Reducing the risk from dropped objects when working at …€¦ · Reducing the risk from dropped objects when working at height Paul Marks Business Unit Director, BlueSky Solutions

Reducing the risk from dropped objects when working at height

Paul Marks Business Unit Director, BlueSky Solutions

A Lavendon Group CompanyNationwide Platforms


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August 2016

SkyScreenTM has been developed and manufactured by BlueSky Solutions, which is part of the Lavendon Group plc. BlueSky Solutions designs, develops and manufactures industry-leading systems and equipment, exclusively available to Nationwide Platforms customers, for improving the safety, efficiency and productivity of powered access machines.


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August 2016

Contents

1. Executive summary 4

2. Current legislation 4

3. Defining the problem 5

4. Current solutions 7

5. The SkyScreenTM solution 8

6. SkyScreenTM main features 9

7. SkyScreenTM benefits 10

8. Summary 11

9. Contacts 11

10. References 11



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1. Executive summary Objects dropped from height, and the resulting hazard to the workforce, is a recognised risk. Certain industry sectors are ahead of others in managing this risk. An increasing number of complex tasks are now carried out using mobile elevating work platforms (MEWPs). Therefore, there is a need to find ways to prevent objects from being dropped while working at height.

This white paper highlights risks resulting from dropped objects, and identifies options currently available for reducing this risk. It reviews the legislation in place. It samples the policies of larger companies in the marketplace, and investigates the steps that manufacturers have taken to address this issue.

It also introduces a new product developed by BlueSky Solutions, which is part of Lavendon Group. This product, called SkyScreen™, is designed to reduce the risk of objects being dropped from height.

2. Current legislationIn the UK, the legislation for the management of health and safety risks is provided by the Health and Safety at Work Act (1974). The Management of Health and Safety at Work Regulations 1999 lays out additional requirements for employers to assess reasonably foreseeable risks, and to implement risk controls.

In addition, more specific regulations exist to identify risks associated with certain activities. For working at height this includes the Working at Height Regulations 2005. Within these regulations, the issue of dropped objects is identified in regulation 10 and 11. These state, in summary, that employers should:

• Take steps to prevent the fall of objects;• If this is not possible, prevent people being struck by such objects;• Ensure nothing is thrown or tipped from height which may cause injury;• Ensure materials are stored securely, avoiding their overturn or unintended movement; • Ensure that, if a risk exists, any affected area should be set up to prevent unauthorised access, and be clearly marked.

This is not just a matter for employers. A responsibility is also placed on employees to work in a safe manner. In particular, with respect to dropped objects, employees should be made aware of the risks, and any controls that have been put in place their they are expected to follow. They should, of course, be appropriately trained to carry out the tasks required of them, and pay close attention to issues such as housekeeping.

In summary, those working at height must recognise the risk of falling objects, and both employers and employees have a duty of care to manage and minimise those risks. On large construction projects these duties often result in a complex arrangement, with responsibility shared across site owners, main contractors and subcontractors.


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3. Defining the problem Dropped objects can be defined as either static or dynamic:

Static – A static dropped object is: “Any object that falls from its previous position under its own weight (gravity) without any applied force: for example, an object that falls from a building or machine due to failure caused by corrosion, vibration or inadequate securing.”

Dynamic – A dynamic dropped object is: “Any object that falls from its previous position due to applied force, for example collisions involving travelling equipment or loads, snagging on machinery or stacked items, motion, helicopter downdraft or severe weather.” (4)

Both types can occur when working at height from a MEWP. For the purposes of this report we will assume that larger payloads, such as pipes and sheets, are carried and secured according to best practice (5) using a proprietary rack and securing straps. Therefore, typical dropped items will include:

• Tools, which by their nature may be potentially heavy and have sharp edges;

• Fastenings and fixings, such as nuts and bolts, plus heavier items such as clamps, hinges and brackets;

• Personal items, such as telephones.

Scale of risks from dropped objectsThe risks arising from dropped objects vary depending on the height from which they fall, and the mass of the object. There are a number of industry tools for calculating the effect of a dropped object. One is the DROPS calculator (6). This is an indicative guide that assumes falling objects are blunt, and that required PPE is being worn, according to best practice, by the person struck.

Fatality

Major

Minor

Slight

Incident

0.2 0.4 0.7 0.9 1.1 1.3 1.5 1.8 2.0

Mass (lb)

50

40

30

20

10

0

Height (ft)

15

12

Hei

ght

(m)

1413

11

8

109

7

4

65

1

32

0

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.0 1.0

Mass (kg)

Fig 1. Example of dropped object calculator

(Source: http://www.dropsonline.org/resources-and-guidance/drops-calculator)

The DROPS calculator indicates that an object weighing no more than a bag of sugar may cause a fatal injury if it falls onto a construction worker wearing a standard hard hat, from a height of little more than 10 metres.


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August 2016

Setting the pace – oil and gas industryThe oil and gas industry has done the most to tackle the risk of dropped objects. Oil platforms are compact multi-layer industrial complexes, with many walkways, steps and platforms. These are often mesh structures to save weight. They can reach heights of more than 100m above water level. Personnel access is required at most levels, often for carrying out tasks that require tools and fixings.

