LIFTING AND SUPPORTING LOADS, MOBILE

EQUIPMENT AWARENESS
ASHAKA 16MW CPP PROJECT NIGERIA
 Presenter
Adakole Udeh
Lifting and Rigging Specialist

Awareness program
  

PLEASE TURN OFF YOUR PHONE OR PUT IT ON

SILENT
 INTRODUCTION
LIFTING AND LOADS SUPPORTING
AND MOBILE EQUIPMENT
  LOLER ACT 1998
 LOLER –Lifting operation and lifting Equipment regulation 1998
Abbreviated to LOLER regulation or LOLER 1998 places
duties on people or companies who own, operate or have control
over lifting Equipment.
In most cases, lifting equipment will also be covered by the
provision and use of work equipment regulation (PUWER).
You need to understand your legal duties when it comes to
maintenance and inspecting lifting equipment.
The LOLER regulations require that all operation involving lifting
equipment must be;

 properly planned by a competent person

 Appropriately supervised

Present Adakole Udeh

 It is also require that all equipment use for lifting is:
a. Fit for purpose
b. Appropriate for the task
c. Suitable marked with suitable maintenance record and defects.

When you undertake lifting operations involving lifting equipment,

you must;
Plan them properly
Supervise them appropriately
Ensure that they are carried out in a safe manner.
  PURPOSE

The purpose of this standard is to communicate LafargeHolcim

Group’s minimum health and safety requirements for managing
the risks associated with lifting and supporting loads.
  SCOPE
This standard applies to all Lifting and Supporting Loads activities
while under LafargeHolcim management control.
The Country must develop and publish its own local standard
that complies with this Group Standard, local legislation and
any other standards, regulations or other requirements to which
the Country has committed to.
Where the requirements of local legislation are more stringent
than those specified in this standard, then the local legislation
must be complied with.
  PROGRAM MANAGEMENT
The Country and its Units must document and implement a program
that establishes:
a) A Country specific standard for managing lifting and supporting
loads (LaSL) and associated activities.
b) Templates for LaSL work procedures and any associated checklists
and record forms.
c) A process for identifying and assessing LaSL hazards and selecting
appropriate risk controls.
d) A process for authoring and publishing LaSL procedures, including
version control and accessibility.
e) Documented roles and responsibilities (including authorizations and
authorities).
f) A process for ensuring that LaSL equipment procurement and
commissioning procedures complies with the requirements in this
standard.
g) Practical and theory training specifically tailored for the following roles:
 Those who develop LaSL procedures.
 Those who manage lifting operations – Lift Manager
 Those who operate lifting machines – Lift Operator.
 Those who select and use slings – Rigger.
 Those who give signals to the lift operator – Signaller.
 Those who, after assessment of competence, formally authorize
 workers to carry out lifting activities.
h) A process to manage changes relating to LaSL.
i) Procedures to manage foreseeable LaSL related emergencies.
j) An initial and then annual review and gap analysis of the program and
its procedures conducted via procedure audits to:
1) Verify that compliance is being achieved.
2) Evaluate the effectiveness and relevance of LaSL procedures.
3) Verify that management of change has been applied.
4) Create an action plan (or update the existing one) to eliminate, or
where not practicable, reduce the risks through the hierarchy of control
5) Document any deviation from minimum requirements, rules and
prohibitions listed in this Group Standard. Those deviations are to be
limited to rare exceptions and are only acceptable in extenuating
circumstances when there is no practical way to be in compliance
  GENERAL REQUIREMENTS
Hazard Identification and Procedure Creation
a) All lifting equipment and support stands (LaSL equipment) must be
subject to a risk assessment in order to determine requirements for:
a. 1. Operator competencies required to operate each type of equipment.
a. 2. Safe Working Load (SWL) of the LaSL equipment.
a. 3. Safety devices (e.g. limit switches, visual/audible warning systems,
or emergency stop controls).
a. 4. Ground conditions needed to operate safely.
a. 5. Signage and demarcation or barricading required for the operating
environment (e.g. working near power lines, ground conditions,
preventing access under areas where the load is being supported
or transferred).
b) A task analysis and a lifting plan must be completed prior to work being
conducted which involves the use of LaSL equipment in the following
situations:
b. 1. Where it is a non-routine task or the task is being performed for the
first time.
b. 2. When workers are required to handle the load during movements
(e.g. guiding loads in and out of restricted areas using hand lines).
b. 3. Where the load is to be suspended or supported in position and the
work requires personnel to work within the drop zone of the load.
b. 4. Performing a tandem lift (e.g. using two cranes to lift a very long beam).
b. 5. Where environmental hazards are present (e.g. power lines, physical
barriers, soft ground conditions, working near water, etc.).
c) Documented job specific procedures must be written for routine LaSL
activities.
 Operation and use of Lifting and Supporting Loads Equipment
Lifting Plan
a) The plan for any lifting operation must address the foreseeable risks
involved in the work and identify the appropriate resources
(including people) necessary for safe completion of the job.
b) The lifting plan must contain, when relevant for the task:
b.1. List of all lifting machines and accessories to be used
b.2. Picture of the machine with the position of the slings and the centre
of gravity (COG) position taken from the machine specification, machine
manufacturer or calculated by a lifting expert.
b.3. A sketch with the lifting factors and machine position versus load.
b.4. A machine loading factor chart
b.5. A picture of the specified area indicating the lifting machine, riggers
and signallers position in both sending a receiving locations.
b.6. A pre-job lifting equipment check-list
b.7. Any other relevant documentation depending on the lift details
(work at height, etc.)
  OPERATIONAL REQUIREMENTS

