Safe use of remote controls for cranes, hoists and winches

Poor design can lead to tragic results

Using remote controls for plant such as cranes, hoists and winches is common. But poor design has led to remote controls making plant operate when it should not. The unintended operation of plant has had tragic results. Plant operators have been hurt and even killed.

There are many types of remote controls or transmitting units. Some units send wireless signals to operate plant, others are wired. With the right app, even a smartphone can become a remote control device.

A range of industries operate plant by remote control. Those industries include:

• construction
• logistics
• mining
• agriculture
• forestry

Operating cranes, hoists and winches can bring them and the items they handle close to people. People can be at risk of serious injury or death if a remote control device activates plant when it should not.

Controlling remote control risks

The following guidance may help control risks from remote controls and remotely controlled plant.

Design of remote controls and plant

• Ensure the remote control has a function enable switch. A function enable switch is a physical switch. It requires the operator to perform a certain action for a device to function. Even if a remote control is turned on, it will not work unless the operator uses the function enable switch. Function enable switches include hold bars, triggers, buttons and pull-to-operate devices.
• Where possible, use remote controls with an automatic power-off feature. Set the power-off to the shortest practical time, usually 5 seconds or fewer. This will help avoid unintended activation of the device.

• Ensure the remote control cannot start plant unless:

  • the plant's movement control functions are in a neutral position
  • the remote control's movement functions are in a neutral position

  This will help ensure the plant does not immediately move when started.

• Ensure controls that can cause the plant to move are of a hold-to-run design. This means plant movement stops when the controls are released.
• Ensure the plant is configured so it 'fails to safe' if it loses a signal from the remote control unit. Fail to safe means the plant stops or goes into a safe state when it loses signal.
• Ensure buttons on remote controls are recessed or protected.
• Ensure remote controls with joysticks or levers have rollover-prevention features.
• Ensure the operator controls on the remote control device are clearly identified. Suitable identification will indicate the nature and function of the operator controls.
• Ensure operator controls are located so the user can readily and conveniently operate the controls.

Safe use of remote controls

• Require employees to switch off or deactivate remote controls after use.
• Regularly check the operating frequencies of remote controls. Ensure signals from remote controls do not affect other plant at the workplace.
• Inspect controls regularly. Ensure all controls that cause the plant to move return to a neutral position once released.
• Take steps to prevent unauthorised use of remote controls. For example, ensure remote controls are securely locked away when not in use. Another option is to use remote controls with a Personal Identification Numbers feature. The remote control only functions when users enter the correct code.
• Ensure remote controls are not placed on the floor or somewhere they can be knocked or stepped on. Provide a holder or designated storage location for the remote control.
• Have set areas for operators to use remote controls. Ensure the areas:
  • are free of tripping hazards
  • are not in a location with an unprotected fall hazard
  • provide adequate line-of-sight of the activity being undertaken
• Ensure operators do not use remote controls while moving to another location. The operator should isolate or switch off the remote control before moving. This will help prevent unintentional activation of the remote control.
• Follow the manufacturer's specifications for the remote control's:
  • set-up
  • pairing
  • inspection
  • maintenance
  • operation
  • storage

Legal duties

The Occupational Health and Safety Act 2004 is a law that helps keep people safe at work. It's known as the OHS Act.

The OHS Act sets rules to identify hazards and control risks. A hazard is something that can cause harm. A risk is the chance of a hazard causing harm. Harm includes injury, illness or death.

Those with duties under the OHS Act include the following:

Employers

Employers have obligations under the OHS Act. They must provide and maintain a working environment that is safe and without risks to health. Employers must do this so far as is reasonably practicable.

Employers must also:

• provide or maintain plant or systems of work that are safe and without risks to health
• ensure their work does not expose people who are not employees to health and safety risks

Employers must do these things so far as reasonably practicable.

Risks from plant

Employers must eliminate any risk associated with plant. They must do this so far as is reasonably practicable.

