Académique Documents
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9/98-1-B72
Guidance Notes on
Safe Use of Earth-Moving Machinery
First edition
September 1998
This guidance notes is issued free of charge and can be obtained from
offices of the Occupational Safety and Health Branch. Addresses and
telephone numbers of the offices can be found in the booklet "The Labour
Department Offers You its Services" or by telephone 2559 2297.
Table of Contents
1.
INTRODUCTION
2.
3.
SELECTION OF MACHINERY
4.
11
5.
SAFE OPERATION
14
6.
OWNER
21
7.
22
8.
COMPETENCE OF MECHANIC
24
9.
COMPETENCE OF OPERATOR
26
29
USEFUL INFORMATION
31
1 . INTRODUCTION
1.1
In recent years there has been an increasing spate of serious
accidents arising from the use of earth-moving machines on construction
sites. The common causes of these accidents are often due to the absence
of a safe system of work for the operation, inappropriate selection on the
use of the equipment, operators being not properly trained and incompetent,
poor maintenance of the equipment and failure in observing the necessary
safety precautions.
1.2
The legal obligations on employers and contractors in relation to
the safe operation of earth-moving machines on construction sites are laid
down under the provisions of the Factories and Industrial Undertakings
Ordinance and its subsidiary regulation.
1.3
Regulation 45 of the Construction Sites (Safety) Regulations requires
that only trained and competent workman over 18 years of age is allowed
to operate a mechanical equipment inside a construction site. No person
under 18 years of age is allowed to give signals to the operator of the
equipment. Contravention of the said regulation would be an offence and is
liable to a fine of $50,000.
1.4
Mechanical equipment includes any bulldozer, compactor, dumper,
excavator, grader, loader, locomotive, lorry, scraper, truck and any mobile
machine which is used for the handling of any material on a construction
site. Mechanical equipment includes earth-moving machines. Amongst the
listed mechanical equipment, excavators are lifting appliances in the context
of the Factories and Industrial Undertakings (Lifting Appliances and Lifting
Gear) Regulations. Excavators should be inspected, thoroughly examined
and tested periodically in accordance with the statutory requirements. Figure
1 illustrates some of the earth-moving equipment commonly used in
construction sites.
1.5
The Factories and Industrial Undertakings Ordinance (FIUO) also
imposes general duties on every proprietor with regard to the health and
safety at work of his employees in industrial undertakings which cover
construction sites. This includes the legal requirements to provide plant and
system of work that are, so far as is reasonably practicable, safe and without
risk to health. The general duties extend to include the provision of
information, instruction, training and supervision for all persons employed
by him. The proprietor and contractor must provide all necessary information,
instruction, training and supervision for operators of earth-moving machines.
A proprietor or a contractor who fails to observe the above legal provisions
commits an offence and is liable on conviction to a fine of $500,000 and to
imprisonment for 6 months.
1.6
Section 6B of the FIUO also imposes a legal obligation to an
employee, including an operator of an earth-moving machine, to take
reasonable care for the health and safety of himself and of other persons
who may be affected by his act or omissions at work. Any person who failed
to observe the requirement commits an offence and is liable on conviction
to a fine of $50,000 and to imprisonment for 6 months.
1.7
This Guidance Notes, set out in details from section 2 onwards,
aims to provide the essential safety guidelines to the owners, contractors,
site management personnel, mechanics and operators in the construction
industry for improving the safety standard in connection with the use of
earth-moving machinery. Reference should always be made to individual
operation and maintenance manual for handling a specific machine to ensure
the safety of the operators and the site personnel working in the vicinity.
1.8
The Construction Industry Training Authority's training centre offers
'Earth-Moving Machine Operation Course' for workers. Persons having
successfully completed the course are generally considered 'trained and
competent' to operate the relevant machine.
1.9
Advice and information regarding the legal aspects and operational
safety involving the use of such type of machines can be obtained at the
branch offices of the Occupational Safety and Health Branch of the Labour
Department. The Advisory & Development Division under the same branch
of this department also offers general advice and assistance on the subject.
Useful information can be found at the back of this guidance notes.
