C7 Presentation
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Transcript of 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