Safe Design and Maintenance of MEWPs

International Standards and Safety Devices and Inspections

Presenter

David Single
Product Parent for MEWPs and Telehandlers, JLG Australia Australian Standards Committee Member for ME005-10 MEWP Standards and ME005-22 Telehandler Standards.

Content
Types of Standards Description ANSI Description EN280 Explanation of CE Compliance Description of ISO16368 and AS/NZ1418-10 2011 Structural Comparison Stability Comparison Safety Devices from MOM list. Inspection and maintenance requirements of safety devices, their location and function Questions

Types of Standards
Each country has their own OH&S Regulations. These are LAWS, and non -compliance brings prosecution. For AWPs / MEWPs there are internationally acceptable Construction standards, developed by Industry Associations and Regulators, and use the State of Knowledge and Best Practice principles, as well as well proven in use and proven reliable design. Concensus Standards are Guidance documents, NOT LAWS. The Standards are guidance documents and are used to determine if the AWP/MEWP meets the structural, stability and safety requirements of the OH&S regulations in each country. Different Standards can use different methods to get to the same safety outcome. Based on this you could use a proven international standard, either ANSI A92 series of 5 individual standards (USA) , EN280 Standard (European Norms), ISO16368 (International) or Australian Standards new draft of AS/NZ 1418-10 2011, to comply with the countries OH&S Laws.
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ANSI Types
ANSI has five (5) separate standards.
The Scaffold Industry Association (SIA) serves as a secretariat for the ASC A92 Main Committee. ASC A92 Standards are applicable to U.S. operations. They are used by manufacturers, dealers, owners, users and operators of AWP equipment. The purpose of the standards is the proper and safe use of machines and the prevention of accidents and injuries. These standards also establish criteria for the manufacturers as well as aid the manufacturers, dealers, owners, users and operators of AWP equipment to understand their various responsibilities. This document references the following A92 Standards:

Description ANSI
Roles of ANSI and OSHA ANSI promotes safety in the industry by developing recommendations in the form of standards and guidelines. While ANSI standards are considered recommended guidelines, they are not laws or regulations. Complying with ANSI standards is voluntary. OSHA is an agency of the U.S. government that issues and enforces regulations for employers to ensure workplace safety and health. Though the regulations are often referred to as standards, they are in fact federal laws and therefore compliance is mandatory. Reasons for Complying ANSI standards and OSHA regulations are often confused because they generally address the same issues. In fact, many OSHA regulations were written based on ANSI standards. Also, OSHA often adopts ANSI standards via incorporation by reference. When standards are adopted or incorporated, they become part of the OSHA regulation and are no longer voluntary. To the extent that the current ANSI standards are not incorporated into OSHA regulations, the ANSI standards are voluntary. However, ANSI standards provide guidance as to what may be considered the standard of care. If you comply with ANSI standards, you may have an argument for a defense against claims under OSHAs general duty clause, which requires employers to keep the workplace free from recognized hazards. OSHA has written many rules in the Code of Federal Regulations (CFR), but in some cases has adopted consensus standards to be used as minimum guidelines by their reference in the Code of Federal Regulations. In 1974, they adopted many of the ANSI and National Fire Protection Association (NFPA) standards in order to promote safety rules. In this particular time frame, there was only one aerial lift standard, A92.2-1969 for vehicle-mounted elevating and rotating work platforms. ANSI has since created other standards for other types of aerial lifts and OSHA recognizes these consensus standards. OSHA also has referenced these consensus standards through interpretive letters regarding compliance. All contributing organizations fully support the ANSI/SIA A92 Standards as the recognized standards for AWP equipment. The associations and their members are actively involved on the ASC A92 Main and Subcommittees.
Extract from 02-11-AWP-SBP002 Statement of Best Practice for PFP Feb 2011. Keywords: Voluntary, Mandatory, Standard or care, Concensus Standards.

