Equipment Rollover Susan B. Harwood Grant Training Program

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Equipment RolloverSusan B. Harwood Grant
Training Program
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Equipment RolloverSusan B. Harwood Grant
Training Program
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Disclaimer/Usage Notes

• Photos shown in this presentation may depict
  situations that are not in compliance with
  applicable OSHA requirements.
• It is not the intent of the content developers to
  provide compliance-based training in this
  presentation, or to train employees how to
  operate the equipment depicted. The intent is
  more to address hazard awareness in the
  construction industry, and to recognize the
  overlapping hazards present in many construction
  workplaces.
• It should NOT be assumed that the suggestions,
  comments, or recommendations contained herein
  constitute a thorough review of the applicable
  standards, nor should discussion of issues or
  concerns be construed as a prioritization of
  hazards or possible controls. Where opinions
  (best practices) have been expressed, it is
  important to remember that safety issues in
  general and construction jobsites specifically
  will require a great deal of site- or
  hazard-specificity a one size fits all
  approach is not recommended, nor will it likely
  be very effective.

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Disclaimer/Usage Notes

• No representation is made as to the thoroughness
  of the presentation, nor to the exact methods of
  remediation to be taken. It is understood that
  site conditions vary constantly, and that the
  developers of this content cannot be held
  responsible for safety problems they did not
  address or could not anticipate, nor those which
  have been discussed herein or during physical
  presentation. It is the responsibility of the
  employer, its subcontractors, and its employees
  to comply with all pertinent rules and
  regulations in the jurisdiction in which they
  work. Copies of all OSHA regulations are
  available from your local OSHA office, and many
  pertinent regulations and supporting documents
  have been provided with this presentation in
  electronic or printed format. This presentation
  is intended to discuss Federal Regulations only -
  your individual State requirements may be more
  stringent.
• It is assumed that individuals using this
  presentation or content to augment their training
  programs will be qualified to do so, and that
  said presenters will be otherwise prepared to
  answer questions, solve problems, and discuss
  issues with their audiences.

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Disclaimer/Usage Notes

• As a presenter, you should be prepared to discuss
  all of the potential issues/concerns, or problems
  inherent in those photos with the students

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Why Require Training?

• Operator training is required by
• OSHA
• Manufacturers
• Clients
• Employers

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Why Is Training Needed?

• OSHA investigated two fatal accidents in 2005 in
  southern Colorado involving the rollover of
  pneumatic rubber-tired roller/compactors

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Accident 1

• May 2005
• Employee was fatally injured while operating a
  pneumatic rubber-tired roller

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Accident 1

• Roller ran off the road and traveled down a
  22-degree embankment
• Rolled over 1½ times, stopped on its top
• Operator was thrown from the machine
• Fatally crushed between the machine and ground

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Accident 1

• Roller was originally equipped with a ROPS and a
  seatbelt
• Both had been removed prior to the accident

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Accident 2

• August 2005
• Employee was rolling material into the gravel
  using a pneumatic rubber-tired roller

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Accident 2

• Roller ran off the road and down a 28-degree
  embankment
• Compactor rolled onto its side and came to a stop
  
• Operator was thrown from the machine and fatally
  crushed
• Roller was not provided with a ROPS, operator not
  wearing a seatbelt

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Summary of Accidents

• In both cases,
• If the machine had been equipped with a ROPS
  system, and
• If the operator had been wearing a seatbelt,
• The operators survival would have increased
  significantly

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Additional Accidents

• Between 2000 and 2006
• OSHA investigated over 50 rollover incidents

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Roller Compactor Safety

• Always be aware that a rollover hazard exists
• ROPS and seatbelts ALWAYS reduce the risk of a
  fatality
• Highest hazard locations were roadway or
  embankment edges

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Roller Compactor Safety

• When operating on uneven surfaces, chances of a
  rollover increase
• Another hazard was runaway machines, typically
  down slopes
• Evaluate roadways and work surfaces for
  dangerous inclines/declines

