Telehandler Health and Safety

Company fined £160,000 after worker loses legs

A company has been fined £160,000 after an employee lost both legs whilst working at its site near Warrington.

On 20 June 2022, Andrew McAuley, from Runcorn, an employee of William Stobart & Son Limited was picking orders at the firm’s warehouse in Appleton Thorn.

The 64-year-old was working in close proximity to a forklift truck (FLT) which was being used to load pallets of slate tiles onto a waiting truck. The FLT was carrying two pallets, one on top of the other. The top pallet was not secured to the one below, and when the driver turned the vehicle, both pallets became detached from the forks, with the upper pallet striking Mr McAuley, crushing his legs.

Mr McAuley had to have both legs amputated below the knee. He has been left dependent upon a wheelchair and unable to drive or climb stairs, leading to the need for extensive adaptations to the family home.

An investigation by the Health and Safety Executive (HSE) found that William Stobart & Son Limited failed to ensure this area of the warehouse was organised so that vehicles and pedestrians were segregated and circulated in a safe manner and loads were secured so far as was reasonably practicable.

William Stobart & Son Limited, of Ashville Way Industrial Estate, Sutton Weaver, Runcorn, Cheshire pleaded guilty to breaching regulation 2(1) of the Health and Safety at Work etc Act 1974. The company was fined £160,000 and ordered to pay £4,478 costs at a hearing at Warrington Magistrates Court on 30 July 2024.

The prosecution was supported by HSE enforcement lawyer Sam Tiger and paralegal Sarah Thomas.

After the hearing HSE Inspector Lorna Sherlock said: “Mr McAuley has been left with devastating and life changing injuries.

“The company failed to implement a safe system of work for loading and unloading activities, thereby exposing employees, and others, to the risk of being struck by loads or workplace vehicles. This case illustrates the consequences of failing to segregate vehicles and pedestrians, and to properly secure loads.

“This injury could easily have been prevented. Employers should make sure they assess work activities sufficiently and apply effective control measures to minimise the risk from workplace transport.”

Safe Use and Operation of a Telehandler

Introduction

Telehandlers, also known as telescopic handlers, are versatile machines widely used in construction, agriculture, and industry for moving materials and goods. Their ability to handle heavy loads and reach high places makes them invaluable. However, due to their power and versatility, telehandlers also pose significant safety risks if not operated correctly. This newsletter aims to provide essential guidelines for the safe use and operation of telehandlers to ensure a secure working environment.

Understanding Telehandlers

Telehandlers combine the features of a forklift and a crane, equipped with an extendable arm for lifting and moving heavy objects. They are designed for a variety of tasks, including loading, unloading, and reaching difficult areas. Given their complexity and power, it is crucial for operators to be well-trained and knowledgeable about the specific telehandler model they are using.

Key Safety Guidelines

Operator Training and Competence

• Ensure all telehandler operators are trained, competent, and authorised to operate the specific model in use. Training should cover machine controls, safety features, and operational limits.
• Regularly update training and conduct competence checks to maintain high safety standards.
• Pedestrians should be instructed in safe pedestrian routes on site and the procedure for making drivers aware of their presence.

Pre-Operational Checks

• Perform daily checks on the telehandler to ensure it is in safe working condition. Inspect for visible damage, check fluid levels, brakes, tyres, and ensure all safety features are functional.
• Report any defects immediately and do not operate the machine until issues are resolved.
• Regular inspections and servicing schedules should be established in accordance with the manufacturer’s instructions and the risks associated with each vehicle.

Planning and Hazard Identification

• Plan the telehandler’s route and identify potential hazards such as uneven terrain, overhead obstructions, and confined spaces. Clear the area of debris and ensure there is enough space for safe manoeuvring.
• Use risk assessments and lifting plans to manage lifting operations safely, especially when using telehandlers as cranes.

Telehandler hazards

Most fatal and serious injuries involving telehandlers occur when the vehicle is:

• Moving – and strikes a pedestrian, particularly while reversing.
• Lifting – and overturns trapping the operator or person nearby.

Both of these hazards should be identified within a risk assessment and suitable control measures put in place.

