05 November 2024
Raising The Bar Guidance - Tipper – Rigid or Articulated Equipment Requirements
Tipper trucks, available in rigid or articulated configurations, are critical for transporting and unloading bulk materials like sand, gravel, and debris on construction and highway sites. Their tipping function allows for quick and efficient unloading, making them ideal for high-demand environments. However, due to the risks associated with heavy loads, tipping mechanisms, and manoeuvring in tight spaces, National Highways' "Raising the Bar 1" guidelines establish specific safety and operational requirements to ensure the safe and compliant operation of tipper trucks on all projects.
General Minimum Requirements
The General Minimum Requirements (GMR) establish foundational safety and operational standards for all plant and equipment, including rigid and articulated tipper trucks:
Daily Inspections: Tipper trucks must undergo thorough pre-use inspections daily. Operators should complete a checklist, checking for any mechanical issues, such as brake efficiency, tire condition, and hydraulic system functionality.
Compliance with Legislation: Tippers must meet UK regulatory standards, including UKCA certification and compliance with the European Commission Machinery Directive (2006/42/EC), with a declaration of conformity.
Safety Decals and High-Visibility Markings: Safety decals must be clear and legible. Access steps, handrails, and high-traffic control points should be marked in high-visibility colours to support safe entry, exit, and operation.
Seat Belts: Seat belts are mandatory and must be worn by the operator at all times to enhance safety during transport and tipping operations.
Public Highway Compliance: When used on public highways, tippers 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
The unique characteristics of rigid and articulated tippers, particularly the tipping function and potential for load instability, require specific safety standards for safe operation:
Amber Beacon and Seat Belt Indicator: An amber beacon must be installed for visibility, and an external green light should indicate when the operator’s seat belt is fastened. The green light may be turned off on public highways to meet lighting regulations.
360° Visibility Standards: Tippers must meet 360° visibility standards, using mirrors, cameras, or other visual aids to provide operators with a clear view around the vehicle, especially when reversing or operating in high-traffic areas.
Reversing Alarm: A directional, white-noise reversing alarm is essential for warning nearby personnel and vehicles when the tipper is reversing. The alarm should be clearly audible outside the cab.
Tipping Stability Control: Tipper trucks should be equipped with a tipping stability control system to prevent accidental tipping and ensure safe unloading. This includes checking ground conditions and verifying that the vehicle is on stable, level ground before tipping.
Load Distribution Control: To avoid shifting loads and instability, operators should ensure loads are evenly distributed in the bed. Articulated tippers, in particular, require careful load distribution to prevent tipping hazards.
Tailgate Lock and Safety Checks: Tailgates must be securely locked before transport and only unlocked when the vehicle is stationary in a designated unloading area. Operators should inspect the tailgate locking mechanism as part of the daily inspection.
Body Prop or Locking Mechanism: Tippers should be equipped with a body prop or locking mechanism to secure the bed during maintenance or when accessing under the raised body.
Splash Guards and Debris Containment: To prevent debris from spilling, tipper trucks should be fitted with splash guards and containment measures for loose materials, especially when operating on public highways.
Load Management and Tipping Standards
Given the large loads and tipping function of these trucks, managing loads safely is crucial to prevent accidents and maintain stability:
Safe Working Load (SWL) Compliance: Operators should ensure that the tipper truck’s load does not exceed its SWL, as indicated by the manufacturer. Overloading can increase the risk of tipping and mechanical failure.
Ground Condition Checks for Tipping: Before tipping, operators should check that the ground is level and stable. Tipping on sloped or uneven ground significantly increases the risk of instability and tipping accidents.
Controlled Tipping and Bed Angling: Tipping should be performed slowly and in a controlled manner, with the bed angle adjusted as needed. Sudden tipping can cause the load to shift abruptly, destabilizing the vehicle.