If it is not reasonably practicable to eliminate the risk, employers must reduce the risk. They must reduce the risk so far as is reasonably practicable by:

• substituting the plant with plant that has a lower level of risk
• isolating the plant from people
• using engineering controls
• using a combination of these risk control measures

A risk can remain after using the listed controls so far as is reasonably practicable. In this case, employers must use administrative controls to reduce the risk. Again, they must reduce the risk so far as is reasonably practicable. Administrative controls are work methods or procedures. They are designed to minimize exposure to a hazard.

Employers may find that a risk remains even after complying with all the listed requirements. In this case, they must reduce the risk so far as is reasonably practicable with personal protective equipment (PPE).

Administrative and PPE tend to be the least effective controls. They do not control the hazard at the source. They rely on human behaviour.

Use administrative controls and PPE only:

• as last resorts when there are no other practical control measures available
• as an interim measure until introducing a more effective way of controlling the risk
• to increase the effectiveness of higher-level control measures

Employers must also eliminate the risks of:

• powered mobile plant overturning
• powered mobile plant operators being ejected
• powered mobile plant colliding with other powered mobile plant
• objects falling on the operator of the powered mobile plant

Employers must eliminate these risks so far as is reasonably practicable. If employers cannot eliminate the risks, they must reduce them. Again, they must reduce the risks so far as is reasonably practicable.

Information, instruction, training and supervision

Employers must also provide employees with information, instruction, training or supervision. Employers must meet a certain standard when fulfilling this duty. They must provide what is 'necessary' for employees to work safely and without risks to health. Under the OHS Act, employees can include:

• independent contractors the employer has engaged
• employees of the independent contractors

Self-employed people

Self-employed people also have duties under the OHS Act. They must ensure their work does not expose people to health and safety risks. Self-employed people must do this so far as is reasonably practicable.

Occupational health and safety regulations

The Occupational Health and Safety Regulations 2017 are another set of laws. Known as the OHS Regulations, they build on the OHS Act. They set out how to fulfil duties, obligations and processes that support the OHS Act.

The OHS Regulations include duties relating to warning devices. One duty says powered mobile plant must have a warning device if there is a chance of it colliding with:

• other powered mobile plant
• pedestrians

Fulfilling this duty is the responsibility of employers and self-employed people.

People with management or control of a workplace

People who manage or control workplaces have OHS duties. They must ensure:

• the workplace is safe and without risks to health
• the means of entering and leaving the workplace are safe and without risks to health

They must do this so far as reasonably practicable.

Employees

Employees have obligations under the OHS Act. They must take reasonable care for their own health and safety. They must also take reasonable care for the health and safety of people their work may affect. Employees must cooperate with their employer's efforts to comply with the OHS Act or OHS Regulations.

Plant designers

Designers of plant have duties under the OHS Act. This includes the designers of remotely controlled plant and remote control units for plant. If plant designers know or reasonably should know the plant is to be used at a workplace, they must do the following:

• Ensure the plant is designed to be safe and without risks to health when used for its designed purpose. Plant designers must do this so far as is reasonably practicable.
• Test and examine the plant, or arrange for its testing and examination, to ensure the plant is safe and without risks if used for its designed purpose.
• Provide adequate information to each person they give the design and who will use the design. The information must include:
  • the purpose for which the plant was designed
  • the plant test and examination results
  • any conditions that apply to ensure the plant is safe and without risks if used for what it was designed
• On request, provide the information to any person who uses or plans to use the plant.

Designers of plant also have duties under the OHS Regulations.

Plant suppliers

Suppliers of plant have duties under the OHS Act. This includes the suppliers of remotely controlled plant and remote control units for plant. If plant suppliers know or reasonably should know the plant is to be used at a workplace, they must do the following:

• Ensure the plant is safe and without risks to health when used for what it was designed, manufactured or supplied. Plant suppliers must do this so far as is reasonably practicable.
• Give adequate information to everybody they provide the plant concerning:
  • the purpose for which the plant was designed, manufactured or supplied
  • any conditions necessary to ensure the is plant safe and without risks if used for the purpose it was designed, manufactured or supplied
• On request, provide the information to a person who uses or plans to use the plant.

Suppliers of plant also have duties under the OHS Regulations.

Find more information about workplace duties on the WorkSafe website.