Controlling the risk

It is important to select the right vehicle for the job and site. There are a number of precautions that can reduce the risk of persons being struck or the vehicle overturning. These are:

• Visibility: Select telehandlers with the best view around them directly from the driver position.
• Rear visibility: Visibility to the rear may present a significant hazard. The vehicle should be equipped with adequate aids so drivers can see areas where people may be at risk. A signaller may be needed in some circumstances.
• Forward visibility: Similarly, when in operation with the boom raised and other configurations, there may be a significant ‘blind spot’ to the front right-hand side of the vehicle.
• Ground conditions: Working on sloping, uneven or unstable ground can be hazardous. Telehandlers normally require prepared, flat, graded surfaces to operate safely. Even rough-terrain lift trucks have strict operational limits that need to be observed.
• Loading: Overloading can be prevented by selection of the correct vehicle and good management. Moving with a raised load is dangerous and should be avoided at all times.
• Speed: a site speed limit should be established. Driving at excessive speed around corners can cause the vehicle to overturn.

Load Management

• Secure loads properly to prevent shifting or falling during transport. Ensure the load is within the telehandler’s capacity and evenly distributed.
• Avoid overloading and adhere to the manufacturer’s guidelines for attaching and detaching loads.

Conclusion

By adhering to these safety guidelines, operators can significantly reduce the risks associated with telehandler operations. Prioritizing safety through proper training, regular checks, careful planning, and cautious operation is essential for creating a safe working environment for everyone involved. Remember, safety should always be the top priority when operating machinery.

 

How do I plan a safe route for a telehandler

To plan a safe route for a telehandler, follow these key steps:

Identify Hazards: Before moving the telehandler, conduct a thorough assessment of the planned route to identify potential hazards. Look for uneven terrain, obstacles, overhead obstructions, and confined spaces. Ensure the area is cleared of debris and that there is sufficient space for safe manoeuvring.

Segregate Pedestrians and Vehicles: Organize the site to separate pedestrian pathways from telehandler routes. This reduces the risk of accidents involving pedestrians, especially when the telehandler is reversing or moving with a load.

Ensure Visibility: Choose telehandlers with optimal visibility from the driver’s seat. Use visibility aids like mirrors or cameras to monitor blind spots, particularly when reversing. Consider employing a signaller if necessary to guide the operator in areas with limited visibility.

Assess Ground Conditions: Ensure that the route consists of stable and level ground. Telehandlers require flat, prepared surfaces for safe operation, even if they are designed for rough terrain. Avoid sloping or unstable ground to prevent tipping.

Plan for Overhead Cables: Be aware of any overhead cables or power lines along the route. These can be difficult to spot from a distance, so planning the route to avoid them is crucial for safety.

Set Speed Limits: Establish a site speed limit to prevent accidents due to excessive speed, especially when navigating corners or carrying raised loads.

By following these steps, you can significantly enhance the safety of telehandler operations on your site. Prioritising hazard identification, visibility, and ground conditions will help in creating a safer working environment for everyone involved.

 

Thorough Examination

The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) require that all lifting equipment is thoroughly examined by a competent person at specified intervals. In the case of a telehandler, it should be thoroughly examined as follows:

• When the telehandler is put into service for the first time (LOLER Reg. 9(1)).
• At regular intervals of:
  • A period not exceeding 12 months if the telehandler is only used for lifting goods.
  • A period not exceeding 6 months if the telehandler is used for lifting persons.
• After any major alteration or damage (event).

Where periodic thorough examinations are carried out, it is incumbent on the competent person to set the date of the next thorough examination. This is generally six or twelve months from the date of the thorough examination but should be reduced by the competent person where they judge that the rate of deterioration of the lifting equipment may lead to a dangerous situation occurring before the next thorough examination, if it were made at the maximum interval.

Examples of this are where a telehandler:

• Is being used in a corrosive environment such as a petrochemical plant or close to the sea.
• Is being used more frequently than normal i.e. double shifting.
• Is always lifting loads at or near the rated capacity.
• Has components that are wearing rapidly and require frequent replacement.

Reports of thorough examination should contain the details required by Schedule 1 of LOLER.

Thorough examinations should be carried out by competent persons who are sufficiently independent and impartial.

Thorough Examination of Lifting Accessories and Lifting Attachments

 

LOLER requires that lifting accessories and lifting attachments are thoroughly examined at intervals not exceeding six months.