The operation of LaSL equipment must address the following

requirements:
a) A visual inspection of the LaSL equipment must be performed prior to
use.
b) A visual inspection of the workplace must be conducted before the
task stats. In particular, inspection must identify the presence of
obstacles in the lifting area and how the related risks are going to be
controlled.
c) A single person (the Lift Manager) must be responsible for the whole
lifting operation.
d) All lifting hooks must be fitted with a safety latch.
e) LaSL equipment must not be loaded above its SWL.
f) LaSL equipment known or suspected to have been overloaded must
be withdrawn from service and re-tested and/or examined prior to
being introduced back into service.
g) Where the lifting operator position is above 1.8m from the ground,
the Lift Operator activities must also be managed as a working at
height activity. Refer to HSS-05 Working at Height Standard.
h) Loads must be carried as near to the support surface as practicable;
i) Loads must not be lifted over people.
 a. 1. In the case of e.g. vehicle lifts, they must be confirmed to be out of
lift mode and the lift mechanically locked before persons go under
the vehicle.
j) People must be prevented from entering a drop zone (e.g. by using
barriers) unless other suitable controls are in place and those who enter
are authorized.
k) Adequate lighting must be provided during all lifting operations
k.1. Special consideration must be given for lifting operations that
involve silos, ships holds, or other potentially dark places.
k.2. Special consideration must be given to the potential for a lifting
operation crossing into the hours of dusk and or darkness.
k.3. Lighting must be in place before the lifting operation begins.
I) Lifting rigs (sling combinations) must be used within their design
parameters, e.g.:
i.1. Two legs, at an angle no greater than 90o between the legs.
i.2. Three legs, at angles no greater than 45o between the leg and the
centreline of the hook.
i.3. Four legs, at an angle of no greater than 90o between the opposite
legs.
i.4. Where angles cannot be achieved, a Spreader-Beam’ or
an alternative safe method of lifting must be used.
m) A crane or hoist must not to be left unattended unless the following
actions, where applicable, have been taken:
m.1. all loads have been removed from the hook;
m.2. the hook has been raised to a position where it is safely clear of
other operations, hooked back or otherwise appropriately secured;
m.3. all powered motions have been disabled; and
access to the cabin / controls has been securely restricted.
Storage of Lifting Accessories
Lifting Accessories’ not in use must be stored:
a) Off the ground on racks, hooks, or shelves.
b) Segregated by type or capacity to allow for ease of identification.
c) In the case of synthetic fibre slings, stored away from direct
sunlight to
prevent UV damage.
Support Stands
) The correct use and positioning of support stands under each load
must be identified by referring to manufacturer’s manuals or a safe
work procedure written by a competent person.
) Support stands must be secure and safely positioned.
c) Support stands must be suitable to safely suspend the
intended load.
a.1. cc each lifting machine in a position easily visible from the
operator’s position.
a.2. Inspection tags must be displayed on lifting machines
where the Operator can easily see it.
a.3. The safe working load (SWL) must be displayed on al
l lifting accessories and support stands.
a.4. Storage areas for lifting accessories must have signs
showing the safe working load (SWL) for the accessories
stored (e.g. a sign above a hook where slings of a certain
SWL are stored).
  Design and Commissioning
a) Fabricated or custom built lifting equipment and support stands must
be supplied with engineering calculations and drawings, checked and
certified by a competent engineer, which demonstrate it can support
the rated Safe Working Load (SWL).
b) LaSL equipment must meet the following requirements:
b.1. Operator manuals and load charts must be supplied with the LaS
equipment.
b.2. Lifting equipment used to raise/lower people (including lifts
/elevators) must, where no legal requirements are in force, use
an accepted engineering design.
b.3. All mobile lifting machines must be subject to pre-commissi
oning requirements, and must be commissioned before first use.
  Maintenance and Inspection
a) A maintenance program for all LaSL equipment must be established
and include:
a.1. A register of all LaSL equipment.
a.2. Schedules for conducting planned preventative maintenance.
a.3. The recording of all preventative maintenance, defects, and
repair work conducted.
a.4. On cranes that can be broken down for transport, each part
mustbe inspected and tagged.
b) An inspection process for all lifting equipment and support stands
must be established. The inspection process, must address:
 Maintenance and Inspection
b.1. Checklists to prompt critical aspects of the equipment which must
be inspected.
b.2. Schedules for conducting inspections. As a minimum the following
will apply
b.2.1. Support stands must be inspected at six-monthly intervals.
b.2.2. Lifting accessories must be inspected and tagged with the next
inspection date at six-monthly intervals.
b.2.3. Lifting machines must be inspected no less frequently than
every 12 months.
b.3. The recording of all inspections conducted. Where the lifting
equipment or a support stand does not comply it must be removed
from service/operation.
c) Where a defect, including excessive wear, is identified it must be
recorded.
d) Lifting equipment must be removed from service, and the LaSL
register amended accordingly, if it is: damaged; incorrectly tagged;
or outside the defined inspection date.
  Emergency Controls
a) Each overhead crane (e.g. a gantry crane) must be provided with
appropriately positioned main isolation devices which must be signed
and easily accessible to shut down the crane in the event of an
emergency. Refer to HSS-103 Energy Isolation Standard.