SHOVEL LOADER
EXCAVATOR
VIBRATING ROLLER
BULL DOZER
TRACTOR
GRADER
DUMPER
SCRAPER
Fig.1
(i) observing all potential unsafe conditions that may arise during
the earth moving operation and introducing preventive measures
to ensure the safe operation of the machines at all times. In the
case where the machine is operated in special circumstances
such as in congested work environment, close to nearby fixture,
at dusk or at night, banksman should be assigned to give signal
to the operator of the machine;
(j) identification of site personnel to execute the rules and safety
precautions, supervise the operation and impose stop work
order for a hazardous working condition;
(k) procedures and safety precautions for loading and unloading
the machine on site;
(l) emergency preparedness, including the arrangement and
provision rescue appliances to recover and restore the
equipment; and
(m) checklists for certain 'dos' and 'don'ts' to be observed for safe
operation, maintenance, inspection,testing and examination of
the machine.
2.3
The safe system of work should be published in simple language
so that every one can read and understand it. It should be distributed to site
personnel responsible for the earth moving operation, including the operator.
3 . SELECTION OF MACHINERY
3.1
It is important to choose a proper machine for a certain type of
earth moving work. Factors such as whether a new or used machine, its
size and model, whether rubber or track mounting, country of original,
availability of local agent, maintenance support to meet the working condition
and environment etc. should be taken into consideration in the selecting
process.
3.2
3.3
It is important that whenever a machine is required to work on slope
or travel on inclined road, the slope limit of the machine should be checked.
The machine should be equipped with a roll over protection structure and a
seat belt as shown in Figure 2 for the safety of the operator.
Fig.2
10
11
Leaks
Surfaces of the machine, and the ground under it, should be inspected for
evidence of leakage of lubricating or hydraulic oil, or coolant (see figure 3).
In the hydraulic system, leaks are usually at joints. If the hose itself starts to
exude oil, it should be replaced immediately. Leakage for fuel oil and airsystem should also be inspected. Any evidence of leak should be
investigated and rectified with defective parts replaced immediately.
Radiator
The fluid levels should be checked at the beginning of each shift. The radiator
should be filled to within a few inches of the filler cap. For engine with auxiliary
container for coolant, the level of the coolant should be maintained within
the upper and lower levels as indicated or in accordance with the
manufacturer's instruction manual. Never loosen the filler cap of the radiator
until the engine is cooled down.
Reservoirs
Almost any piece of equipment has one or more fluid reservoirs whose level
is checked by a dip stick, usually while the engine is shut off (see Figure 4).
There is always a dip stick for the engine. The operator must be sure to use
it, and to add oil if necessary, before starting. The tank for hydraulic system
should be checked either by a sight gauge, a dip stick or a look through the
filler cap opening. Air reservoirs (or air-vessels) should be regularly drained
to remove the condensation water to maintain their efficiency.
Air Cleaner
Open and check the presence of trash in the air cleaner. Remove any trash
and replace worn out parts. Keep the air cleaner in a serviceable condition
all times.
Roll Over Protection Structure
Look for any loose or damaged bolts. Replace damaged bolts or missing
bolts with original equipment parts only. Replace the structure mounting
supports if the structure rattles or makes a noise when the machine is
operated on a rough surface.
12
5 . SAFE OPERATION
Fig.3
13
5 . SAFE OPERATION
5.1
The following safe precautions summarize essential requirements
to use and operate an earth-moving plant. In any case, site safety personnel
should make reference to the safety notes in the operation and maintenance
manual to get a complete picture of the machine before it is put into service.
Site preparations
5.2
Before any earth moving operation is commenced, site personnel
should carry out site preparations for safe operation of the earth-moving
machinery. The following safety measures should be observed:
14
15
Fig.4
Operation
5.4
During the operation of the machine, the following precautions should
be adopted by the operator:
16
(a)
(b)
(c)
(d) After starting the engine, check gauges, instruments and warning
lights,all controls and all warning and safety devices and
indicators. Check operation of service and parking services on
level ground if possible according to the manufacturer's
instructions. Particular attention should be focused on abnormal
noise, undue vibration and smell.
(e) Check service brakes in both forward and reverse operation in
level ground according to the manufacturer's instructions.
