Raising The Bar Guidance - Lorry Loader Crane Equipment Requirements

Raising The Bar Guidance - Lorry Loader Crane Equipment Requirements

The Lorry Loader Crane, a versatile vehicle-mounted crane, is commonly used to load and unload materials directly from the lorry bed, making it highly valuable on construction and highway projects. This equipment combines mobility with lifting capabilities, allowing operators to transport and position heavy materials quickly and efficiently. However, the inherent risks associated with lifting and movement in confined spaces mean that strict safety standards are required. National Highways’ "Raising the Bar 1" guidelines outline essential requirements to ensure the safe and effective use of Lorry Loader Cranes.

General Minimum Requirements

The General Minimum Requirements (GMR) provide a foundation of safety and operational standards for all equipment, including Lorry Loader Cranes:

1. Daily Inspections: Lorry Loader Cranes must undergo thorough pre-use inspections each day, with a checklist documenting any issues before operation.

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

3. Safety Decals and High-Visibility Markings: Safety decals should be clear and legible. Access steps, handrails, and other high-traffic points should be colour-coded in high-visibility colours to ensure safe entry and exit.

4. Seat Belts: Seat belts are mandatory and must be worn by the driver/operator at all times.

5. Public Highway Compliance: When used on public roads, Lorry Loader Cranes must display registration plates, have fully operational lights, and be equipped with amber beacons as required by Chapter 8 of the Traffic Signs Manual.

Equipment-Specific Safety and Compliance Standards

Lorry Loader Cranes present specific hazards due to their dual function as both transport and lifting equipment. The following standards apply to manage these risks effectively:

1. Amber Beacon and Seat Belt Indicator: A flashing amber beacon must be installed for visibility. An external green light should indicate when the operator’s seat belt is engaged, though it may be turned off on public roads to avoid conflicts with lighting regulations.

2. 360° Visibility: The crane must meet 360° visibility standards, using mirrors, cameras, or other visual aids to ensure the operator can monitor all angles around the vehicle, with a visibility height and distance of at least 1 meter.

3. Reversing Alarm: Lorry Loader Cranes should have a directional, white-noise reversing alarm, clearly audible outside the cab, to warn nearby personnel when the vehicle is reversing.

4. Fall Protection: The vehicle body should be equipped with edge protection, such as handrails or fall arrest systems, particularly in areas where the operator or slinger/signaller may need to access during loading or unloading.

5. Stabilizers and Outriggers: Stabilizers must be deployed when operating the crane. The operator must strictly adhere to manufacturer instructions for stabilizer deployment to prevent accidental movement and ensure stability.

6. Safety Reminders for Arm Position: Audible and visual warnings should remind the operator if the hydraulic arm is not safely stowed before driving. This prevents accidental damage and reduces risks on public highways.

7. Fall Arrest Systems: Where operators are required to access the vehicle body, appropriate fall arrest or edge protection systems should be in place to prevent falls from height.

8. Remote Control Systems: Remote control systems, if used, must be regularly checked for sufficient battery power. Emergency stop buttons and isolating devices on remote controls should be tested before operations begin.

Lifting Operations Standards

Lifting is a primary function of the Lorry Loader Crane, requiring strict compliance with Lifting Operations and Lifting Equipment Regulations (LOLER) to ensure safe handling of loads.

1. LOLER Certification: All lifting equipment on the crane must have a valid LOLER inspection certificate. The crane itself must have a 12-month certificate, while all on-board lifting tackle and accessories should be inspected every six months.

2. Overload Testing and Indicators: A four-year overload test certificate or a thorough examination is required as per best practices for crane maintenance. Load indicators and overload warnings are also essential to prevent lifting beyond the crane’s rated capacity.

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

4. Lifting Duty Charts: The crane’s lifting duty chart should be displayed on the boom or at the operator’s station to allow the operator to quickly confirm the crane’s safe lifting capacities for different extensions and angles.

5. Stabilizer Safety Protocols: Operators should follow all stabilizer safety protocols, including outrigger lock-out mechanisms that prevent crane operation if the stabilizers are not fully deployed.