Note: Off switches on pendants and remotes are not to be considered

as being main isolation devices.

b) Rescue of lifting machine operators where the operator position is

above 1.8 m from the ground must be managed as working at height.
Refer to HSS-102 Working at Height Standard.
Emergency Controls devices
  Worker Health and Safety
Workers must comply with planned operating hours, rest breaks and
daily and weekly rest periods.
 Health
a) An occupational health assessment of fitness for duty must be
conducted pre-placement and at least every 2 years for workers
who operate lifting machines.
b) Workers must be advised during training programs to notify their
supervisor if they develop a health condition or start medication that
may affect their fitness for duty so that they can be referred to the
occupational health service for assessment.
c) Requirements must be established for:
c.1. An occupational health assessment program for workers that
operate lifting machines including formal reporting to management
of fitness for duty outcomes after each assessment.
c.2. Rules to manage fatigue, including stipulating the maximum hours
that a lifting machine operator can work and, the required daily rest
breaks and daily and weekly rest periods.
  Prohibited Behaviours
a) Deliberately lifting loads over people.
b) Riding on loads being lifted.
c) Lifting people in an unauthorized platform (e.g. bucket or other
container).
d) Operating/using LaSL equipment for which they are not authorized.
e) Allowing other persons to operate/use LaSL equipment for which
they are not authorized.
f) Overloading LaSL equipment, or lifting a load without verifying its
weight.
g) Operating lifting machines on unsuitable ground.
h) Using lifting equipment that is unsafe (e.g. defective or its inspection
tag has passed its next inspection date).
i) Not reporting a lifting or load supporting incident to a supervisor.
  Management of Change
a) Any installation or modification of LaSL equipment must trigger:
a.1. Review of applicable lifting and supporting of loads procedures
and controls.
a.2. Update where controls are found to be no longer valid or
ineffective.
a.3. Communication about the change to all relevant workers.
a.4. Where a new plant is to be constructed, the design phase must
include a documented design review that identifies ways to
eliminate, or where this is not possible, to reduce the risks
associated with lifting operations (e.g. identify opportunities
for
Installing fixed lifting devices for routine lifts, ensure access
for
mobile lifting equipment, etc.)
7. Training, Competency and Authorization
a) Lifting activities must be managed by using a competency and
training matrix that explicitly states the required competency and
training for both workers and their supervisors.
b) Procedures must be in place to ensure that workers who carry out
lifting activities are formally authorized for those activities.
c) A list of workers that have been formally authorized to carry out
lifting activities must be available at the site.
d) The competency of each worker who is assigned to carry out lifting
activities must be periodically evaluated and documented.
d.1.Evaluation of competence must be conducted at the time of
initial and refresher training.
e) Line management must ensure that on-going observation of workers
skills and compliance is carried out as part of daily operations and
that the information gathered is used during competency assessment.
 Roles Relating to Lifting of Loads
The Country must include these roles in their procedures for lifting.
Lifting Manager
The lifting manager must:
a) Be responsible for all lifting operations, except for fork lift operations.
b) Issue authorizations to Operators, Riggers and Signallers.
c) Review and approve the lifting plan
c.1. Verify the load weight before selecting ‘Lifting Accessories’.
c.2. Select and use ‘Lifting Accessories’ that have sufficient safe
working load (SWL) for the load to be lifted and the nature
of the lifting operation:
c.3. Include the number of sling legs and the angle of sling legs into
account when calculating the Lifting Accessories capacity.
c.4. Select the appropriate lifting points having considered the load
centre of gravity, likelihood of slippage, etc.
d) For non-routine lifting, witness the entire operations
  Lifting Operator
The Lifting Operator must:
a) Operate lifting machines and /or use lifting accessories as per the
training that they received.
b) Only lift loads that are within the capacity of the lifting equipment
that they are operating.
c) Follow the direction of their Signaller.
d) Only conduct lifting activities that the Lifting Manager has authorized
them for.
d.1. Forklift trucks using the tines (forks) to lift loads during routine
operations are excluded from this requirement; the Traffic
Manager authorizes in this case. Refer to HSS-101 Mobile
Equipment and Traffic Management Standard.
Signaller
The Signaller must:
  Signaller
The Signaller must:
a) Only work as a signaller if they are authorized to do so.
b)Use the standard signals and verbal commands that are authorized
in the Country.
c) Not stand under loads.
 Rigger
The Rigger must:
a) Only work as a rigger if they are authorized to do so.
b) Not stand under loads.
c) Check ‘Lifting Accessories’ and report any defect to the Lifting
Manager
d) Check that the load is properly secured and balanced.
  Training Delivery
Due to the large number of different types of Lifting Equipment, it
is not practicable to provide comprehensive Group requirements
for the content and duration of initial and refresher training.
Training requirements must be defined by the Country and, as a
minimum be comprised of:
a) Competency standards defined for persons required to:
a.1. Operate lifting machines or, use lifting accessories or support stands
a.2. Conduct risk assessments or task analysis on activities involving
lifting and supporting loads
a.3. Approve the lifting plan
a.4. Direct crane movement and overhead loads (Signaller).
a.5. Perform slinging and rigging of loads (Rigger).
a.6. Inspect LaSL equipment.
a.7.Perform maintenance on LaSL equipment.
b) Refresher training must be provided on a regular basis to personnel
who are required to operate or use or direct the use of LaSL
equipment.
c) Refresher training must also be carried out when an incident
investigation or audit identifies a competence deficiency, and when
the worker has not carried out any lifting of loads work in the
previous 12 months.
d) The following persons must be aware of, understand the
requirements of, and be competent in the requirements of this
Standard as they are defined within the Country’s own lifting loads
standard:
d.1. The person(s) responsible for writing the Country lifting loads
standard.
d.2. The person(s) responsible for providing technical expertise
support on lifting loads.
Training Delivery
  Record Retention
The requirement for record retention in this standard is an exemption
from the Group HSMS Standard.
a) Records relating to the inspection and maintenance of LaSL
equipment must be retained in accordance with manufacturer’s
requirements, or for a minimum of 36 months, whichever is the
longer.
b) When, according to manufacturer, specific maintenance and
inspection activities are to be completed at a frequency that is longer
than every 36 months, the last two specific inspections /maintenance
records must be retained.
Records relating to the initial installation and the modification of LaSL
equipment must be retained for the duration that they remain in use
plus 36 months.
  Document Control