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ROPS

• A ROPS is a protective frame mounted on the
  machine and extends above the operators seat
• ROPS bear the weight of the machine during a
  rollover event
• ROPS minimize the likelihood that the machine
  will overturn completely

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ROPS

• A principle in ROPS design is to restrict the
  overturn to 90 degrees
• ROPS must to be used in combination with a
  seatbelt
• A ROPS only provides protection if the operator
  remains in the seat

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Roller Compactor Safety

• A number of hazards associated with rollovers
  were pointed out, including
• Working near road edge or embankment was the most
  hazardous
• The second most hazardous were steep slopes and
  roadway curves
• Problems with gear-shifting and brakes resulted
  in runaways

Source Compactor Overturns and Rollover
Protective Structures
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Roller Compactor Safety

• Compacting soil appeared to be more hazardous
  than other operations
• Hazards included the soil edges and soft soil
  pockets that could drop under the weight of the
  unit.

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Compactor Roller Safety

• Loading and unloading machines onto trailers
  posed a potential overturn hazard
• Hazards were caused by
• skidding on the ramps,
• using wood blocks or planks as ramps,
• or a machine that was too narrow to span both
  sides of the ramp

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Need for ROPS

• Studies show that if the machines involved are
  equipped with ROPS, and if the operators are
  wearing seatbelts, the operators survival
  increases significantly

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Regulations

• OSHA does not have a standard requiring the use
  ROPS or seatbelts
• OSHAs position is that the hazard of equipment
  rollover is a recognized hazard within the
  meaning of the General Duty Clause of the OSH Act

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General Duty Clause

• (a) Each employer --(1) shall furnish to each of
  his employees employment and a place of
  employment which are free from recognized hazards
  that are causing or are likely to cause death or
  serious physical harm to his employees(2) shall
  comply with occupational safety and health
  standards promulgated under this Act

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General Duty Clause

• (b) Each employee shall comply with occupational
  safety and health standards and all rules,
  regulations, and orders issued pursuant to this
  Act which are applicable to his own actions and
  conduct

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Other Regulations

• 29 CFR 1926.20(b)(4), states the employer shall
  permit only those employees qualified by training
  or experience to operate equipment and machinery.

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Other Regulations

• 29 CFR 1926.21(b)(2), Safety training and
  education, states further that the employer
  shall instruct each employee in the recognition
  and avoidance of unsafe conditions.

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Compactor Roller Safety

• Employers performing construction work are
  required to ensure that their operators are
  trained
• To use the equipment properly and
• To understand how to recognize those situations
  and conditions that pose a rollover hazard

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Compactor Roller Safety

• For example, operators need to understand that
• Soft edges can cause one side of the equipment to
  sink and therefore may pose a risk of rollover
• Turning away from a slope with articulated
  steering can destabilize the compactor

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Compactor Roller Safety

• Improperly inflated tires can destabilize
  roller/compactors and
• Rain or wet conditions can pose a hazard during
  unloading and loading
• and can increase the possibility of rollovers
  near embankments as soil conditions become
  unstable

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Roller Compactor Safety

• Leaving a compactor vibrator engaged while
  stationary has led to the settling of soil on one
  side of the unit, allowing it to overturn
• Articulation of a mobile unit with the jackknife
  pointed toward an edge presents a substantial
  overturn hazard

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Roller Compactor Safety

• Remember to always think safety, the life you
  save may be your own
• Always use ROPS and seat belts
• Now we will review as well as discuss proper
  procedures for operating your machine

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Safety is Important

• Three reasons Safety is important
• Accidents can cause death or serious injuries, or
  disability,
• Accidents can cost both you, and your employer
• With proper training, and with Machine Operators
  making it their responsibility to work safely,
  accidents can be prevented

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Safety Alerts

• The Safety Alert Symbol is used to
• Identify important safety messages
• Alert you to the possibility of injury or death