Therefore, the hazards of dropped objects are well recognised. This includes the risk of dropping a critical or expensive object into the water. Close attention is paid to preventative measures, including:

• Tool tethering;

• Barricades on open walkways;

• Work mats to hold tools and fixings in place;

• Toe boards to stop objects being knocked off working areas;

• Mandatory use of PPE.

Many of these practices also extend to refinery operations, which are similarly complex industrial installations. This has led to the development of specific dropped object safety policies and campaigns instigated by leading global corporations.

Dropped objects – construction industry

Some of these solutions have been taken up by the construction industry. Scaffold must now be fitted with toe boards and the use of debris nets should be considered. Users must also pay close attention to stacked or stored objects at height. Other trades have adopted the use of tool tethers while working at height. All are expected to consider barricading off immediate areas of danger below the work area.

Applying insights to powered access

Applying this learning to the use of MEWPs reveals similarities and differences. Most machines have open baskets and kick rails. Booms often have mesh floor fixed to floor struts, though some are solid. Most have open basket rails designed to prevent personnel from exiting the cage, but not to prevent dropped objects.

Operational issues, such as side forces generated by wind loading, and the need to minimise basket weight to maximise a MEWP’s payload must also be considered when devising a method to prevent dropped objects. Best practice in the use of exclusion zones around the base of MEWPs, to protect the immediate area of risk, should always be followed.

Falling tools are a risk when working in MEWPs


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What is not always obvious is the required size of this area for the hazard. Additionally, risks associated with an object falling such as, striking another object and then being diverted horizontally, are difficult to quantify and mitigate in complex work environments.

Risks to personnel are of greatest concern. However, in the powered access industry, potential damage to structures is also a concern. MEWPs, particularly booms, are frequently required to move up and over buildings, roofs, fragile structures and other objects. Falling objects could cause damage that would be costly and difficult to repair. Therefore, it would be better to prevent the object from falling in the first place.

4. Current solutions There are a number of methods for preventing dropped objects:

Tethering

This is the practice of attaching potential dropped objects to a securing point. This system is most commonly applied to tools. A lanyard is attached to the tool at one end and a securing point at the other. This may be a permanent structure or an attachment point in a MEWP basket. For smaller personal tools, the securing point can be an operative’s wrist, a belt, or a tool holster.

Tethering systems usually require specially-designed tools, with manufacturer-supplied attachment points. Or they need an aftermarket attachment point to be fitted to the tool, These can range from tapes and D Rings to welded attachment points. Some suppliers now also offer solutions for commonly-used product such as padlocks.

Tethering can be applied to larger objects, and those not suited to being harnessed at a single point. Netting can be used to completely enclose such objects, and to provide a single point of attachment. Smaller personal items can also be secured in this way, without affecting operational performance.

Barriers

There are numerous barrier protection methods on the market. These are generally used to protect open walkways or platform edges. They usually consist of a plastic moulded or metal mesh profile that can be attached to scaffold or handrails to prevent objects from being dropped through the mesh. The effect of wind loading and weathering needs to be considered when protecting open structures.

As discussed earlier, the impact of a barrier-style safety system on the wind rating and weight of MEWPs would also be a critical factor. Storage and transport of barrier systems, and their application to MEWP baskets of different designs and sizes, would also be a challenge.

Anti-drop mats

Several manufacturers offer anti-drop mats. These are designed to sit on an open mesh walkway to prevent tools and objects rolling away, or falling through the gratings in the floor structure. They usually lay flat on the floor surface. They work by reducing the apertures through which products can fall. Versions are also available for MEWPs. These products help to


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prevent small fixings from dropping through a mesh. They also help to secure objects as part of good housekeeping practice.

Original equipment manufacturer solutions

MEWP manufacturers have addressed the problem of dropped objects in a number of ways. In the past, it was common to offer baskets with mesh type panels as standard. However, most manufacturers have moved away from this approach.

Some manufacturers offer a removable mesh insert that can be fitted in the basket. Others have solid floors to stop objects falling through them. However, in general, the risk of dropped objects is seen as a customer-specific issue to be addressed at site level. This is highlighted in IPAF guidance on attaching products to MEWP cages (7), which is intended to outline specific problems that may arise when attaching nets to machines. Any such enclosure solution should be considered carefully, as there are significant stability and compliance implications.

5. The SkyScreen™ solution

In response to customer demand to address the problem of dropped objects from MEWPs at a site level, BlueSky Solutions has developed SkyScreenTM. It is designed to effectively counter dropped object risks when working at height with fixings and tools.

SkyScreen™ consists of a strong mesh structure which provides drop protection around the entire MEWP basket. It provides protection for objects, including smaller fasteners and fixings, that cannot be secured by tethering. Even smaller items, when dropped from height, can gain a significant momentum and create a risk of injury if dropped when working at height.

For example, the DROPS calculator(6)indicates that an object weighing just 0.5kg can cause major head injury to a person wearing a hard hat when dropped from a height of 12 metres.