The latest version of this document, and therefore the only

controlled version, is available on the Group Intranet Health
& Safety pages. No other copy of this document is to be
considered to be the latest or controlled copy.
 Hand Signals
The Work Team Leader is responsible for assigning the Signalman to
each lift. It is essential that the Signalman understands what to do
during crane operations, as well as what not to do. In all cases, the
Crane Operator and Signalman must agree on the hand signals.
Every hazardous situation that an operator might encounter cannot be
covered by a written set of rules, but the use of standardized hand
signals from a designated Signalman can reduce risks.
Use Standard Hand Signals
The hand signals shown are standard signals recommended in the
API RP 2D (Operation and Maintenance of Offshore Cranes):
Figure 1. Standard Crane Hand Signals.
In some cases there may be a need for special signals not covered in
the signal charts. In these cases, the special signals used MUST
BE AGREED UPON IN ADVANCE BY THE QUALIFIED CRANE OPERATORAND THE
SIGNALMAN. These special signals must not be confused in any way with the
standard hand signals
  Rigging Equipment
Pre-Use Inspections
If an item of equipment is seen to be defective or suspected of being
defective either during the pre-use inspection or in service, it must be
removed from service immediately and the Work Team Leader notified.
When an item is being scrapped, it is to be physically destroyed in
order to prevent any further use of any kind. If it is not immediately
physically destroyed, it must be clearly marked “NOT TO BE USED” and
should be placed in a “quarantine area” until it can be destroyed.
 Pre-Use Inspection Steps
Ensure the correct type of shackle bolt or pin is fitted. A common
problem exists where high-grade shackle pins are replaced with
standard bolts that are not capable of taking the load.
  Pre-Use Inspection
The pre-use inspection will be performed and documented before
crane use, typically daily and then as the Qualified Crane Operator
deems necessary during the day for extended operations.
The Crane Pre-Use Inspection Checklist, Appendix A, shall be maintained
in the crane. The Qualified Crane Operator will perform this inspection.
If the Qualified Crane Operator changes, a new crane pre-use inspection
should be performed and documented by the new Qualified Crane
Operator.
Check that the sling set is correctly fitted, e.g., no twists in the legs.
Check that the appropriate securing arrangements are installed
(split pins, wire mousing, etc.). The preferred style of shackle is the
bow or anchor type fitted with a safety pin that is, bolt, nut and split pin.
Any Questions?
  Purpose
The purpose of this standard is to communicate LafargeHolcim Group’s
minimum health and safety requirements for managing the risks
associated with mobile equipment and on-site traffic.
 Scope
This Standard applies to all Mobile Equipment (ME) and on-site Traffic
Management (TM) activities that take place while under LafargeHolcim
management control.
The Country must develop and publish its own local standard that
complies with this Group Standard, local legislation and any other
standards, regulations or other requirements to which the Country has
committed to.
Where the requirements of local legislation are more stringent than
those specified in this standard, then the local legislation must be
complied with.
  Program Management
The Country and its Units must document and implement a program
that establishes:
a) A Country specific standard for mobile equipment and on-site traffic
management.
b) Templates for ME and TM procedures and any associated checklists
and record forms.
c) A process for identifying and assessing ME and TM hazards and
selecting appropriate risk controls.
d) A process for authoring and publishing ME and TM procedures
(including site traffic plans), including version control and accessibility.
e) Documented roles and responsibilities (including authorizations and
authorities).
f) A process for ensuring that equipment procurement and
commissioning complies with the requirements in this standard
g) Practical and theory training specifically tailored for the following roles:
g.1. Those who create the traffic plan and associated procedures to
manage mobile equipment and on site traffic, and pedestrians
d.2. Those with the authority to operate mobile equipment – Operator
d.3. Those who manage on site traffic plan- On Site Traffic Manager
d.4. Those who, after assessment of competency, formally authorize
Operators
d.5. Those with authority to supervise mobile equipment and or on-site
traffic activities
h) A process to manage changes relating to mobile equipment and on-site
traffic management
i) Procedures to manage foreseeable mobile equipment or on-site traffic
related emergencies.
j) An initial and then annual review and gap analysis of the program and its
procedures conducted via procedure audits to:
 j.1. Verify that compliance is being achieved.
j.2. Evaluate the effectiveness and relevance of ME procedures and
on-site TM plans.
j.3. Verify that management of change has been applied.
j.4. Create an action plan (or update the existing one) to eliminate,
or where not practicable, reduce the risks through the hierarchy
of control.
j.5. Document any deviation from minimum requirements, rules and
prohibitions listed in this Group Standard. Those deviations are to
be
limited to rare exceptions and are only acceptable in extenuating
circumstances when there is no practical way to be in compliance.
In such cases,  the country must document the conflict and a
formal
specific procedure with alternative controls must be in place
General Requirements
Hazard identification and Procedure Creation
a) A competent person must identify the mobile equipment and on-site
traffic flow hazards associated with any job task and assess the risks,
and then eliminate or control those risks that have the potential to
result in harm to people.
b) Documented job specific procedures must be written that consider
the following, as a minimum:
b.1. The types of ME; specifically:
b.1.1. Capability of carrying loads
b.1.2. Capability of lifting loads
b.1.3. Capability of operating on rough terrain
b.1.4. Capability to carry passengers
b.1.5. Capability for working in hazardous conditions
(e.g. quarries, explosive atmospheres, heat, etc.).
b.2. The traffic patterns, including volumes (normal and peak traffic),
direction, speeds, etc.
b.3. The persons who might be exposed to ME hazards and their
competency
b.4. Effectiveness of existing ME and Traffic control methods, including
supervision. Special consideration is needed for remote/automated
control systems e.g. traffic signals.
b.5. Verification that maintenance procedures comply with or are more
stringent than manufacturer requirements.
b.6. Identification of any ME access hazards, such as ladders, etc.
b.7. Identification of the associated hazards and risks of the operating
environment.
b.8. The competency, authorization and supervision required to
operate every ME.
  Traffic Management Plan
a. Each site must have a Traffic Management Plan that is specific to it and
is based upon hazard identification and risk assessments.
b. The traffic management plan must include the controls set out in the
following sections.
  Site Map
a) The site map must include:
a.1. Roadways and other traffic areas or high risk zones (e.g. places
where reversing is likely).
a.2. Traffic direction, one-way roads, traffic restrictions, etc.
a.3. Location of signs and road markings.
a.4. Any traffic controls such as maximum speed and other traffic
signals, access control, etc.
a.5. Specific hazards (such as overhead cables or other height
restrictions, etc.).
 a.6. Bridges or other structures and their safe load capacities.
a.7. Pedestrian routes and segregation/separation controls.
a.8. PPE-free zones.
b) The site map must be kept up to date.
c) The plan must be available to those that manage traffic on site,
including those who will direct traffic, and must be communicated to
all those that can be involved in on-site traffic operations including
pedestrians and incoming drivers and visitors.

