Raising The Bar Guidance - Tracked 360° Excavator (>10T) Equipment Requirements

Raising The Bar Guidance - Tracked 360° Excavator (>10T) Equipment Requirements

The Tracked 360° Excavator is a powerful and versatile machine capable of rotating a full 360 degrees, enabling operators to excavate and lift materials from any direction around the machine. This flexibility makes it essential in construction and highway projects, where heavy-duty excavation and handling are required. However, the significant size and power of tracked excavators over 10 tonnes also present heightened risks, necessitating adherence to rigorous safety standards. The National Highways "Raising the Bar 1" guidelines set forth specific requirements to ensure the safe and compliant operation of these machines.

General Minimum Requirements

The General Minimum Requirements (GMR) section outlines the baseline safety and operational protocols that apply to all plant and equipment, including the Tracked 360° Excavator:

1. Daily Inspections: Tracked excavators must undergo comprehensive pre-use inspections daily, with the operator completing a pre-start checklist to verify that the machine is in safe working order.

2. Compliance with Legislation: Excavators must meet UK regulatory requirements, including the European Commission Machinery Directive (2006/42/EC) or UKCA certification, with a declaration of conformity for safety and operational compliance.

3. Visibility and Safety Markings: Clear and legible safety decals must be in place, and access steps and handrails should be colour-coded for high visibility, allowing operators to enter and exit safely.

4. Seat Belts: Functional seat belts are mandatory and must be worn at all times during operation.

5. Public Highway Compliance: When used on public roads, Tracked 360° Excavators must display registration plates, have fully operational lights, and include flashing amber beacons as outlined in Chapter 8 of the Traffic Signs Manual.

Equipment-Specific Safety and Compliance Standards

The Tracked 360° Excavator presents unique operational challenges due to its size, rotation capabilities, and high lifting power. Additional safety standards for this equipment are as follows:

1. Amber Beacon and Green Seat Belt Indicator: A flashing amber beacon is required for visibility. Additionally, a green light must indicate when the operator’s seat belt is engaged. This green light may be turned off on public roads where it could conflict with lighting regulations.

2. 360° Visibility: The machine must ensure a clear 360° line of sight at a distance of 1 meter and a height of 1 meter around the equipment, achieved through line-of-sight, mirrors, or cameras.

3. Roll Over and Falling Object Protective Structures: The cab must be equipped with ROPS (Roll Over Protective Structure) and, where necessary, FOPS (Falling Object Protective Structure) based on a risk assessment of the working environment.

4. Movement Alarms: Tracked 360° Excavators must be fitted with a movement alarm that is clearly audible outside the cab, alerting nearby personnel when the machine is in motion.

5. Quick Hitch Mechanism: If a quick hitch attachment is used, it must be a fully automatic double-locking device. An in-cab warning alarm should notify the operator if an attachment is not securely locked.

6. Height Restrictors: When operating near overhead obstructions or power lines, height restrictors should be fitted, and operators must follow the Health and Safety Executive’s GS6 guidance on avoiding overhead power line hazards.

Lifting Operations Standards

The Tracked 360° Excavator is frequently used for lifting operations, which require strict adherence to Lifting Operations and Lifting Equipment Regulations (LOLER) standards.

1. LOLER Certification: Lifting equipment on the excavator must have a valid LOLER inspection certificate (valid for 12 months) and undergo regular six-monthly inspections for all lifting accessories.

2. Certified Lifting Points: Each lifting point must be certified, with the Safe Working Load (SWL) clearly marked to prevent overloading.

3. Overload Warning Systems: An audible or visual overload warning system must be installed to alert the operator if the lifting capacity is exceeded.

4. Lifting Plans and Risk Assessment: A detailed lifting duty sheet, lift plan, and risk assessment are mandatory. Check valves must also be fitted to the excavator’s boom and dipper rams to maintain stability during lifting operations.

5. Lifting Attachments: If using a lifting eye, the attachment must be fitted with an internal thrust bearing swivel hook to avoid dangerous swinging. Short sling chains should be used to prevent side loads on the excavator.

Operator Competency and Requirements

The operator’s knowledge and experience are crucial for safe operation of the Tracked 360° Excavator. The following requirements apply:

1. Licensing and Authorization: Operators must have the appropriate driving license category for the excavator and require authorization before operating on public highways.

2. Quick Hitch Training: If a quick hitch attachment is in place, operators must be trained in its safe use and conduct daily inspections to confirm it is securely attached.

3. Ground-Breaking Permits: Operators must have permits and follow proper procedures for ground-breaking operations, understanding the location of underground utilities.

4. Seat Belt Protocol: Operators must wear seat belts at all times in the cab, as per the general safety requirements.

Desirable Features

Several additional features are recommended to further enhance the safety and operational capabilities of the Tracked 360° Excavator:

1. 360º Camera System: Advanced 360º camera systems provide interlinked images from multiple angles around the excavator, improving operator awareness and minimizing the risk of collisions with surrounding workers.

2. Pedestrian Detection Technology: Some camera systems offer pedestrian detection, alerting operators when personnel are within a 5-meter proximity of the machine, creating safer operating zones.

3. Zero Tail Swing: For improved manoeuvrability in tight spaces, zero tail swing is a desirable feature, allowing the excavator to rotate fully without the counterweight extending beyond its track width.

4. Stage V Emission Compliance: To minimize environmental impact, Stage V engine compliance is recommended for projects aiming to reduce emissions.

5. Slew Restrictors: When appropriate, slew restrictors can enhance control, especially in restricted spaces or near exclusion zones.

Hazard Identification and Mitigation

Due to the heavy-duty nature of the Tracked 360° Excavator, specific risks must be mitigated through careful planning and adherence to safety protocols:

• Risk of Overturning: The risk of overturning is present if the excavator is on uneven ground or lifting duties are exceeded. Operators should always work on level ground where possible and strictly adhere to lifting guidelines.

• Underground Utilities: When excavating, the operator must have a ground-breaking permit and knowledge of underground services to avoid interference with utility lines.

• Quick Hitch Detachment: If the quick hitch attachment is improperly secured, it may detach unexpectedly. Operators must conduct daily inspections and ensure the hitch is securely locked before beginning operations.

• Crushing Hazards: The rotating structure poses a risk of crushing if personnel enter the slewing zone. Operators must use barriers and clear exclusion zones to prevent pedestrian entry into these areas.

• Height Obstructions: Overhead power lines and structures require the use of height restrictors and compliance with safety guidelines such as GS6 to avoid accidental contact.

Summary

The Tracked 360° Excavator is a critical asset for large-scale excavation and material handling on construction sites. However, its operational capabilities also present significant hazards. National Highways’ "Raising the Bar" standards provide comprehensive guidelines to ensure that these machines are operated safely and effectively. By following the specified requirements for ROPS/FOPS, quick hitch protocols, and lifting standards, operators can ensure both personal safety and operational compliance. Optional safety features like 360° cameras, pedestrian detection systems, and environmental compliance with Stage V emissions can further enhance site safety and efficiency.