to help level the machine. Some tip overs are the result of not using the outriggers or extendable axels that are part of the lift, as the following accident will show:

AERIAL LIFT HAZARDS

• Aerial lift hazards • Power line contact

• Falls from tipover

• Falls from platform • Struck or crushed by lift • Maintenance related accidents • Other hazards


Maintenance Related


Accident profile #2

Haz_3_b: Accident profile #2 At approximately 2:30 p.m. on May 8, 1996, Employee #1 and #2, roofers, were using a telescopic boom lift, from a height of approximately 60 ft to place ridge caps atop a section of roof on a breezeway connection. The vehicle toppled over and Employees #1 and #2 fell to ground with a 30-degree slope, for a total fall of approximately 80 ft. Employee #1 sustained a broken right wrist, fractured ribs, and a fractured leg. Employee #2 sustained severe facial and head injuries, internal injuries, and fractured ribs. The extendable axles were not extended while the lift was being operated; this was in violation of the manufacturer’s recommendations and cautions.


AERIAL LIFT HAZARDS





Working on slopes

Haz_3_d2: Working on slopes Know the maximum slope and grade for which the lift is rated and never exceed it. Some aerial lifts may be equipped with tilt sensors. These sensors as well as other safety devices must be operational and never be altered or disabled. Never depend upon the tilt alarm as a level indicator.


AERIAL LIFT HAZARDS





Stability enhancing devices

Haz_3_d3: Stability enhancing devices If equipped, use all stability enhancing means such as outriggers, outrigger pads, stabilizers or extendable axles.


AERIAL LIFT HAZARDS





Rough terrain

Haz_3_d5: Rough terrain Use extreme care when traveling over unstable or rough surfaces .


AERIAL LIFT HAZARDS





Allowable side forces

Haz_3_d8: Allowable side forces While elevated, do not push or pull on any object outside of the platform. Check the operator’s manual for maximum allowable side forces.


AERIAL LIFT HAZARDS





Avoid bouncing boom

Haz_3_d9: Avoid bouncing boom When maneuvering the machine or platform near obstacles, use the slowest speed to avoid “bounce” of the platform.


AERIAL LIFT HAZARDS





Introduction

Haz_4_a: Introduction One in five of the most common hazards in aerial lift operation is falls from the platform. In the majority of these cases, there was no fall protection being used and the operator was climbing on the rail or outside of the platform during the lift. In a few cases, the lift was struck by another vehicle causing the boom to flex and throwing the operator from the platform. Consider the following accident:

AERIAL LIFT HAZARDS



• Falls from platform

• Struck or crushed by lift • Maintenance related accidents • Other hazards


Maintenance Related


Accident profile #3

Haz_4_b: Accident profile #3: Employee #1 and a coworker were at the intersection of two streets to repair a signal light. They could not locate the problem from the ground, so they moved the bucket truck into the intersection for Employee #1 to work out of the elevated basket. The bucket was being lowered and was at a height of approximately 15 ft when a semi-truck struck it. Employee #1, who was not wearing a safety belt, was thrown out. He was taken to Port Huron Hospital, where he was pronounced dead. The employer was cited for violations of no accident prevention program; providing no hard hats; not providing and maintaining signal, signs or barricades; no traffic control devices; and, no safety harness use in a man lift. What went wrong?

AERIAL LIFT HAZARDS







Don’t climb down an elevated boom

Haz_4_d4: Don’t climb down an elevated boom Never attempt to climb down the boom from a raised platform.

AERIAL LIFT HAZARDS







Wear fall protection

Haz_4_d5: Wear fall protection Always wear a harness with a lanyard that is connected to the designated anchorage point. Never tie off to the railing if it is not a rated anchorage point.

AERIAL LIFT HAZARDS







Keep free-fall to a minimum

Haz_4_d6: Keep free-fall to a minimum The lanyard and tie-off point should be such that if you are thrown out of the platform your free-fall will be limited to 6 feet or less. For example, if you have a 6 foot lanyard tied off to an anchorage point on the top rail and a vehicle hits the lift causing the boom to flex, you could be tossed up six feet making your free fall 12 feet! In this case you must use a shorter lanyard or tie off lower in the platform.

AERIAL LIFT HAZARDS







Struck or crushed by lift

Haz_5_a: Struck or crushed by lift Twelve percent of the accidents associated with aerial lifts are being struck or crushed by the machine. These can be broken down into two categories; the operator is struck or crushed or the machine strikes or crushes some other person working near the lift. Both are a result of the operator not being aware of his surroundings or familiar with the controls. Consider the following accident.