Note: It is most likely that a site map will be too complex for incoming
vehicle drivers to understand in the limited time that is available to
read, understand and retain the information contained in the map;
therefore:
d) Sufficient effort must be given to designing and installing simple to
follow direction signs, e.g. colour coded/shape and simple arrows –
large enough to be easily seen and simple enough to be understood.
 Reversing
a) the need for reversing must be eliminated (e.g. implementing one-
way systems or designated turning areas)
b) Where reversing cannot be eliminated, the reversing areas must be
designed with adequate space, edge protection, guidance markings
and lighting.
c) Rules for the elimination or control of pedestrian traffic in reversing
areas must be implemented.
  Traffic Separation
Conflict between different types of traffic must be eliminated. When
elimination is not possible, it must be reduced to a level where under
normal operating conditions, conflict is unlikely.
a) One-way systems must be implemented wherever this is practicable.
b) The need of traffic wardens must be assessed and, if deemed
necessary, implemented.
c) All land (e.g. areas currently used for gardens, etc.) must be
considered as areas potentially used during the re-design of the traffi
management plan in order to improve traffic separation.
 Pedestrians
a) Pedestrians must be separated from running ME. The use of separa
traffic routes and physical barriers between pedestrians and ME
must be the first consideration;
b) Where a) is not practicable, alternative control measures must be
established.
b.1. Any working activity that requires workers (pedestrians) to
work near running ME must be conducted under a written
specific procedure and formally authorized by the Unit Manager.
 Heavy Equipment and Light Vehicles/ME
a) Smaller vehicles/ME must be kept away from areas where heavy ME
operates
b) When a) is not practicable then the following rules must be established:
b.2. The justification for lack of segregation must be documented and
reviewed annually.
b.2. Heavy ME has priority over light vehicles/ME.
b.3. ME must operate with headlights and flashing beacons turned
on at all times.
b.5. Flags (i.e. buggy whips) must be fitted to light vehicles/ME and must
be easily visible to the operators of large ME/vehicles that share
roadways, yards, etc.
b.6. Rules that restrict access to either heavy ME or light vehicles at one
time must be established.
b.7. Light vehicles used in places where heavy ME might operate, must:
b.7.1. Be fitted with a 50mm wide strip of retro-reflective material
on the front, rear and both sides (red at the rear, yellow on
sides, and white at the front).
b.7.2. Be driven with headlights turned on at all times.
b.7.3. Be driven with flashing lights (i.e. beacon, strobe lights) on and
where it aids visibility.
b.8. Motorcycles, bicycles and tricycles are prohibited in the areas where
heavy ME operates
c) The presence of light vehicles in the workplace (beyond designated
parking areas) such as cars, pick-up trucks, vans or delivery vehicles
must be properly controlled. An authorization must held by the driver
while on site and an entry and exit register must be maintained.

