Industrial sites have repetitive operations. The same movement, the same setups, the same routes past machinery. Every day there are the same hazards, the same legislation, and the same predictable accidents.
Lifting Equipment and LOLER
LOLER, the Lifting Operations and Lifting Equipment Regulations 1998, means the security of lifting frame equipment and the security of the frame and the lifting tackle are strengthened. It also means that lifting operations are supervised and planned, and that lifting equipment is examined at set periods.
LOLER requires a higher standard of examination than an inspection. An inspection can be conducted by a trained operator. A thorough examination must be conducted by a competent person who has no vested interest. A thorough examination is required for most lifting equipment, like overhead cranes, every 12 months. If the equipment has the potential to cause a loss of life, a thorough examination is required every 6 months. The daily checks and examinations of the equipment are the responsibility of the operator.
There are many more requirements for overhead cranes in LOLER. End stops, brakes, limit switches, hook latches, and other items need to be examined. The structural components of the crane runway are also required to be examined, even if the crane is not. Many sites will examine the crane and ignore the runway, which is where fatigue cracking will develop.
Section 2.4 Chain Blocks and Lever Hoists
Chain blocks and lever hoists are found in almost all industrial environments. The chain shows the most degradation. The most common type of wear is corrosion. Damaged chain links are difficult to evaluate during visual inspections. Even corroded chain links may look serviceable — a chain that appears to be in good condition may only have 80 to 85 percent of its rated capacity. The most common criterion for replacement is an increase in length. Chain is considered unserviceable when a sample of ten links is longer than the acceptable limit as prescribed by the manufacturer.
8.2 Load Cells
Load cells function wherever the monitoring of safe working loads is critical. Examples include the overload protection for cranes, the verification of the weighbridge, and the monitoring of the tension of cable stays. The selection process is simple as long as the fundamentals are observed. For the working load limit (WLL), the cell should be fully loaded to a minimum of 125 percent. The selection of the type of cell is dictated by the application. For example, compression cells are used for static weighing, tension cells are used for suspended loads, and shackle-type cells are used when quick rigging is required.
2.5 Racking and Storage Systems
SEMA (the Storage Equipment Manufacturers’ Association) produces the Code of Practice for the Design of Static Steel Pallet Racking. This is the design code for all pallet racking systems in the UK. Any racking systems installer worth their salt will ensure their systems are compliant with SEMA. If they cannot tell you which standard governs their design, you should find someone else.
Pallet racking load capacity is determined by frame capacity and beam capacity. Both should be evaluated. The upright frame supports the load from all beams in its bay. The beam supports the load of a single pallet. Manufacturers specify load capacity, and SEMA guides that these should be posted on the racking. If a rack has no load notices, it has not been commissioned correctly.
Damage is a constant issue. Forklifts collide with the racking’s uprights. Pallets overhang from beams. Loads are stacked above the designated level. All of the above are documented only if there is an inspection. SEMA suggests a contractual racking inspection at minimum once a year, completed by an approved Rack Inspection Association (RIA) inspector. The more effective control is a trained internal inspector that conducts inspections on a daily basis. This internal inspector should be competent enough to classify the damage as green, amber, or red without having to rely on an annual inspection.
Cantilever racking is better suited to accommodate the long stock that cannot be racked on a standard pallet. Since there are no beams on the racking with open-arm designs, users have no way of knowing if they are racking to the maximum level or not. Load notices should be consulted, as arm capacities tend to be lower than average assumptions. With regard to outdoor racking systems, operations with a galvanized or powder coated finish on the racking structures will protect the steel, however, the Arm connectors and base plates should be evaluated for corrosion on a yearly basis.
Mezzanine floors add a layer of complexity to a project. They introduce structural elements governed by Building Regulations. Depending where they are located, some may need planning approval. A floor plate spans a moving frame that supports vertical loads due to point loads from columns. Specifying a load for a mezzanine structure used in pallet racking is most of the time an exercise in undersizing the structure.
PUWER and Machinery Safety
When used in conjunction with LOLER, PUWER covers a large scope of machinery and plant services. PUWER ensures the equipment is suitable for the task, and it remains serviceable and is maintained with care. It also covers guarding an accessible moving element of a machine, and clear control elements.
Pre-use inspections mandated by PUWER differ from location to location. There is also no prescriptive answer to how often a machine needs an examination. This is determined by a risk assessment that takes into account the operational context, the anticipated effect if the equipment were to fail, and how often the equipment is used. A pallet truck in a dry warehouse needs significantly less frequent inspection than one in a chilled warehouse.
PUWER prosecutions tend to center around machine guarding. Fixed guards are preferred over interlocked guards which are preferred over trip devices. Guard removal for access or visibility is the most universal means of injuring maintenance and operational staff, most especially on busy production sites. Fixed guards that restrict access most often simplicitly confess to design failures on the part of the designer; removal of the guard should not be tolerated, but the design of the guard should be improved as the removal of the guard should not be the solution.
Competence records are particularly relevant. PUWER mandates sufficient training for users of work equipment. The regulations do not define ‘sufficient,’ meaning that the duty-holder’s risk assessment essentially establishes the threshold. Courts have taken a broad approach in the interpretation of PUWER — having a documented, retrainable, and regular training scheme is the absolute minimum definable position. On sites where counterbalance trucks and reach trucks are employed, RTITB or ITSSAR training is the accepted standard.