Raising The Bar Guidance - Telehandler Equipment Requirements

Raising The Bar Guidance - Telehandler Equipment Requirements

The Telehandler is a versatile lifting machine equipped with an extendable boom, allowing operators to lift, move, and place materials at varying heights and distances. Due to its flexibility and reach, the telehandler is widely used on construction sites for transporting materials such as pallets, heavy equipment, and bulk goods. However, the risks associated with its lifting capacity, boom extension, and operation on uneven terrain necessitate strict safety standards. The National Highways "Raising the Bar 1" guidelines provide detailed requirements to ensure the safe and compliant operation of telehandlers on all projects.

General Minimum Requirements

The General Minimum Requirements (GMR) establish baseline safety and operational standards for all plant and equipment, including telehandlers:

1. Daily Inspections: Telehandlers must undergo a comprehensive pre-use inspection each day. Operators should complete a pre-start checklist, addressing any potential issues that could affect safety or performance.

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

3. Safety Decals and High-Visibility Markings: Safety decals should be legible and visible. Handrails, access steps, and other high-traffic points should be marked with high-visibility colours to support safe access and egress.

4. Seat Belts: Functional seat belts are mandatory and must be worn at all times to enhance operator safety during movement and lifting operations.

5. Public Highway Compliance: When used on public highways, telehandlers must have registration plates, fully operational lights, and flashing amber beacons, in accordance with Chapter 8 of the Traffic Signs Manual.

Equipment-Specific Safety and Compliance Standards

Telehandlers have unique operational risks, including tipping and instability, due to their extendable boom and high lifting capacities. The following standards apply specifically to telehandlers:

1. Amber Beacon and Seat Belt Indicator: An amber beacon is required 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 to meet lighting regulations.

2. 360° Visibility Standards: Telehandlers should meet 360° visibility standards, achieved through mirrors, cameras, or other visual aids to ensure clear views around the machine at a height and distance of 1 meter.

3. Reversing Alarm: A directional, white-noise reversing alarm should be installed to alert nearby personnel when the telehandler is reversing. The alarm must be clearly audible outside the cab.

4. Stabilizers and Outriggers: Telehandlers equipped with outriggers should use them when lifting at extended heights or distances. Outriggers must be fully deployed on stable ground to maintain stability during operation.

5. Anti-Tip and Load Management System: Telehandlers must be equipped with an anti-tip system or load management indicator that warns the operator if the machine’s stability is compromised by excessive boom extension or load weight.

6. Boom Lock and Safety Checks: A boom lock should be engaged when the machine is stationary or parked, especially on slopes. Operators must regularly check that all boom safety features are functioning properly.

7. Fork and Attachment Safety: Telehandler forks and other attachments must be inspected daily, ensuring that they are in safe working condition and securely attached to the boom.

Lifting Operations and Load Management Standards

Given the high lifting capacity and extendable boom of telehandlers, managing loads safely is crucial to maintaining stability and preventing accidents.

1. Safe Working Load (SWL) Compliance: The SWL must be clearly marked on the telehandler and should not be exceeded. Operators must ensure that loads remain within the SWL to prevent tipping.

2. Boom Extension and Load Stability: The boom should only be extended in line with the telehandler’s load chart. Operators must be aware of the machine’s lifting capacity at different extension angles to avoid compromising stability.

3. Automatic Load Monitoring: An automatic load monitoring system that warns the operator if the machine is nearing its tipping point is recommended for high-capacity telehandlers.

4. Outrigger Use for Stability: When lifting heavy or high-reaching loads, outriggers should be deployed and securely set on stable ground to provide additional stability.

5. Lift Plans and Load Calculations: A lift plan and load calculation should be developed for complex or high-risk lifts. Operators must be familiar with these plans and adhere to all guidelines.

6. Securing Loads: Operators should ensure that all loads are securely attached to the forks or attachments, using straps or chains if necessary to prevent slipping or shifting.

7. Height and Reach Limiters: Height and reach limiters should be used to prevent accidental overextension of the boom, which can destabilize the telehandler.