 Floors and Roads

Floors and roads must be suitably constructed and maintained to minimize
the potential of ME and on-site vehicle related incidents. Suitably
constructed means they must be:
a) Of adequate width for the traffic.
b) Capable of resisting the traffic load, specifically axle loads and special
loading such as cranes, etc.
c) Sufficient for the longest vehicles, e.g. at bends/curves.
d) At a grade that is reduced to the minimum practicable; cambers (US
Cross slope) and super-elevation must be suitable for the traffic speed.
e) Constructed with sufficient drainage for the seasonal weather
conditions.
f) Blind curves and blind brows (US Crests) must be avoided where
practicable.
g) Road surfaces must be flat and regularly maintained to avoid potholes
and be clear of any loose
c) Sufficient for the longest vehicles, e.g. at bends/curves.
d) At a grade that is reduced to the minimum practicable; cambers
(US Cross slope) and super-elevation must be suitable for the traffic
speed.
e) Constructed with sufficient drainage for the seasonal weather
conditions.
f) Blind curves and blind brows (US Crests) must be avoided where
practicable.
g) Road surfaces must be flat and regularly maintained to avoid potholes,
and be clear of any loose rocks and other debris.
h) Parking areas must be properly designed with suitable clearances to
allow for vehicle traffic, designated pedestrian routes and safe crossing
points.
i) The need for lighting of roads, yards, and parking areas must be assessed
and when found to be necessary to reduce the risk of significant
injuries, must be installed.
j) Designated parking places required for emergency vehicles must be
identified (e.g. ambulances at medical centres) and kept clear.
k) Designated parking places for regular delivery/collection (e.g.
discharge to silos) must be defined and kept clear of other vehicles/ME
 Haul Roads
a) The standard maximum sustained grade for a haul road without an
emergency/escape lane must be less than 10%.
b) For all haul roads with a grade greater than 10%, emergency/escape
lanes must be installed or suitable alternatives established.
c) Minimum haul road surface width must be 3.5 times the width of the
widest vehicle for two-way traffic and 2.5 times for one-way traffic.
d) Edge protection and safety berms height must be at least equal to the
radius of the biggest tyre of ME operating in that area.
e) Edge protection must be built with soft materials or a combination of
hard and soft material with sufficient drainage, regularly inspected
(especially after heavy rain), and maintained to ensure efficiency.
f) Roads where ME traffic may circulate along the foot of mining faces
(walls), must, where practicable, have catch berms (also called rock
traps) to protect from rock/material falling from above. Note: The CIP
Quarry Safety Handbook must also be consulted for specific
requirements relating to the design and operation of quarries roads.
 Signage and Markings
a) Signs and markings must be conspicuous, suitable in size for the
reader, and maintained.
b) Traffic routes must be designed to be conspicuous, easily seen and
understood by ME operators, drivers of vehicles, and pedestrians.
c) Information boards must be simple to read, contain the minimum of
text and must incorporate pictograms that are standardized across the
country.
Signage and Markings
 Operation
a) ME must be operated within the manufacturer's stated capabilities
(e.g. ground clearance, safe inclines).
b) Operators must ensure that they select appropriate ME for the
environment that they will be operating in; and if no suitable ME is
available, they must report this to their line-manager.
c) ME must not be left unattended unless it is safely parked and the
ignition key is removed.
c.1. Parking brake must be applied
c.2. Wheel chocks or equivalent system to prevent the vehicle from
moving must be used when parking on an inclined/uneven
surface.
c.3. Key must be kept under control to avoid unauthorized use.
d) When engines must be running for power-take-off devices or other
ancillary equipment, the operator must be close by and have line of
sight of the vehicle/equipment.
 Use of Mobile Communications
Rules for the use of mobile communications must be established and
documented that include when and how radio communications are
used, and when they are prohibited.
 Specific High-Risk Activities
Working Near to Overhead Power Lines
Countries must establish procedures for working near overhead wires
and power lines.
These procedures must include but are not limited to the establishment of:
b) Safe separation zones.
c) Prohibitions relating to working during the hours of darkness, unless
the workplace is properly illuminated for night operations and
overhead power lines are conspicuously marked.
d) Overhead lines at risk of impact must be clearly identified.
e) Installation of warning signs (e.g. ‘Danger Overhead Wire’) both
sides of the overhead wire.
f) ME operators must be trained how to properly and safely respond to
an electrical incident.
g) After ME contact with an overhead power line, the ME must be
parked in a safe remote location free of pedestrians for no less than
24 hours to allow the tires to cool and/or rupture safely.
  Towing
a) Authorization for a towing operation must be obtained from the Unit
manager (or the person responsible for towing operations) who must
specify which competent person must be in charge of the operation.
b) The towing operation must be limited to the minimum distance
required to allow the vehicle to move under its own power, or to
reach the nearest place of safety or repair.
c) Only routinely examined and certified ropes / towing slings and fixed
drawbars may be used.
c.1. The capacity of such devices should be at least 50% above the
maximum weight of the vehicle concerned and must take into
account ground conditions increasing this maximum strain.
 Roll-Over Whilst Tipping/Dumping (Tip-Over)
a) All tipping/dumping locations that are not purpose built and
permanent, used by dump trucks must be regularly measured with an
inclinometer to ensure that any side slope is within the dumping
equipment manufacturer's stated tolerances and is therefore safe for
dumping operations.
a.1. For non-permanent dumping locations, the side slope must be
measured no less frequently than once per day when dumping
activities are taking place.
d) Articulated vehicles must be straight when tipping/dumping.
c) Driver/operator must remain in the seat with seat belt applied.
d) Dumping points must be regularly inspected and free from anything
that could damage equipment tyres.
Roll-Over Whilst Tipping/Dumping (Tip-Over)
e) A hazard-zone must be established to each side of the vehicle/ME
equal to its maximum height when tipping/dumping.
f) Tipping/dumping with cross winds higher that 5 Beaufort (28-38 km/
hr) must be avoided
When loads being dumped become stuck:
g.1. The operator must lower the dump body and seek assistance to
free the load.
g.2. Moving the equipment/jolting with the dump body in an attempt
to release stuck loads is prohibited.
Roll-Over Whilst Being Driven
The following factors must be controlled to eliminate roll-over whilst ME is
being driven:
a) Speed.
b) Load and load stability (e.g. overloading, or uneven loading).
c) Road geometry (bends, camber/cross slope, road gradient).
d) Carrying passenger(s) in load-beds or boxes of pickup trucks, or on
flat-bed trailers, or in a load bucket of a wheeled-loader must be
prohibited.
 Reversing Warning Devices