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Safety Alerts

• Follow the instructions in the safety message to
  prevent injury to yourself or others

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Manufacturers Manual

• States that you must be qualified and authorized
  to operate the machine
• YOU must
• understand the manufacturers instructions
• be trained
• demonstrate the actual operation of the machine
• know the safety rules and regulations

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Signal Words

• DANGER - indicates an imminently hazardous
  situation that will result in death or serious
  injury
• WARNING indicates a potentially hazardous
  situation which could result in death or serious
  injury
• CAUTION indicates a potentially hazardous
  situation that may result in minor or moderate
  injury

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A Word to the Operator

• Remember that Safety is up to YOU, only YOU can
  prevent serious injury or death

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Follow a Safety Program

• Protect yourself by wearing the appropriate PPE
• Hard hats, safety glasses, hearing protection
• WARNING! Do not wear loose fitting or dangling
  clothes
• Be Careful
• Encourage those around you to act safely

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Safe Operation

• Drugs or alcohol use can change your alertness or
  coordination
• Consult with your medical advisor if you are
  taking prescription or over-the-counter
  medication
• Ensure you can safely operate the machine
• Check the label for warnings against operating
  machinery

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Know the Safety Rules

• Your employer on the job site will have rules on
  the proper operation of equipment
• Check with your supervisor or safety coordinator
  to learn the rules for your job site

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Safety Rules for Compactors

• Know how to operate the Machine, and the
  characteristics of the machine
• Never modify or remove part of the machine
• Always fasten your seat belt
• Keep other workers out of the work area

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Safety Rules for Compactors

• Lower the blade and all other hydraulic
  attachments (if equipped) to ground.
• Know the proper shut down procedure for your
  specific machine as this can vary from different
  types and models of machines
• Remove your key to keep unauthorized people from
  operating the machine

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Job Site Traffic

• You must know the rules covering traffic at your
  job site,
• Understand what the signs, flag signals, and
  markings mean,
• Know what hand, horn, whistle, siren or bell
  signals mean
• Use your lights, turn signals, flashers and horn

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Know Your Equipment

• Know how to operate the equipment on your machine
• Know the purpose of the controls, gauges, and
  indicators
• Speed range, braking and steering characteristics
• Know the turning radius, and operating clearances

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Know Your Equipment

• Rain, snow, ice, loose dirt or gravel, soft
  ground all change the operating capabilities of
  your machine
• Study the DANGER, WARNING and CAUTION signs and
  decals on your machine

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Operators Manual

• Study and know the manufacturers operations
  manual before starting the machine
• If there is no manual with the machine Get One
• Ask your supervisor to explain anything that you
  do not understand

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Operators Manual

• If your machine is equipped with other devices,
• Read the manufacturers operating and safety
  manuals that apply to that equipment BEFORE you
  use the device

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Preparation for Use

• Check the safety equipment
• Seat Belt/Operator Restraints
• Lights
• Safety Signs/Decals
• Horn
• Back-Up Alarm
• Mirrors
• First Aid Kit
• Fire Extinguisher

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Preparation for Use

• Falling Object Protective Structure (FOPS)
• Roll-Over Protective Structure (ROPS)
• WARNING NEVER remove a FOPS or ROPS structure
  except for service

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Preparation for Use

• Check the machine each day before use
• Check for broken, missing or damaged parts
• Have necessary repairs made before using
• Check Pneumatic tires (if so equipped) for cuts,
  bulges and correct pressure
• Replace badly worn or damaged tires

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Preparation for Use

• Check the machine each day before use
• Check the service and parking brakes
• Perform all maintenance procedures
• Check the hydraulic system
• Fix any leaks

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Preparation for Use

• WARNING Diesel fuel or hydraulic fluid under
  pressure can penetrate the skin or eyes and cause
  serious injury
• Never use your hand to find leaks
• Wear a face shield or goggles
• Use a board or cardboard to find leaks

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Preparation for Use

• Check the cooling system
• WARNING Allow the radiator to cool before
  checking the level

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Preparation for Use

• Before operating check that the steering frame
  lock on articulated machines has been removed
• WARNING An articulated machine cannot be
  steered with a steering frame lock in place

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Preparation for Use

• If you find an item that needs repair during your
  daily inspection
• report it to your supervisor and tag the machine
  on the start switch or other location where it
  will be noticed.
• You should never operate a machine that isnt in
  safe working condition.