It should also be considered that the object potentially dropped may be of value and needs to be protected. Also, as previously stated, a dropped object can also cause serious and costly damage to a structure over which the MEWP is positioned.

SkyScreen still provides good visibility in the basket


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6. SkyScreen™ – main features

Full basket protection – The light-weight SkyScreen™ mesh fits around the entire basket structure, giving full basket protection.

Tool-less fitting – SkyScreen™ enables tool-less fitting. It is attached to the basket using a novel system of fabric hook and loop fasteners and magnets. This enables any user to quickly fit and remove SkyScreen™ on site.

Fire rated – Fire retardency is a major consideration for all powered access applications. The principle materials of construction of the SkyScreen™ are fire retardant. The screen material is LPS1215-certified to ensure full compliance with fire regulations.

Lightweight – A standard SkyScreen™ weighs less than 2.5kg. In the context of an allowable payload on most machines of 227kg, SkyScreen™ will have a negligible effect.

Wind tested – As outlined previously, IPAF guidelines state that consideration should be given to additional wind loading generated by fitting products to MEWP baskets.

To address this, the form and shape of the SkyScreen™ mesh, and the ratio of its fibre to aperture size, have been carefully selected and tested. Wind loading performance of the mesh with different wind speeds has been theoretically calculated. To confirm these measurements, SkyScreen™ has been thoroughly tested in the RJ Mitchell wind tunnel at Southampton University.

This has confirmed the operational parameters under which SkyScreen™ may be used, determined by the MEWP basket size.

Visibility – Another key consideration in any MEWP attachment is the impact of the product on visibility. Many mesh or screen structures can obscure visibility within the MEWP basket. This can have significant safety implications.

However, the carefully-selected materials of construction used for SkyScreen™ provide excellent visibility.

CE certified – As a result of the above design, construction and extensive formal testing, the SkyScreen™ product is CE approved as an item of interchangeable MEWP equipment.

Quick and easy installation - no tools required


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August 2016

7. SkyScreen™ benefitsSkyScreen™ has been developed to address, specifically, the problem of dropped objects from MEWPs. As such, SkyScreen™ delivers the following benefit for MEWP operators:

• It demonstrates a desire and willingness to achieve full compliance with elements of the Working at Height 2005 Regulations related to dropped objects;

• SkyScreen™ is a practical, low cost method for addressing a range of specific hazards within a risk assessment and method statement (RAMS);

• Once fitted, SkyScreen’s™ effectiveness is not influenced by the behaviours of the operators using the powered access equipment – and supervising personnel can instantly see that it is fitted and in use when carrying out site safety inspections;

• While some systems, such as tethering, address one type of hazard, SkyScreen™ is designed to address a wider range of dropped object risks, including the use of small tools and the vast range of fixings increasingly used when working at height;

• As such, SkyScreen™ is designed to fill a gap in an area of MEWP safety where there are currently limited options;

• Protecting personnel from personal injury is a prime purpose. However SkyScreen™ is also highly effective in reducing the risk of damage to high value structures below baskets, notably from dropped fixings;

• SkyScreen™ is a flexible solution: it need only be applied when the risk (ie construction work) is present, not for other tasks (ie building inspections);

• SkyScreen™ is quick and easy to fit without tools, and provides full basket coverage, without significantly impacting on the operational performance of powered access equipment.

SkyScreen™ is also highly

effective in reducing the

risk of damage to high value

structures below baskets


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August 2016

8. Summary

SkyScreen™ is the latest in a series of innovations from BlueSky Solutions. It is available for rent across a significant portion of the Nationwide Platforms access equipment fleet. Initially, its use is aimed at boom-type MEWPs, for both indoor and outdoor activities. Specifically, these machines are most likely to be operating at significant heights above other personnel or over high value structures or objects. It is anticipated that the SkyScreen™ product range will increase, so solutions can be provided in all types of working at height activity.

9. Contacts

More details about SkyScreen™ can be found on the Nationwide Platforms website:www.nationwideplatforms.co.uk/safety-and-innovations

To hire SkyScreenTM telephone 0845 745 0000 or email [email protected]

For more about BlueSky Solution email [email protected]

10. References

(1) “Annual Offshore Statistics and Regulatory Activity Report 2014/2015” (23rd Sept 2015) hse.gov.uk

(2) https://www.worksafe.qld.gov.au/news/newsletter/esafe-newsletters/esafe-editions/ esafe-construction/november-2013/legal-lessons/crackdown-on-falls-and-falling- objects-breaches

(3) https://www.nibusinessinfo.co.uk/content/reduce-risks-objects-falling-height

(4) http://www.hse.gov.uk/pubns/indg344.pdf

(5) http://www.hse.gov.uk/pubns/priced/hsg150.pdf

(6) http://www.dropsonline.org/resources-and-guidance/drops-calculator

(7) http://www.ipaf.org/en/resources/faqs/

15 Midland Court, Central ParkLutterworthLeicestershireLE17 4PNUnited Kingdom


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Reducing the risk from dropped objects when working at …€¦ · Reducing the risk from dropped objects when working at height Paul Marks Business Unit Director, BlueSky Solutions