a) All ME must be fitted with audible and visible reversing warning alarms.
b) The need for additional visibility devices (i.e. light signal, convex
mirrors, CCTV, radar, etc.) must be determined through documented
risk assessment.
 Falling Object Protection Systems (FOPS)
a) All ME (except light vehicles) operating in quarries must be equipped
with FOPS.
b) Any other ME where the operator is at risk of impact by falling
objects, such as rock or other items must be fitted with FOPS protection.
  Roll-Over Protection Systems (ROPS)
a) All ME (except light vehicles) operating in quarries must be equipped
with ROPS.
b) All other ME (regardless of size) that have the potential to roll-over
more than 90o must be fitted with ROPS.
 Blind Spot Reduction/Control
The Country must minimize the risk from ME blind spots by:
a) Ensuring that every item of ME has a blind spot assessment .
b) Fitting additional mirrors where they will aid visibility.
c) Fitting CCTV cameras to ME where significant blind spots exist and
mirrors are not a suitable solution (e.g. to the rear of wheeled
loaders).
 In-Vehicle-Monitoring-Systems (IVMS)
On-site dump trucks must be fitted with In-Vehicle-Monitoring-Systems
(IVMS). The selection of IVMS must consider the available satellite
coverage in the quarry.
Note: The CIP Quarry Safety Handbook must also be consulted for specific
requirements relating to the design of mobile equipment operating in
quarries.
Maintenance and Inspection
a) ME must be maintained in accordance with the manufacturer's’ preventive
maintenance schedule and manufacturer's recommendations and, all
original safety features must be retained or improved.
b) All ME must have a copy of the operator's manual in the operator's cab
or, it must be easily available at the site.
c) The sources of energy that must be isolated during maintenance activities
must be identified for every ME; the isolation methods for every source
of energy must be included in ME maintenance procedures.
d) Countries must establish a maintenance program that includes:
d.1. Established schedules for conducting periodic inspection and
maintenance
d.2. Records for all maintenance work and inspections
d.3. Monitoring of compliance with the maintenance and inspection
schedule
d.4. Use of manufacturers’ or manufacturer approved compatible parts.
d.5. Records for all defects reported and repaired
d.6. Methods for ensuring that personnel performing maintenance
and repair work are competent to perform the work
Pre-Operation Inspections
a) Countries must develop pre-operational inspection procedures for all
types of ME
b) Inspections must be completed each shift prior to operating the ME
and must be documented.
 b.1. Where workshop technicians complete the inspection prior to
the shift, the ME operators must at least personally complete a
visual inspection of ME condition and a brake test.
c) A check list must be used as a reminder of what to inspect and what
functionality to test
d) The inspection check list must identify the safety critical items that if
found to be defective or missing, must result in the ME being taken
out of service and must include but is not limited to:
d.1. Inoperable seat belt or seat.
d.2. Mirrors damaged.
d.3. Wheels: Tyres damaged or not properly inflated; wheel nuts missing or loose
d.4. Vehicle brakes not functioning correctly.
d.5. Less than two headlights functioning.
d.6. Reverse alarm not functioning.
d.7. Leaking hydraulic lines.
d.8. Cracks in the chassis, or other visually obvious serious safety defect.
 Worker Health and Safety
Operators must comply with planned operating hours, rest breaks and
dailyand weekly rest periods.
 Health
a) An occupational health assessment of fitness for duty must be
conducted pre-placement and at least every 2 years for workers
who operate ME
b) Workers must be advised during training programs to notify their
supervisor if they develop a health condition or start medication that
may affect their fitness for duty so that they can be referred to the
occupational health service for assessment.
c) Requirements must be established for:
c.1. An occupational health assessment program for workers that
operate ME including formal reporting to management of fitness
for duty outcomes after each assessment.
c.2. Rules to manage fatigue, including stipulating the maximum
hours that an ME operator can work and, the required daily rest
breaks and daily and weekly rest periods.
 Prohibited Behaviours
a) Operating ME in an unsafe manner; e.g. unsafe speed, reckless
manoeuvres, reversing without observation.
b) Riding in ME that is not designed to carry passengers: i.e. no
passenger seat and or seatbelt.
c) Using ME for a purpose for which it was not designed.
d) Doing something that distracts from proper concentration i.e.:
d.1. Using mobile communications whilst operating ME
d.2. Not keeping a cabin free of loose objects that could interfere
with its controls.
e) Leaving keys in the ignition of unattended ME.
f) Leaving ME without applying park brake.
g) Knowingly overloading or operating ME with an insecure load
h) Knowingly using ME on unstable or unsuitable ground.
i) Using mobile phones while walking in areas where it could reduce a
person’s ability to hear oncoming traffic.
j) Not reporting ME or on-site Traffic incidents to a supervisor.
  Management of Change
a) Any modifications to existing ME or procurement of new ME or other
changes that have the potential to increase the risk to ME operation
(e.g. changes to site layout) must trigger:
a.1. Review of applicable procedure(s), including Traffic Management
plan, and controls.
a.2. Update of procedures and controls where they are found to be
no longer valid or ineffective.
a.3. Communication about the change to all relevant workers
b) Where a new plant is to be constructed, the design phase must include
a documented design review that identifies ways to eliminate, or
where this is not possible, to reduce the risks associated with ME.
c) The changes to procedures or working methods must also consider the
need for training on the changes and/or familiarization with the changes
  Training, Competency and Authorization
a) ME and on-site Traffic activities must be managed by using a training
and competency matrix that explicitly states the required competency
and training for both workers and their supervisors.
b) Procedures must be in place to ensure that all ME operators are f
or mally authorized to operate the specific ME. A valid operator’s licence
(or local certification) must be held by the mobile equipment operator
for the specific equipment that they operate.
c) A list of workers formally authorized as ME operators must be available at
the site.
d) The competency of each ME operator must be periodically evaluated and
documented.
d.1. Evaluation of competency must be conducted at the time of initial
and at refresher training
e) Line management must ensure that on-going observation of operator
skills and compliance is carried out as part of daily operations and that
the information gathered is used during competency assessment.
Roles Relating to ME and On-Site Traffic
The Country must include these roles in their procedures for managing
ME and on-site Traffic:
On-Site Traffic Manager
One person must be nominated to be responsible for managing traffic on
site. The Traffic Manager’s scope of responsibility may be for example an
entire integrated cement plant, or only one part such as a quarry; but
responsibilities must not overlap.