EN280 Types

Description EN280
EN280 is what CE refers to as a "harmonized" standard, which is equivalent to what you refer to as a "consensus" standard. The OH&S regulations are defined in the Machinery Directive, and compliance to the Machinery Directive is mandatory for machines sold in the CE market. EN280 provides specific guidance on compliance to the Machinery Directive for AWPs. It represents what CE considers to be "best practice," and full compliance to EN280 gives a presumption of conformance to the Machinery Directive within the CE market. Exceptions to EN280 must be reviewed and approved by the notified body. This European Standard has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s). According to the CEN/CENELEC Internal Regulations, the national standards organisations of the following countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and the United Kingdom. This European Standard specifies technical safety requirements and measures for all types and sizes of Mobile Elevating Work Platform (MEWP) intended to move persons to working positions where they are carrying out work from the work platform (WP) with the intention that persons are getting on and off the work platform only at access positions at ground level or on the chassis. Furthermore it is assumed that persons on the work platform in case of power supply failure are NOT incapacitated and can assist in the operation of the overriding emergency device. - As far as possible this European Standard sets out only the requirements that materials and equipment have to meet in the interest of safety, and it is assumed that persons operating MEWPs are adequately trained. - Where for clarity an example of a safety measure is given in the text, this shall not be considered as the only possible solution. Any other solution leading to the same risk reduction is permissible if an equivalent level of safety is achieved. The use of EN 280, without the EU Machinery Directive behind it, could block a lot of machines from being imported, as very few machines, if even any, will meet all requirements in EN 280.
Key words: EU Directives, European Standard, NOT incapacitated, Adequately trained operator, other safety solution.

Explanation of CE Compliance
CE is not a standard. It is CE Compliance, a document identifying compliance to the European Machinery Directive, using EN280 Standard as a guidance document, and employing an EC Notifying Body (such as SGS, RINA, PAC, TUV etc ) proving compliance to and/or accounting for exceptions to the EN280 Standard. Compliance Exceptions can be details such as platform dimensions, enhanced stability and enhanced overload in place of LSS. The EC Notifying body could also be referred to as an Independent 3rd Party Compliance Verifier. As the CE Compliance is compliance to the EU Machinery Directives (the European OH&S Regulations) and this compliance is MANDATORY, so any future changes in the EU Machinery Directives would require the accepting entity in another country to comply with the new EU Machinery Directives. An example of this is: If the EU Machinery Directive directs that platforms are painted PINK, they must be painted PINK. If you paint them White, you are in breach of the compliance certificate. If you remove devices or change the machine features for another market, it NO LONGER complies with the Machinery Directive. That means you have a NON Compliant MEWP. If you change the controls on a boom to allow drive/boom functions simultaneously, then the unit is no longer CE compliant. CE Compliance is effectively only valid in the European countries. The EC notifying body must renew the CE compliance certificate every 5 years. Acceptance of a European countries OH&S Regulations are part of the requirement.
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Description of ISO16368 and AS/NZ1418-10 2011

The ISO Standard ISO16368 is a work item of the International Standards Organisation. It has differences to the EN280 Standard and was used as a template for the new Australian Standard, as Standards Australia is an ISO member. You cannot change the wording of an ISO standard and must take up the contents in its entirety. NO recognized manufacturers build MEWPs or AWPs to the ISO16368 Standard. There are also additional ISO Standards for truck mounted platforms. ISO16368 should NOT be considered as a working standard for the ASEAN market, as no manufacturer builds MEWPs to this standard. The AS/NZ1418-10 2011 standard is a product of a ISO 16368 template, with all the current state of knowledge, AS1418-1, AS1418-10 2004 ANSI, CSA and EN280 sections mixed in the draft. It covers all ranges of MEWPs, with additional sections 5, 6 & 7 to cover the VARIATIONS from the main body of the standard for particular MEWP types. Work started in 2004 on this draft. Note: AS/NZ1418-10 2011 is also a combined New Zealand standard, and New Zealand will need to apply this standard to all new MEWPs imported into and MEWPs manufactured in New Zealand for the Australian & New Zealand Market. Machines built for export from Australia and NZ can be the Standard of the importing market, EN280, ANSI etc. The AS1418 series of Standards, are part of the Crane Standards in Australia. The AS/NZ Standard should not be considered as a Standard of choice for ASEAN region, as it contains sections relevant to Australian applications and ties into too many Australian Standards that are not valid in the ASEAN market. There is no impediment to importing an AS/NZ1418-10 2011 Compliant machine into the ASEAN market. Compliance Verification documents need to be presented and checked.. 9

AS/NZ1418-10 2011 Extras

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Structural Comparison
ANSI
ANSI structural factor of safety is 2.75

EN280
EN280 does not specify a structural factor of safety. General steel guidelines specify a minimum of 1.67 EN280 designed units are usually a lighter structure, most notable on the slender boom dimensions. Where other devices such as truck cranes are used as MEWPs, the Cranes higher factor of safety allows removal of the LSS system. The EN280 design takes into account all loads, including wind loads. To protect the structure from structural overload, LSS is a critical part of the assembly. MEWPs shall be provided with control devices that reduce the risk of overturning and the risk of exceeding permissible stresses. NOTE: It should be noted that load or moment controls are not able to protect against an overload that grossly exceeds the rated load.