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Preparation for Use

• Clean up the machine
• Windshields
• Mirrors
• All lights
• Steps and hand holds
• Remove personal items from the operators area

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Preparation for Use

• Use caution when fueling
• Never overfill or spill fuel
• Ground the fuel nozzle to the filler neck
• Use the correct fuel
• WARNING Never fill when the engine is running,
  and never smoke while fueling up.

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Preparation for Use

• Know the work area
• Inspect the Conditions of area you will be
  working for conditions that could be dangerous
• Drop-offs or other obstacles
• Holes, obstructions, mud or ice
• Heavy traffic
• Thick dust, smoke or fog

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Preparation for Use

• When operating inside a building know your
  clearances
• Overhead
• Doorways
• Aisles
• Weight limitations of floors and ramps

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Preparation for Use

• For Landfill Compactors
• Perform frequent checks for wire or other
  material wound around the axles and remove them
  as soon as possible,
• Travel with the blade in the low position and,
• Make sure you maintain good visibility by keeping
  windows free of materials that could interfere
  with visibility.

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Preparation for Use

• While operating Machine
• Approach intersections with caution
• Observe speed limits and traffic signs
• Know your stopping distance
• Avoid panic stops and sharp turns

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Preparation for Use

• While operating Machine
• Stop and clear all railroad crossings
• Never park in traffic areas
• Use appropriate lights at night
• Pull off the road and set up barricades when
  parking at night

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Preparation for Use

• If the machine will be driven over the road
• Use hand signals or turn signals when turning

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Starting Safely

• Mount the loader safely
• When you get on or off the machine
• Maintain 3 point contact with the steps and hand
  holds
• Face the machine
• Never jump on or off the machine

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Starting Safely

• Mount the Roller Compactor safely
• When you get on or off the machine
• Never attempt to mount/dismount a moving machine
• Do not use the steering wheel or any control
  lever as a hand hold

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Starting Safely

• Warn personnel before starting
• Before starting, walk completely around the
  machine
• Make sure no one is under the machine servicing
  it, or close to it
• Let other workers know you are starting the
  machine

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Starting Safely

• WARNING Start the machine from the operators
  seat only
• Never by-pass neutral-start circuits by jumping
  the starter terminals
• The machine may start in gear and injure or kill
  you or someone else if started in gear

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Starting Safely

• Know the starting procedure for your machine
• Sit in the seat and adjust it so you can operate
  all controls properly
• Fasten the seat belt
• Engage the parking brake, put controls in neutral

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Starting Safely

• Know the starting procedure for your machine
• Familiarize yourself with warning devices, gauges
  and operating controls
• Clear the area of all persons
• Start the engine

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Starting Safely

• WARNING Exhaust fumes can kill
• Be positive there is adequate ventilation while
  operating

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Starting Safely

• Jumper cables
• Follow instructions on proper use of jumper
  cables
• Operator must remain in seat to control machine
• Jump starting is a two-person operation

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Starting Safely

• Ether Starting Fluid
• Ether is highly flammable and explosive
• Read the instructions on the container and in the
  manufacturers manual.
• Do NOT use ether if the machine has a pre-heater

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Starting Safely

• After Starting the Engine
• Observe gauges, instruments and warning lights
• Run an operating check
• Do not use a machine that is not in proper
  operating condition
• It is the OPERATORS RESPONSIBILITY to check the
  condition of the machine

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Starting Safely

• Test the Controls
• Make sure the machine is operating correctly
• Put machine in neutral, test the engine speed
  control
• Operate each control lever for proper function

