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

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

The Wheeled 360° Excavator is a robust and versatile machine capable of full 360° rotation, allowing operators to excavate, lift, and move materials around the machine’s entire perimeter. With its wheeled configuration, this excavator provides enhanced mobility, making it particularly suitable for operations on paved or relatively smooth surfaces. However, given its size, power, and mobility, strict adherence to safety and operational standards is required to mitigate risks. The "Raising the Bar 1" guidelines set forth by National Highways provide comprehensive requirements to ensure the safe and effective use of Wheeled 360° Excavators over 10 tonnes.

General Minimum Requirements

The General Minimum Requirements (GMR) outline baseline safety standards for all equipment, including the Wheeled 360° Excavator:

1. Daily Inspections: The excavator must be inspected thoroughly before each use. Operators should complete a pre-start checklist, documenting the machine’s condition to identify any potential hazards.

2. Compliance with Legislation: All excavators must comply with UK regulatory standards, including the European Commission Machinery Directive (2006/42/EC) or UKCA certification, with a declaration of conformity.

3. Safety Decals and Visibility Markings: Safety decals should be clear and legible, and all access steps and handrails should be marked in high-visibility colours to facilitate safe entry and exit.

4. Seat Belts: Operators must wear seat belts at all times while operating the excavator.

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

Equipment-Specific Safety and Compliance Standards

Given the unique hazards associated with the Wheeled 360° Excavator, specific safety and operational requirements must be met:

1. Amber Beacon and Seat Belt Indicator: An amber beacon must be installed for visibility, along with an external green light that indicates when the operator’s seat belt is fastened. This green light may be deactivated on public roads where it could conflict with lighting regulations.

2. 360° Visibility Standards: The machine must ensure full 360° visibility using mirrors, cameras, or other visual aids, providing a clear view at a height and distance of 1 meter around the excavator.

3. Roll Over and Falling Object Protective Structures (ROPS and FOPS): The cab must have ROPS to protect the operator in case of rollover, and, where necessary, FOPS to shield against falling objects, as determined by a task-specific risk assessment.

4. Movement Alarm: The excavator should have a functional movement alarm that is audible outside the cab, warning nearby personnel whenever the machine is in motion.

5. Brake Efficiency Testing: Brake efficiency tests should be carried out regularly and documented, including tests of the park, service, and dynamic brakes as recommended by the manufacturer.

6. Axle Locks and Stabilizers: When the excavator is operating in wheeled mode, axle locks should be used for stability. In situations requiring greater stability, stabilizers must be deployed.

7. Quick Hitch Mechanism: If a quick hitch attachment is in use, it must be a fully automatic double-locking device with an in-cab alarm to alert the operator if the attachment is not secure. Operators should also conduct daily inspections of quick hitches to confirm stability and safety.

8. Height Restrictors: If operating near overhead obstructions, such as power lines, height restrictors must be installed. Operators should also follow the Health and Safety Executive’s GS6 guidance on avoiding contact with overhead power lines.

Lifting Operations Standards

Wheeled 360° Excavators often perform lifting tasks, which require compliance with Lifting Operations and Lifting Equipment Regulations (LOLER) to ensure safe handling of loads.

1. LOLER Certification: The excavator’s lifting equipment must have a valid LOLER inspection certificate (valid for 12 months) and undergo six-monthly inspections for all lifting accessories.

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

3. Overload Warning Systems: The excavator should be fitted with an audible or visual overload warning system to alert operators if the load exceeds the safe limit.

4. Lifting Plans and Risk Assessment: A lift plan, risk assessment, and machine-specific duty sheet must be available and understood by the operator for each lifting operation. Check valves should be fitted to the boom and dipper circuits to maintain stability when lifting.

5. Lifting Eye and Safety Precautions: When using a lifting eye, the attachment must be fitted with a swivel hook to prevent swinging or side loads. Operators should use a short sling chain to reduce side load risks.

6. Lift and Carry Duties: Specific risk assessments should be conducted if the excavator will perform lift-and-carry tasks, taking into account the manufacturer’s instructions and the terrain.

Operator Competency and Requirements

The skill and training of the operator are critical to the safe operation of the Wheeled 360° Excavator. The following standards apply:

1. Licensing and Authorization: Operators must have the appropriate driving and operating licenses and require prior authorization for public highway use.

2. Quick Hitch Training: Operators using quick hitch attachments must be trained in their correct usage and conduct daily inspections to ensure secure attachment.

3. Permit to Break Ground: Operators must have a permit to break ground and should be briefed on the location of underground utilities to prevent accidental interference.

4. Seat Belt Use: Operators are required to wear seat belts at all times, in compliance with safety protocols.

5. Safe System of Work: Operators must be briefed on the approved Safe System of Work (SSoW) documentation and site-specific Plant, Vehicle, and People Management Plan (PVPMP) before beginning operations.

Desirable Features

Additional features are recommended to enhance the safety and efficiency of the Wheeled 360° Excavator:

1. 360º Camera System: An advanced 360º camera system that provides interlinked images from multiple angles around the machine can significantly improve operator awareness and safety.

2. Pedestrian Detection System: Some camera systems offer pedestrian detection, which alerts operators when personnel are within a 5-meter range, helping to prevent unintentional contact with pedestrians.

3. Engine Emission Compliance: For projects with environmental goals, a Stage V-compliant engine is recommended to minimize emissions.

4. In-Cab Indicators: An in-cab indicator that shows the track or wheel direction helps operators maintain control, especially in reverse or confined space operations.

5. Slew Restrictors: Slew restrictors can improve control when working in restricted areas or near exclusion zones, enhancing both safety and operational precision.

Hazard Identification and Mitigation

The Wheeled 360° Excavator presents certain risks that must be managed carefully to ensure safe operation:

• Overturning Risks: These excavators may overturn if lifting duties exceed safe limits or if operated on uneven ground. Operators should conduct terrain assessments and adhere strictly to lifting protocols to minimize overturning risks.

• Underground Utilities: Ground-breaking activities can interfere with underground services. Operators must have proper permits and locate all utilities before beginning excavation.

• Quick Hitch Detachment: Quick hitches can pose hazards if not secured correctly. Operators must complete daily inspections of quick hitches and confirm they are locked before operating.

• Visibility and Blind Spots: The machine’s size can create blind spots. The use of 360° camera systems and pedestrian detection technology is advised to minimize risks to surrounding workers.

• Slew Hazards: The 360° rotation of the excavator increases the risk of accidental contact with nearby personnel or structures. Clear exclusion zones and barriers should be established, and operators must be vigilant when slewing near others.

• Noise Hazards: Wheeled 360° Excavators generate significant noise, which may pose risks to operators and surrounding personnel. Hearing protection is recommended for operators, and exclusion zones should be marked for others on-site.

Summary

The Wheeled 360° Excavator is a powerful and versatile asset in construction and highway projects, especially when mobility and flexibility in handling materials are essential. However, its size, lifting power, and mobility also necessitate strict adherence to safety standards set out in the National Highways "Raising the Bar 1" guidelines. By following the requirements for ROPS/FOPS, quick hitch inspections, and comprehensive visibility standards, operators can ensure safe and effective use of the machine. Optional features like 360° cameras, pedestrian detection, and emission-compliant engines enhance operational safety and align with environmental best practices.

This article provides an in-depth overview of the critical safety standards, operator requirements, and hazard management strategies for using the Wheeled 360° Excavator, ensuring that National Highways projects maintain both safety and efficiency in high-risk environments.