Cylinder Burst pressures are rated as four (4 ) times the system pressure.

Cylinder burst pressure is rated at a ratio of rod/piston diameter. The hose and fittings burst pressure is rated at three (3) times the maximum relief pressure.

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Stability Comparison
ANSI AWPs rated for level ground and tested on 5 degree incline EN280 Rated for use on level ground, but can be used for chassis inclination on the manufacturers plate. Tested at the incline on the Compliance plate, plus additional degree. Static tests The MEWP shall be set up on the maximum allowable chassis inclination defined by the responsible entity plus 0,5. Stabilizers, if provided, shall be used as specified by the responsible entity. If the MEWP is supported in the working position by pneumatic tyres and is not protected by a low-tyre-pressure operator warning system, the MEWP shall be set up with the inclination taking into account a deflated tyre. Test loads shall be applied to represent all the least favourable load and force combinations

Static load test on slope The aerial platform shall be tested on a slope 5 degrees greater than the slope for which it is rated by the manufacturer. The test shall be conducted: (1) While sustaining static vertical load equal to 1.33 times the rated work load of the platform applied the platform floor surface at a location 12 inches (0.30m) inboard from the railing or floor transition, or on the platform centreline, whichever places the center of gravity of the load closest to the guardrail.

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Stability Test Sample

Sample 60ft boom at ANSI forward stability test. AWP set up on 5 degree incline, 133% load and manual force load applied to handrail of 150lb or 15% of capacity, or 50lb per person, whichever is greatest. Sample 60ft boom at EN280 forward stability test. MEWP set up on 3 degree + 0.5 degree. Apply test load plus 10%, apply manual force load of 400N plus 10%, apply wind load + 10%.

Test slope is 5 degree = ANSI

Rated capacity 500lb/230kg x 1.33 = 306kg

3.5 degree Chassis inclination = EN280 with LSS Rated capacity 500lb/230kg x = 230kg Manual force 400N x 1.1 = 45kg Wind load @ horizontal boom angle x 1.1 = 5kg x 1.1 = 5.5kg, Must remain stable and not overturn with the boom extended horizontal with 280.5kg @ 3.5 degree Or Wind load @ 80 degree boom angle x 1.1 = 55kg x 1.1 = 60.5kg .Must remain stable and not overturn with the boom fully elevated with 330kg @ 3.5 degree

Must remain stable with the boom extended horizontal with 306kg @ 5 degree slope. THIS DOES NOT CONSTITUTE A STABILITY TEST, SAMPLE ONLY

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Safety devices from the MOM List

Proposed List of mandatory safety devices for mobile elevated work platform (MEWP) 1) Level indicator Level indicator to indicate whether the inclination of the MEWP chassis is within the limits permitted by the manufacturer. 2) Load sensing system Load sensing system to alarm and stop the work platform when certain rated load situations have been exceeded. Note: a) If the load sensing system was triggered during normal movement of the work platform, the possibility of normal movement may remain. b) For MEWPs, where the vertical projection of the centre of gravity of the load is always inside the tipping lines, the load-sensing system need not be activated until the work platform is elevated more than 1 m or 10 % of lift height, whichever is the greater, above the lowest position. If an overload condition is sensed at or above this height, further elevation shall be prevented. 3) Position control Mechanical stops or control systems to limit the MEWP to its working envelope. 4) Moment sensing system Moment sensing system to provide visual warning when overturning moment is reached and prevents further movements, except those that reduce the overturning moment 5) Movement Controls a) MEWPS shall be provided with controls such that all movements of the MEWPS can only take places whilst the controls are being activated. The controls, when released shall automatically return to the neutral position. The travel controls in the cabs of vehicle mounted MEWPs do not need to be of this type. b) All controls, especially foot operated controls, shall be constructed to prevent inadvertent operation. c) The control devices shall be situated on the work platform. This does not preclude the provision of duplicate controls operated from the base or ground level. Duplicate controls shall be protected against unauthorized operation. 6) Emergency stop button MEWPS shall be provided with emergency stop button. All machine functions are disabled when the button is activated.