AERIAL LIFT HAZARDS


• Falls from tipover • Falls from platform

• Struck or crushed by lift

• Maintenance related accidents • Other hazards


Maintenance Related


Accident profile #4

Haz_5_b: Accident profile #4 Employee #1 was operating an aerial lift to install insulation brackets in the ceiling of a warehouse. He had the boom of the lift turned to the backside of the base platform, a position in which the operating controls are reversed. Employee #1 was elevated to the roof and was snug against a rafter. He apparently wanted to move away from the rafter and pushed forward on the control lever to move forward. With the controls reversed, he was actually pushing against the rafter instead. Employee #1’s body was pressed against the control lever and he became caught between the lift basket and the rafter. He was unable to free himself and he died of asphyxia. What went wrong?

AERIAL LIFT HAZARDS







Keep hands safe

Haz_5_d3: Keep hands safe Keep hands inside the platform when moving the lift or swinging the platform near obstacles. Some machines will have an inner rail to grasp onto to keep you from pinching or crushing your hand when maneuvering in tight quarters. Use it.

AERIAL LIFT HAZARDS







Barricade area if needed

Haz_5_d4: Barricade area if needed When setting up for a lift you may need to barricade the area around the machine to protect pedestrians and keep vehicles away.

AERIAL LIFT HAZARDS







Wear hard hats below

Haz_5_d7: Wear hard hats below Workers on the ground associated with the lift operation should wear hard hats and other suitable protection.

AERIAL LIFT HAZARDS







Maintenance related accidents

Haz_6_a: Maintenance related accidents Aerial lifts that aren’t kept in good repair account for ten percent of all aerial lift accidents. Never operate an aerial lift that is damaged or in need of repair. Frequent and periodic inspections can help identify problems with the machine before a failure can occur. Consider the following accident:

INTRODUCTION ANATOMY

Maintenance Related

STABILITY SAFE OPERATIONS HAZARDS

AERIAL LIFT HAZARDS


• Falls from tipover • Falls from platform • Struck or crushed by lift

• Maintenance related accidents

• Other hazards


Accident Profile #5

Haz_6_b: Accident Profile #5: Employee #1 was a foreman for a tree trimming service. He was approximately 30 ft above the ground when the aerial boom he was operating fell from the truck on which it was mounted. He suffered head, leg, and internal injuries, and was transported to the hospital. Subsequent investigations revealed that the bolts that secured the base of the boom to the truck mounting had sheared off. Nine of the bolts were rusty, indicating old breaks; 16 of the bolts showed fresh metal without rust. From the front of the truck, the nine rusty bolts were located on the backside of the boom drive gear. What went wrong?

AERIAL LIFT HAZARDS




• Other hazards



Never use lift as a ground for welding

Haz_6_d5: Never use lift as a ground for welding Never use the lift as a ground for welding. This could send an electrical current through the machine that could damage some components.

AERIAL LIFT HAZARDS




• Other hazards



Other hazards

Haz_7_a: Other hazards Of the five accidents in the “other” category three of them were related to loading or unloading the lift. Consider the following:

AERIAL LIFT HAZARDS


• Falls from tipover • Falls from platform • Struck or crushed by lift • Maintenance related accidents

• Other hazards


Maintenance Related


Accident Profile #6

Haz_7_b: Accident Profile #6: Employee #1, a truck driver, was delivering two scissor lifts to a construction site. He was backing the second lift from a Lowboy transporter when he ran off the ramp and the lift fell, landing on its side. Employee #1 was thrown to the ground, fracturing his upper left arm and several ribs. The scissor lift could have been driven off the ramp remotely, using a cable-connected controller. Other drivers had used these controllers routinely, and the employer has directed all drivers to use the remote system in the future, and not to ride the units. What went wrong?

AERIAL LIFT HAZARDS



• Other hazards



Never push or pull another object

Haz_7_d5: Never push or pull another object Never use the lift to push or pull another object. Never use the boom to try to free another machine by lifting.

AERIAL LIFT HAZARDS



• Other hazards



Do not operate in bad weather

Haz_7_d8: Do not operate in bad weather Never operate a lift during inclement weather, unless approved by the manufacturer for this purpose.

AERIAL LIFT HAZARDS



• Other hazards



Medications

Haz_7_d9: Medications If you are taking prescription or over-the-counter drugs you should obtain medical advice on whether it is ok to use an aerial platform.

AERIAL LIFT HAZARDS



• Other hazards



Conclusion SAFE OPERATION

Conc_1_a1: Aerial lifts, like all equipment, can inflict serious injury or death when misused or abused. Improper training, poor operation, failure to perform preventive maintenance, and failure to inspect can have serious consequences.



Conclusion SAFE OPERATION

Conc_1_a2: Safety is the responsibility of everyone involved in aerial lift operations, from operators to maintenance personnel. You can help ensure safe operation by knowing and following all safe work practices and safety regulations that are applicable to your workplace.


Aerial Lift Training

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