Tailgate Safety During Tipping: Operators should verify that the tailgate is unlocked and fully open before beginning to tip. A partially locked tailgate can result in load accumulation at the rear, causing instability.
Avoiding Overhead Obstructions: When tipping, operators should ensure there are no overhead obstructions, such as power lines or tree branches, which could interfere with the raised bed.
Operator Competency and Requirements
A skilled and trained operator is essential for safe operation of tippers, especially during tipping and load management. The following requirements apply:
Licensing and Certification: Operators must hold the appropriate license category for the vehicle type and configuration, particularly for articulated tipper trucks.
Safety and Familiarization Training: Operators must receive training specific to the type and model of tipper they will be using, including load management, tipping safety, and stability control.
Load Distribution and Stability Awareness: Operators should be trained to understand how load placement and ground conditions affect vehicle stability, particularly during tipping operations.
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 each specific worksite.
Emergency Procedures: Operators should be trained in emergency shutdown procedures and methods for handling unexpected issues such as load shifting or tailgate malfunctions.
Desirable Features
Additional features are recommended to improve safety, efficiency, and environmental compliance for tipper trucks:
360º Camera System: A 360º camera system improves visibility, helping operators avoid obstacles, personnel, or other vehicles, especially when reversing or operating in confined spaces.
Tipping Stability Control System: An automated stability control system can monitor the bed’s angle and the truck’s balance, warning the operator of potential tipping risks.
Load Monitoring System: A load monitoring system provides real-time feedback on load weight, allowing operators to manage loads within safe limits and avoid overloading.
Stage V Emission Compliance: For projects emphasizing environmental impact, Stage V-compliant engines reduce emissions and align with eco-friendly project goals.
Proximity Sensors and Pedestrian Detection: Proximity sensors and pedestrian detection systems alert operators to nearby obstacles or people, enhancing safety in high-traffic areas.
Overload Protection System: An overload protection system automatically warns operators if the load exceeds safe weight limits, helping prevent tipping and mechanical strain.
Hazard Identification and Mitigation
Operating rigid and articulated tipper trucks involves specific hazards, and hazard mitigation is essential for safe operation:
Tipping Risks: Tipper trucks are at risk of tipping, particularly when loads are improperly distributed or when tipping on uneven ground. Stability control systems, proper load management, and ground assessments are essential to mitigate this risk.
Load Shifting and Falling Debris: Sudden load shifts during tipping can destabilize the vehicle, and falling debris can endanger nearby personnel. Operators should ensure that loads are secured, tailgates are fully open, and tipping is conducted in designated areas.
Blind Spots and Limited Visibility: The size and configuration of tipper trucks create blind spots, especially when reversing. A 360º camera system and proximity sensors help operators maintain awareness of surroundings, particularly in busy work zones.
Overloading and Mechanical Strain: Overloading increases mechanical strain and risk of tipping. Load monitoring and overload protection systems can prevent operators from exceeding the SWL.
Traffic and Pedestrian Proximity: Tipper trucks often operate in high-traffic areas or near pedestrians, posing collision risks. Reversing alarms, proximity detection, and designated exclusion zones help reduce these hazards.
Tailgate Malfunctions: If the tailgate is not fully unlocked, materials can accumulate and cause an uneven weight distribution. Regular inspection and clear communication between operators and ground personnel help prevent this risk.
Summary
Rigid and articulated tipper trucks play a critical role in material transport and unloading on construction and highway projects. However, their high-capacity loads and tipping function necessitate strict compliance with National Highways’ "Raising the Bar 1" guidelines. By following protocols such as daily inspections, 360° visibility, and tipping stability controls, operators and site managers can ensure safe and efficient operation of tipper trucks. Additional safety features like load monitoring systems, tipping stability control, and proximity sensors can further enhance operational safety and environmental compliance.
This article provides a comprehensive overview of the safety standards, operator requirements, and hazard management strategies for tipper trucks, ensuring compliance with National Highways' guidelines and promoting a safer work environment.