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Starting Safely

• Test the Controls
• Operate the shift controls to ensure forward,
  neutral and reverse operate correctly
• Check the parking and service brake systems
• Test steering while moving slowly

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Starting Safely

• Test the Controls
• WARNING Be certain you can control both speed
  and direction before moving the machine

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Working Safely

• Stay in the operators seat at all times
• Keep your seat belt fastened when you drive or
  operate the Roller Compactor
• Be in control of your machine at all times
• Assure yourself that the work area is clear of
  other persons
• Look and listen for malfunctions
• Stop if a malfunction is detected
• Do not use the machine as a ram

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Working Safely

• Never allow an untrained or unqualified person to
  operate your machine
• WARNING Your Roller Compactor is a one-person
  machine, NEVER permit riders

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Working Safely

• If operating Machine on road make sure you use
  appropriate warning signs and emblems Slow
  moving vehicle
• Look before you back up, and make sure backup
  horn is working properly
• Know the pinch points and rotating parts on the
  machine

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Working Safely

• Traveling on the job site
• Take it slow and easy
• Watch out for congested areas
• Give the right-of-way to loaded machines
• Maintain a safe distance from other machines
• Pass cautiously

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Working Safely

• Dont obstruct your vision when traveling
• Operate slow enough to have complete control at
  all times
• Travel slowly on rough, slippery ground or
  hillsides
• Avoid operating your machine too close to an
  overhang, deep ditch, or hole
• Always use service and parking brakes carefully

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Working Safely

• Stay in gear when traveling downhill, never shift
  into neutral
• Maintain engine RPM to provide steering and
  braking
• Use the same gear traveling down that you would
  use travel up a hill
• Follow manufacturers manuals on brake use

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Working Safely

• Extreme caution should be used when working along
  the top of a bank or slope
• Keep away from the edge
• Always look back when backing up
• Be extremely alert in hazardous areas
• Always be alert for low branches and dead trees

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Working Safely

• Before entering buildings, underpasses, tunnels
  or bunkers check for hazards or obstructions
• Check clearance height
• Avoid turning on an incline
• Use extreme caution and make the turn wide and
  SLOW

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Working Safely

• When in dust, smoke, or fog use extreme caution
• Keep speed to a minimum when visibility is poor

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Working Safely

• Keep the work area flat and level if possible
• Be aware of potential caving edges and,
• Always travel slowly over rough terrain or avoid
  it and go around it

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Working Safely

• WARNING Never enter or allow anyone else to
  enter the Roller Compactor swing pivot area,
• Death or serious injury can result
• Always make sure you follow the manufacturers
  recommendations before you operate the Roller
  Compactor

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Working Safely

• WARNING Never operate the controls from the
  ground
• Severe injury or death can result
• Always operate the Roller Compactor from the
  correct operating position

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Working Safely

• When operating your Machine on the road
• Know your stopping distance at whatever speed
  youre going
• NEVER turn corners at high speeds
• Always look in all directions before you travel
  forward or reverse

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Working Safely

• Never operate Machine when extremely tired
• Your response time will be slower
• Your judgment will be impaired
• Remember Safety is your responsibility

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Working Safely

• Be Aware of
• Trenches that may be to close to your Vibratory
  Compactor, as it could cause a collapse
• Buildings and Light Poles that might be to close
  to where your Vibratory Compactor is operating as
  damage may occur
• Always be sure workmen and others are far enough
  away to avoid injury

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Working Safely

• WARNING Always remember that regardless of how
  heavy or stable your machine may feel or appear
  to you, there is always a chance of a rollover
  when working on steep slopes
• Always wear your seatbelt and make sure your ROPS
  is on your machine

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Working Safely

• Towing over-the-road is not recommended
• If your machine must be towed on the job site
• Use a rigid tow bar (not a chain or rope)
• Never allow anyone to ride on towed machine