Operator Competency and Requirements

Competency is essential for safe operation of the telehandler. Operators must understand the equipment’s capabilities and potential hazards, particularly during lifting operations.

1. Licensing and Certification: Operators must hold the appropriate certification, such as a Construction Plant Competence Scheme (CPCS) qualification or equivalent, to operate a telehandler safely.

2. Telehandler-Specific Training: Operators must receive training specific to the type of telehandler they will be using, including training on boom extension, load management, and safety protocols.

3. Understanding of Load Dynamics: Operators should be trained in load dynamics and how changes in load position and boom extension affect the machine’s centre of gravity and stability.

4. Safe System of Work: Operators must be familiar with the site’s Safe System of Work (SSoW) and should sign onto the Plant, Vehicle, and People Management Plan (PVPMP) for the worksite before beginning operations.

5. Ground Condition Assessment: Operators should assess ground conditions prior to lifting, particularly when working on slopes or near excavation sites, to prevent instability.

Desirable Features

To improve operational safety and efficiency, certain additional features are recommended for telehandlers:

1. 360º Camera System: A 360º camera system enhances visibility, helping operators avoid obstacles and personnel, particularly when reversing or manoeuvring in tight spaces.

2. Load Moment Indicator (LMI): A load moment indicator provides real-time feedback on the telehandler’s load capacity, warning operators when the machine is approaching its tipping limit.

3. Automatic Stability Control (ASC): ASC automatically adjusts the telehandler’s stability in response to changes in boom angle and load, reducing the risk of tipping.

4. Stage V Emission Compliance: For projects with environmental goals, Stage V engine compliance is recommended to reduce emissions.

5. Proximity Sensors and Pedestrian Detection: Proximity sensors and pedestrian detection systems alert operators when personnel or obstacles are near, enhancing situational awareness and safety.

6. Boom and Attachment Sensors: Sensors that monitor the boom’s angle, height, and attachment security help operators avoid unintentional movements that could destabilize the machine.

Hazard Identification and Mitigation

Operating a telehandler involves specific risks, and proper hazard mitigation is essential for safe operation:

• Tipping Risks: Telehandlers are prone to tipping if operated beyond their load or extension limits, especially on uneven ground. Anti-tip systems, outrigger deployment, and adherence to the load chart are essential to prevent tipping.

• Blind Spots and Visibility Challenges: The machine’s size and boom positioning can create blind spots. A 360º camera system and proximity sensors help minimize visibility risks, especially when working near personnel or other machinery.

• Falling Loads: Incorrectly secured loads can shift or fall, posing serious risks. Operators should use restraints such as straps or chains, and forks should be adjusted to the appropriate width to secure the load effectively.

• Overhead Power Lines and Obstructions: Telehandlers often work at height, increasing the risk of accidental contact with power lines or structures. Height restrictors and a site survey for overhead hazards are essential to mitigate these risks.

• Uneven Ground and Stability Issues: Telehandlers operating on sloped or uneven ground are at greater risk of instability. Outriggers should be used on uneven surfaces, and operators should assess ground conditions before positioning the machine.

• Swing Radius and Personnel Hazards: The swing radius of the telehandler’s boom can be hazardous to nearby personnel. Exclusion zones should be established around the telehandler, and operators should be vigilant about their surroundings.

Summary

The Telehandler is a highly versatile and essential piece of equipment on construction sites, enabling efficient material handling and placement. However, its extendable boom and high lifting capacity present unique risks that require strict adherence to National Highways’ "Raising the Bar 1" standards. By following key requirements like daily inspections, anti-tip systems, and stability controls, operators and site managers can ensure safe and effective telehandler use. Additional features such as 360° cameras, load monitoring indicators, and pedestrian detection can further enhance safety and operational efficiency.

This article provides a comprehensive overview of the safety standards, operator requirements, and hazard management strategies necessary for the safe operation of telehandlers, ensuring compliance with National Highways’ guidelines for safe and efficient project execution.