(f) When operating a machine, always stay in the operator's station
and fasten the seat belt if so provided. Never mount or dismount
a machine unless it is stationary. If the machine is equipped
with a cabin, ensure that the cabin door is securely closed.
(g) Always operate the machine slowly until fully familiarized with
its control.
(h) Prevent asphyxiation. If you must operate in a building or other
enclosed area, be sure that there is sufficient ventilation at that
area for effective dispersion of the engine exhaust. If your
machine is equipped with an enclosed cabin, be certain there
is adequate ventilation.
(i) When working on slopes, avoid sidehill travel whenever possible.
The danger of sliding and tipping during sidehill is always present
regardless of how heavy or stable your machine may appear to
be. Figure 5 illustrated the sidehill travel of a loader.
17
Fig . 5
(j) Always fasten the seat belt if your machine is equipped with a
roll over protection structure.
(k) When climbing or descending steep slopes, always select the
proper gear before proceeding to the slope to assure adequate
power or engine braking. If your machine has a gear shift, select
a low gear. If your machine has a hydrostatic drive, the speed
control should be in the slow travel position, close to neutral.
Never engage in the fully displace position.
(l) When climbing or descending slopes, on machines that have a
gear shift and a hydrostatic control, both controls must be in
their slow travel position. Always be sure that manually operated
gear type transmissions are fully engaged before proceeding
to the slope.
18
Parking
5.5
Having finished the earth moving operation, the machine should be
stationed in a place off the work area or access road. The following points
should be noted:
(a) Park on level ground, with the parking brake firmly applied and
blocked by suitable wedges, where appropriate. For wheeled
machine, the wheels should be chocked by suitable wedges
and never chock the wheels with rocks. Avoid parking near
edges of slopes and excavations.
19
Fig.6
20
J
6 . OWNER
6.1
The owner of the machine should ensure that the machine is of good
mechanical construction and free from patent defects before the machine
is used for earth moving operation. He should ensure that the machine is
maintained to its efficient state by his service engineer and mechanic in
accordance with the manufacturer's specification. In the case where
excavators are used, he should also ensure that the machines are inspected,
thoroughly examined and tested periodically in accordance with the Factories
and Industrial Undertakings (Lifting Appliances and Lifting Gear)
Regulations.
6.2
Tests for service and parking brakes, steering alignment, check for
pump efficiency, travel speed test, test for hydraulic pressure of the power
system, should be conducted in the workshop within the maintenance
intervals and also after repair in accordance with the manufacturer's
instructions. A systematic recording of all tests and servicing data and
periods should be kept and available for reference.
6.3
The service and maintenance records and essential safety
precaution notes should be provided and accompany the machine for the
reference of the hirer and operator.
6.4
The owner should provide information concerning the dimensions,
weight, and configuration of the machine for loading and unloading, and in
case of mishap, the recovery procedure.
6.5
The owner should provide basic, on-the-job, and where appropriate
advanced training to machine operator.
21
The site personnel should exercise control over the following areas:
(a) never allow unqualified or unauthorized personnel to operate
the machine. Preferably, the authorization should be in written
documentation;
(b) never allow other personnel to ride on the machine unless
appropriate seating is provided and only if authorized to do so;
(c) never allow the machine to perform operation which is not
specified by the manufacturer;
(d) circle off a parking area for the machine when it is not in use.
Park in an off the road area, out of traffic. If the machine has to
be parked in a traffic lane, use the appropriate barriers, lights
and warning signal to warn the approaching traffic; and
(e) the parking area should be of level ground whenever possible.
Ensure that the machine is safely blocked and the parking brake
is firmly applied.
7.3
Loading and unloading machines always involves potential hazards.
The site personnel should develop a method statement for the correct loading
and unloading for the machine in the site.The procedure recommended by
the manufacturer should always be followed.
22
7.4
Reasonable steps should be taken to ensure that the operator is
trained and competent to operate the machine. A simple test conducted by
the mechanic of the equipment such as the knowledge on safety precautions
of the machine is of often helpful to reveal the competence of the operator.
7.5
Maintenance and test record of the machine should be kept in the
site for reference.
