Operating mobile plant on raised ramps and elevated stockpiles

Background

An incident has occurred within a quarry where a Front End Loader (FEL) has overturned whilst topping up edge protection on the left-hand side of a ramp.

The employee involved in the incident was an experienced operator of mobile plant. The employee lost control of the mobile plant and became trapped when it toppled over. The employee was able to call for help and exit the plant safely, without suffering any injuries.

Safety issues

Hazards that can lead to mobile plant overturning include:

• poor ramp grade selection for the plant being used
• raised bucket when turning
• unsafe bund construction which can create an upwards shift in the centre of gravity
• not enough systems in place, such as stockpile design for the safe handling of aggregates in raised stockpiles
• failure to use long reach earthmoving equipment in installing or repairing earthen bunds
• failing to do pre-start checks and visual inspections of ramp before operating plant
• lack of site preparation or limited access for unloading
• failure to provide significant footprint area for front end loaders to safely move and operate.

Recommended ways to control risks

To reduce the risk of overturning, employers should:

• when operating mobile plant on and around ramps:
  • consider the original equipment manufacturer’s recommendations and instructions manual for maximum gradients which the plant can be operated on
  • be aware of mobile plant bucket positioning and ensure that employees are aware of the impact to changes in the centre of gravity which may lead to plant being overturned
• design stockpile locations and size to allow fit for purpose plant to operate safely in and around them
• ensure ramps are wide enough to allow for the installation of adequate physical edge protection (earthen bunds) on either side of the ramp
• ensure that ramps are designed so that the last few metres of the ramp are level, so the vehicle is not discharging uphill
• do regular maintenance of edge protection installed on ramps and haul roads so that they remain in an operational condition
• identify risks where overturning or fall of mobile plant exists — this means doing a risk assessment and risk management process to identify all potential hazards.

Use the hierarchy of control to control risks with operating mobile plant. This includes eliminating the use of fixed plant feed systems such as surge tunnels and fixed mechanical handling feed and dump systems that reduce the use of mobile plant.

Where risks cannot be eliminated, they must be reduced so far as is reasonably practicable. This may require more than one control measure to ensure all the risks are controlled. Any control measures must be reviewed and should be revised as necessary after an incident.

Legal duties

Under the Occupational Health and Safety Act 2004 (OHS Act), employers have a duty, so far as is reasonably practicable to:

• provide and maintain a working environment, including the use of fit for purpose plant and the associated systems of work, that is safe and without risks to the health of employees and contractors.
• where a risk cannot be eliminated, reduce the risk so far as is reasonably practicable
• provide the necessary information, instruction, training or supervision to employees, including how to identify hazards and safely operate mobile plant, to enable employees to do their work in a way that is safe and without risks to health
• consult with employees, contractors and health and safety representatives, where present, when identifying hazards and risks
• consult with employees, contractors and health and safety representatives, where present, when implementing controls to eliminate hazards and risks or, where not reasonably practicable to do so, minimize them
• review and revise any measure implemented to control risk.