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Safety devices from the MOM List

1. Level Indicator

ANSI

EN280

1. Spirit level on Vertical lift. 2. Level sensor alarms on boom type MEWPs when elevated and chassis reaches the manufacturers level sensor setting on slope.

1. Spirit level on Vertical lift. 2. Level sensor cuts lift up only on scissorlift (Group A -type 3) when elevated and chassis exceeds manufacturers rated slope. Elevated drive speed still available to continue driving on the slope. 3. Level sensor alarms on boom type MEWPs when chassis reaches the extreme limits of inclination.

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Safety devices from the MOM List

2. Load Sensing system

ANSI

LSS not installed.

EN280 LSS installed to protect from exceeding structural stresses and overturning.

1. 2.

Structural factor of safety 2.75 Cylinder burst pressure ratio 4:1

Exceeding structural stresses and overturning covered by ANSI structural factor of safety and ANSI stability test.

1. Structural factor of safety not specified. 2. Cylinder burst pressure ratio based on cylinder piston/rod dimensions, and hoses and fitting at burst pressure ratio of 3:1 3. LSS in platform cuts platform functions if load exceeds 120%. Can only be overridden at ground controls, or remove overload and reset controls. 4. Enhanced stability based on smaller platform dimensions and enhanced overload can be used, Needs an EC Notifying body verification or full EN280 compliance.
As/NZ1418-10 2011 Australian Spec, override at platform emergency pump controls.

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Safety devices from the MOM List

3. Position Control

ANSI

Envelope control system

EN280 Envelope control system.

1.

2.

3.

Large multi extension booms that reach taller than the ability to reach horizontal, are envelope controlled AWPs. These can be straight telescopic, or telescopic knuckle booms. The safety devices for these functions are the same as in EN280. Devices include redundant length sensors and redundant angle sensor and redundant limit switches

1. Where non-mechanical limiting devices are used, permissible positions of the extending structure shall be limited by a device which measures positions of the extending structure, and operates through the control systems to limit movements to the working envelope. This device shall be backed up by a safety device.

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Safety devices from the MOM List

4. Moment Sensing System

ANSI 1. Moment sensing, a system that prevents the boom from exceeding positive loads that create forward instability and overturning, and negative loads to prevent rearward instability and overturning. The moment system can be a load pin and angle position sensor, or stabiliser contact pressure sensor to indicate that the AWP is close to the design limits before instability occurs. These devices (where installed), are the same as EN280 devices.

EN280 moment sensing system installed to protect from exceeding structural stresses and overturning.

2.

1. The moment sensing system is a safety device and shall operate in the following way: - When the permissible overturning moment is reached a visual warning shall be given and further movements shall be prevented except those which reduce the overturning moment. -The control system for the moment sensing system shall comply with the safety system

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Safety devices from the MOM List

5. Movement Controls
a) MEWPS shall be provided with controls such that all movements of the MEWPS can only take places whilst the controls are being activated. The controls, when released shall automatically return to the neutral position. The travel controls in the cabs of vehicle mounted MEWPs do not need to be of this type. b) All controls, especially foot operated controls, shall be constructed to prevent inadvertent operation. c) The control devices shall be situated on the work platform. This does not preclude the provision of duplicate controls operated from the base or ground level. Duplicate controls shall be protected against unauthorized operation.

ANSI 1. Joysticks move in the direction of travel, and are protected from inadvertent operation by enable /deadman footswitch or separate hold to run enable switch on the platform controls. 2 ANSI AWPs allow travelling controls, (drive) and boom functions to operate simultaneously. This allows swing, lift up, jib and platform level functions to aid the ground surface visibility for the operator. 3. Ground duplicate controls (not travelling controls) enable the person on the ground to retrieve the operator in the elevated platform.

EN280 Controller direction and override from ground controls

1. On MEWPs of types 2 and 3 it shall not be possible for

the travelling controls to be operated simultaneously with any other controls. This does not apply to rail mounted MEWPs. This shall be achieved by a safety device. 2. The control devices shall be situated on the work platform. This does not preclude the provision of duplicate controls operated from the base or ground level. Duplicate controls shall be protected against unauthorised operation and may be used to serve as the emergency device If movement can be controlled from different control positions, the controls shall be interlocked at the duplicate control position in such a way that control is only possible from one pre-selected control position. This shall be achieved by a safety device

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Safety devices from the MOM List

6. Emergency Stop Button
MEWPS shall be provided with emergency stop button. All machine functions are disabled when the button is activated.
ANSI EN280 Emergency stop switch.