8 . COMPETENCE OF MECHANIC
23
7
8 . COMPETENCE OF MECHANIC
8.1 The mechanic for inspection and maintenance of earth-moving
machinery should receive the necessary training both in safety knowledge
and precautions. He should be fully familiar with the following aspects of
knowledge and skill:
(a) the understanding and application of the local safety regulations
such as the Construction Sites (Safety) Regulations, the Factories
and Industrial Undertakings (Lifting Appliances and Lifting Gear)
Regulations, and the general duties provisions of the Factories
and Industrial Undertakings Ordinance, Cap 59;
(b) precautions to be observed when operating earth-moving
equipment and attachments, and the safe and proper handling
of all hydraulic tools, air tools, special tools and equipment;
(c) location of master switches and methods of immobilizing
machinery, including the type of earth-moving base and
equipment;
(d) dangers associated with high pressure systems;
(e) safe method of dismantling wheels and the use of a protective
cage during inflation of tyres and hydro-inflation, etc.;
(f) the skill of using hand tools and power tool as applied to
maintenance and servicing requirements;
(g) the requirements and technicalities of scheduled servicing,
routine repairs and maintenance on sites, and major workshop
repairs and overhauls. This includes the checking of the correct
functioning of ancillary systems, the steering wheel alignment,
the experience of assisting in the recovery of damaged machines
24
8.2
The mechanic should be able to conduct simple tests on site
according to the manufacturer's specification, including service and parking
brakes, steering mechanism, and safety switches and interlocks. He should
keep a record of service of the machine and make available for inspection
by site personnel. He should be capable of preparing simple technical
reports outlining the main findings and the cause of the accident.
25
j
9 . COMPETENCE OF OPERATOR
9.1
The operator should be at least 18 years old and have reasonable
degree of both physical and mental fitness.
9.2
The operator should be able to understand what is involved in safe
operation. He should be able to understand and read instructions, signs,
charts and manuals.
9.3
The operator should receive both basic training and advanced
training for specialized groups of machines. Throughout the training it must
continually be emphasized that one of the most important aspects of
machine operation and servicing is safety.
9.4
After the completion of the basic training, the operator should be
able to understand and appreciate the following:
(a) the designed purpose, capabilities, capacities and limitations
of the machine;
(b) the procedures for the preparation for operation, operation,
parking, loading and unloading ;
(c) basic dimensional data such as length, width, mass, ground
bearing pressure, speed ,etc.;
(d) appreciation of the factors affecting machine productivity;
(e) routine inspection and servicing tasks appropriate to him;
(f) the use of machine to meet the work condition, such as confined
areas, cold stores, slopes, rough terrain, and bad weather
condition;
26
27
28
10 . SAFETY NOTES
10.1
It is important to ensure that the machine is operated safely. Reemphasis on SAFETY is the most important aspects of training and machine
operation. Some typical subjects are:
(a) regarding the machine, including chocking the wheels, parking
etc.;
(b) regarding the site, including do not work on a machine on a
slope which is liable to collapse and slid;
(c) do not work above or under overhanging embankments or
undercut with potential hazard of collapse;
(d) ensure buckets, blades and any sharp attachment to be lowered
to ground after completing the work;
(e) watch for trees and branches and overhead lines;
(f) ensure all safety devices are always intact and fully operational,
including, for example, emergency brakes and steering, reverse
alarms, headlights, and roll over protection structure and seat
belt;
(g) greasing and other servicing or repair work should not be carried
out when the engine is running;
(h) identification and observation of safety signs, notices and
symbols; and
(i) the machine should be repaired by competent mechanic and
service engineer and only genuine spare parts should be used.
29
10.2
Operator, mechanic and site personnel working in connection with
earth moving work should be reminded of the context of 'SAFETY' from
time to time to ensure the safety of their own and the safety of other personnel
working within the vicinity.
30
USEFUL INFORMATION
If you wish to enquire about this guidance notes or require advice on
occupational safety and health, you can contact the Occupational Safety
and Health Branch through:
Telephone :
Fax
2915 1410
laboureq@labour.gcn.gov.hk
31
Guidance Notes on
Safe Use of Earth-Moving
Machinery
9/98-1-B72