The On-Site Traffic Manager is responsible for:

a) Publishing and communicating the On-Site Traffic Management Plan.
b) Issuing authorizations to ME operators, and maintaining a list of Operator
 Mobile Equipment Operator
The person(s) who operate ME must:
a) Be authorized by the On-Site Traffic Manager to operate specific ME
b) Be competent in relation to the nature, hazards and risks of operating
ME and of any associated activities that they will carry out, including
emergency procedures
c) Operate only the ME he/she is authorized for.
 Training Delivery
Training requirements for ME must be defined by the Country, and, as a
minimum, be comprised of:
Who Where Initial Refresher
Operator Classroom 4 Hours  
(Initial Theory)
Operator Controlled place using 3 Days  
(Basic technical skills & Test) equipment (Ratio, 1 trainee:1
  instructor)
4 Days
(Ratio, 2 trainees:1
instructor)
5 Days
(Ratio, 3 trainees:1
instructor)

Operator Workplace under close 1 Day  

(Familiarization with tasks supervision
and workplace)

Operator     ≤3 Years
(Refresher, assessment and (1 Day)
test)
Due to the large number of different types of Mobile Equipments, it is
not practicable to provide comprehensive Group requirements for the
content and duration of initial and refresher training.

When training requirements (training duration and refresher period) for

the above mentioned roles are defined by country regulation, country
regulation will apply. When there is no country regulation applicable,
the above table must be used.

a) Training and authorisation must be specific to each type of mobile

equipment.
b) Where a mobile equipment operator has not operated the equipment
for which they are authorized during the previous 12 months, they must
undergo refresher training to maintain their authorization.
c) Records relating to the procurement of ME, or the installation/
construction of facilities (e.g. dumping points), must be retained for
the duration that they remain in use plus 36 months.
d) Records relating to ME operator competency and training must be
retained for the duration that they remain as employees plus 36
months.
Document Control
The latest version of this document, and therefore the only controlled
version, is available on the Group Intranet Health and Safety pages. No
other copy of this document is to be considered to be the latest or
controlled copy.

Latest Version /
Date Change since the previous version/revision

Version 1.0 / Feb 1, First publication.

2018
Appendix 1- Definitions
Term Definition

3 points safety belts A webbing strap that is secured to the structural parts of the ME The
webbing crosses both the operator’s lap, and diagonally across their torso.

Blind brows (US Crests) A place where the road elevation rises and drops away so that the road
ahead is obscured.

Camber (US Cross slope) The cross sectional slope of a road surface, typically used to drain away
rainfall.

Competent person Someone who has sufficient skills, knowledge and experience to complete
the assigned tasks properly. The level of competency required will depend
on the complexity of the situation and the particular tasks or responsibilities
that they are assigned.

Conspicuous Clearly visible under the prevailing conditions against its background – it is
‘eye-catching’ and increases the likelihood that a person will see it.

Falling Object Protection System A professionally engineered reinforcement installed onto or into a vehicle to
(FOPS) reduce injury and increase operator protection in the case of a falling object
landing on the vehicle (such as a rock or piece of machinery).
Haul road A road, typically unsealed (un-metalled) that connects two operational places. A
haul road is typically used for the bulk transfer of materials.

Mobile equipment Equipment that can move under its own power within a workplace. This
includes everything from heavy equipment such as dump trucks used in mining
or equipment performing road paving or construction works, to small fork lift
trucks used in warehouses.
Vehicles that were designed mainly for off-road use (e.g. personal cars, cement
trucks, ready-mix trucks…) are included in the scope of this standard whilst they
are on-site under the control of the on-site Traffic Management Plan.
Heavy Mobile Equipment refers to mobile equipment used in quarry and
construction that can be operated off-road which includes but is not limited to
the following :
o Loading units (backhoe, front end loaders, excavator)
o Hauling units (rigid and articulated dump truck)
o Service units (graders, wheel and track bulldozers, water truck)
 

Practicable Something is practicable when the time, effort and cost to do it is not grossly
disproportionate to the benefit that would be gained by doing it.
Procedure audit A process, carried out by competent persons, to systematically
obtain evidence about the level of implementation and
effectiveness of a procedure. The objective of a procedure audit is
to ascertain whether or not: a) a specific procedure has been
implemented and is being complied with, and b) to assess the
effectiveness of the procedure under all operational conditions.
The normal process is to examine the documented procedure prior
to the audit, and to design a set of tests that the auditor will use to
obtain the evidence necessary to enable the auditor to make a
proper assessment. Tests must include visual observation of the
procedure in action, questions and discussion with workers
involved in the process, and inspection of records.
Roll-Over Although roll-over and tip-over are almost identical, a roll-over is
when a vehicle rolls-over whilst it is travelling. Typically this is due
to excessive speed or unsafe loading and whilst negotiating a bend
in the road.
Roll-Over Protection System A framework, safety canopy, or similar structure, installed as
(ROPS) original equipment by a mobile equipment manufacturer,
designed and intended to protect the equipment operator should
the mobile equipment overturn.
Super-elevation Where the outside edge of a road on a bend is higher than the
inside edge of the bend. Higher speeds can be achieved more
safely when the difference (super-elevation) is greater.
Tip-Over Although roll-over and tip-over are almost identical, a tip-over is
when a vehicle rolls-over whilst it is stationary. Typically this is
due to dumping on a slope, failure of one or more parts of the
dumping system, or an unsafe load.
Traffic Management Plan The formal document that contains the arrangements for on-site
traffic safety management.
Wheel nuts Sometimes known as ‘Lug Nuts’ or Retaining Nuts’. Means the
nuts that are fitted to threaded wheel studs. Sometimes wheel
bolts are used.
Thank you for participation