6. Lift Plans and Risk Assessment: For each lift, operators must have a detailed lift plan, risk assessment, and a machine-specific duty sheet to ensure all lifting parameters and safety protocols are followed.

7. Fall Prevention During Lifting: When using the crane for lifting, operators should ensure there are no loose materials or equipment near the boom or stabilizers that could fall during operation.

Operator Competency and Requirements

A competent operator is essential for the safe and effective use of a Lorry Loader Crane. The following standards ensure operator safety and competency:

1. Licensing and Authorization: Operators must have the appropriate license category for the vehicle and lifting operations and must hold a valid Driver Certificate of Professional Competence (CPC) qualification.

2. Familiarization and Safety Training: Operators must complete familiarization training for the specific type of Lorry Loader Crane they will be using, including safe lifting techniques and emergency procedures.

3. Fall Protection Knowledge: Operators must be briefed on fall protection and use of edge protection when accessing the vehicle bed or boom area.

4. Remote Control Training: If remote control systems are in use, operators should be trained in safe handling and familiar with the emergency stop and isolating features.

5. Safe System of Work: Operators must follow the approved Safe System of Work (SSoW) and have signed onto the Plant, Vehicle, and People Management Plan (PVPMP) for the specific worksite.

Desirable Features

To enhance safety and operational effectiveness, additional features are recommended for the Lorry Loader Crane:

1. 360º Camera System: An advanced 360º camera system with interlinked views around the crane can help operators maintain full situational awareness, improving safety for nearby workers and reducing collision risks.

2. Pedestrian Detection System: Some camera systems provide pedestrian detection, alerting operators if personnel are within a 5-meter range, ensuring a safer working environment.

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

4. Seat Belt Operation Interlock: An interlock system that prevents crane operation if the operator’s seat belt is unfastened further enhances safety and compliance.

5. Slew and Height Restrictors: These restrictors prevent the crane from extending or rotating into areas with restricted access, such as power lines, railways, or live traffic zones.

6. Edge and Fall Protection: A fall protection system or edge barriers on the lorry bed provides added safety, especially when operators must access the vehicle bed to secure loads.

Hazard Identification and Mitigation

Lorry Loader Cranes present unique hazards that must be managed to ensure safe operation. Below are key risks and their mitigations:

• Overturning Risk: Failure to deploy stabilizers correctly or lifting beyond capacity can result in overturning. Operators must follow all stabilizer protocols and use the load indicator to stay within safe lifting limits.

• Dropped Loads: To prevent dropped loads, operators should always confirm that all lifting accessories are securely attached and within the rated capacity of the crane. The use of lifting hooks with safety catches is essential.

• Fall Hazards: Edge protection and fall arrest systems should be in place to prevent falls when accessing the lorry bed. Operators should also be trained in proper fall protection measures.

• Visibility and Blind Spots: The vehicle size can create blind spots. Installing a 360° camera system or pedestrian detection technology can help minimize the risk to personnel on the ground.

• Accidental Operation with Stabilizers Stowed: Operators should check stabilizer deployment before lifting. Outrigger lock-out mechanisms, which prevent crane operation unless the stabilizers are deployed, should be tested and operational.

• Highway Hazards: When operating on public highways, operators must ensure that the crane arm is safely stowed, and all lights and beacons are operational to meet legal requirements.

Summary

The Lorry Loader Crane is an essential tool for loading, unloading, and transporting materials on construction and highway projects. However, its dual function as a transport and lifting vehicle means strict safety protocols are crucial. By adhering to the "Raising the Bar 1" requirements, which include LOLER certification, visibility standards, and stabilizer protocols, operators and site managers can ensure the crane is used safely and effectively. Optional features like 360° cameras, pedestrian detection, and Stage V emissions compliance can further enhance safety and environmental performance.

This article provides an in-depth overview of the critical safety standards, operator requirements, and hazard management strategies for using Lorry Loader Cranes, ensuring both safety and efficiency on National Highways projects.