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Loading and Unloading

• If the machine is equipped with a ROPS, you must
  wear the seat belt or restraint when loading or
  unloading the machine
• Follow the procedures recommended by the machine
  manufacturer for loading and unloading

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Loading and Unloading

• Several precautions are applicable to all
  machines
• Know the correct loading and unloading procedure
• Load and unload on a level surface
• Block the transport vehicle so it cannot move

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Loading and Unloading

• Several precautions are applicable to all
  machines
• Never load or unload the machine by yourself
• Keep all people not involved in the loading or
  unloading process clear
• The ramp and trailer must provide adequate
  traction for loading or unloading machine

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Loading and Unloading

• Several precautions are applicable to all
  machines
• Use ramps of adequate size and strength,
• Proper ramp angle and height
• Keep the trailer bed and ramps clear of mud, oil,
  ice, snow and other slippery materials

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Loading and Unloading

• Several precautions are applicable to all
  machines
• On articulated machines, attach the steering
  frame lock after loading, remove before unloading
• Chain and block machine securely for transport
• Keep everyone clear of the area

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Loading and Unloading

• Know the overall height and width of the
  transporter and Roller Compactor combined to
  avoid overhead and narrow obstructions

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Safety Rules for Compactors

• Whenever you park the machine
• Park away from road and traffic,
• Park on level, stable ground whenever possible
• When it is not possible to park on level ground
  park the machine at right angles to the slope
• Block your machine in both directions, and apply
  parking brakes

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Park Safely

• Safe Shutdown of the machine
• Stop the machine use the service brake
• Lower attachments to the ground
• Shift controls to neutral/park and lock
• Engage parking brake

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Park Safely

• Idle engine to cool down
• Stop engine
• Cycle all hydraulic controls
• Remove the key, and
• Shut off the master switch

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Park Safely

• Safe Shutdown of the machine
• Maintain three point contact when leaving the
  machine
• NEVER jump off the machine
• Be careful of slippery conditions
• Block wheels if on a slope or incline

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Maintenance

• Do not perform any work on a machine unless you
  are authorized and qualified to do so
• Attach a DO NOT OPERATE tag to the switch if
  maintenance is needed
• Remove the key if the engine should not be started

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Maintenance

• Never work on the machine with the engine running
• Exhaust fumes are hazardous to your health, if
  necessary to run the engine in an enclosed area
  use an exhaust pipe extension or have proper
  ventilation.

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Maintenance

• Be careful of fluids under pressure
• Use a piece of cardboard or wood to find leaks
• Never use your bare hand
• Wear a face shield or safety goggles
• If fluid is injected into any part of your body,
  go to a doctor for treatment immediately

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Maintenance

• Stop the engine while refueling
• Dont smoke while refueling
• Dont smoke when using starting ether
• Lead acid batteries can be explosive
• Keep arcs, sparks and flames away

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Maintenance

• Special tools and procedures are required for
  tire repair
• Call a repair service
• Maintain correct tire pressure
• Do not over-inflate
• Do not operate equipment if
• Tires are cut or damaged
• Lug bolts are missing

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Test Your Knowledge

• Do you understand
• Your safety program
• The machine manuals
• Proper clothing and PPE
• The machine controls, warnings and devices

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Test Your Knowledge

• How to inspect, mount and start your machine
• How to check for proper operation
• Your work area and any special hazards
• Proper operating procedures

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Test Your Knowledge

• Do you understand
• Proper parking, shutdown and dismounting
• Proper maintenance procedures
• Proper unloading and loading procedures
• The conditions where you should not operate your
  machine

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Conclusion

• It is impossible for this course to cover every
  hazardous situation you may encounter.
• Your knowledge of the safety precautions from
  this course and adherence to the basic rules of
  safety will help you use good judgment in all
  situations.
• Safety is your business and responsibility

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Questions?

• Answers to additional questions can be found in
  the following source materials
• 29 CFR 1926 Construction Regulations
• AEM Roller/Compactor Safety Manual