1.

2.

Emergency stop device. The aerial platform shall be equipped with readily identifiable emergency stop devices, located at the upper control and lower control stations, which deactivate all powered functions. The ground controls override the platform emergency stop to enable the possible need to retrieve an operator.

1. MEWPs shall be provided with emergency stop controls in accordance with EN 418 at each control position. Emergency stop controls are not required on MEWPs with full-flow control valves with control handles connected mechanically to the control valve spools (manual override).

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Safety device location.

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Safety Devices Function and Inspection. Sample for Boom type MEWPs

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Safety Devices Function and Inspection. Sample for Boom type MEWPs
Provision for emergency retrieval Retrieval of platform in the event of loss of normal power Ground controls Lower controls return to off and correctly labelled Lower controls isolate upper controls Emergency controls Duplication of controls Emergency deadman functions correctly Removeable key switch or other lockable ground controls Mushroom emergency stop switch coloured RED Motion alarm sounding when lifting or travelling Strobe or Flashing light operating when travelling Level Sensor Inclination alarm On a self-propelled MEWP, an acoustic signal audible alarm at the work platform shall operate when the extreme limit of inclination has been reached
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Safety Devices Function and Inspection. Sample for Boom type MEWPs
Tyres: Tyre pressure labels, where tyres are pneumatic. Puncture proof tyres. Urethane ( Foam Filled indicated usually by a Coach bolt visible opposite the valve stem to release trapped air during curing) Solid cushion tyres. Out-of-service brake The self-propelled elevating work platform shall be equipped with a brake capable of holding it in the out-of-service mode In-service brake The self-propelled elevating work platform shall be equipped with a brake capable of holding it on a slope that can be negotiated by the platform when loaded Swing drive brake The self-propelled MEWP shall be equipped with a brake capable of holding the rotating structure it on a the maximum slope, at the limit of inclination.

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Safety Devices Function and Inspection. Sample for Boom type MEWPs
Platform Platform to be in good condition without evidence of excessive damage, corrosion debris etc. An open platform shall incorporate the following: (a) A non-skid floor. (b) Guard-railing or other structure around its upper periphery not less than 1 m above the platform floor. (c) A mid-rail. (d) Kick-plates at sides and ends not less than 100 mm high. The kick-plate may form partn of the means of ingress and egress. (e) Drain holes, where the floor has no other openings. Gate Where provided, hinged access doors should open inwards. Hinged access doors shall automatically and positively return to the closed position and be self-locking. Drop bars fulfil this purpose.
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Safety Devices Function and Inspection. Sample for Boom type MEWPs
Fall Arrest Anchor Points Boom-type MEWPs shall have suitable anchorages for the attachment of safety harnesses for each occupant. Each anchorage shall be designed to withstand the forces specified. Platform Controls Upper controls correctly labelled. Upper controls return to off and neutral position. Emergency controls Emergency dead-man/Enable trigger switch functions correctly Mushroom emergency stop switch, coloured RED. Platform controls mounted correctly, lever below guard rail. Foot Switch Assembly Platform alarms and indicator lights.
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Safety Devices Function and Inspection. Sample for Boom type MEWPs
Hydraulics All hydraulic hoses in serviceable condition and routed correctly No evidence of oil leakage from reservoir No evidence of oil leakage from hoses No evidence of oil leakage from hydraulic valves No evidence of oil leakage from steer cylinder(s) No evidence of oil leakage from lift cylinder(s) No evidence of oil leakage from telescope cylinder No evidence of oil leakage from platform level cylinder(s) No evidence of oil leakage from jib boom cylinder No evidence of oil leakage from Drive motors No evidence of oil leakage from Swing motor
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Safety Devices Function and Inspection. Sample for Boom type MEWPs Electrical Electrical looms adequately installed and protected Electrical switches secured and operational Work lights function correctly (if fitted) Rotating beacons operate correctly (if fitted) Limits switches secured and operating. Elevated boom travel limit switch Telescopic boom limit switch Envelope control limit switch Drive orientation limit switches Envelope control system (where fitted) Moment control system (where fitted ) Axle limit switches
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