Preventing Falls

and Falling Loads

from Tail Lifts

Produced by IRTE, a professional sector of SOE

SOE (Society of Operations Engineers) is a professional membership organisation
representing some 17,000 individuals and companies in engineering. It supports and
encourages members throughout their careers and is committed to their ongoing growth and
personal development.

Through a network of trustees, industry partners and members, SOE promotes best practice
in operational and health and safety initiatives. SOE offers members continuing professional
development and support throughout their careers, providing definitive recognition for both
achievement and status. The organisation is a Licensed Member of ECUK and can nominate
members for ECUK registration at EngTech, IEng and CEng levels.

SOE represents the Professional Sectors IRTE, IPlantE and BES and developed the
technician-licensing scheme, irtec.

IRTE (Institute of Road Transport Engineers), one of the most respected names in UK
transport, has always been recognised as an impartial voice of the industry.

IRTE publishes an industry-leading technical journal, Transport Engineer, every month.

Transport Engineer is renowned for its incisive coverage of key issues, authoritative reporting,
news analysis and informed comment.

IRTE also hosts regular technical seminars and forums and works alongside the DfT to
promote efficiency and best practice. Recent events include trips and falls from vehicles, truck
operation, fuel efficiency and the Road Safety Act. IRTE’s technical committee also produces
regular industry guidance on key topics.

Recent published guides include A Best Practice Guide towards Tachograph Systems
Compliance, Roadworthiness: Industry Best Practice, Coupling or Uncoupling & Parking of
Large Goods Vehicle Trailers and Tail Lift – Specification Guide for Road Vehicles.

IRTE members come from a wide variety of transport-related roles. These include workshop
managers, fleet engineers, transport managers, company directors, apprentices and
technicians in the light and heavy goods vehicle and bus and coach sectors.

If you are interested in becoming involved with the IRTE Technical Committee, please
contact Ian Chisholm, Head of Membership and Technical Services, on 020 7630 1111
or email [email protected].

This guide was first published by the SOE in May 2009

ISBN 978-0-9 555685-3-4
Editor: David Jones Design and Guide Coordinator: Sarah Prest
© 2009 Society of Operations Engineers
Preface

Each year, approximately 50% of all tail lift accidents reported are attributed to people
falling from, or slipping on, tail lifts or from being struck by a falling load. This guide has
been produced by the members of a Tail Lift Users Group, which included tail lift operators,
manufacturers and HSE, to provide guidance for the prevention of falls and falling loads from
tail lifts. This would include load security, personnel security (slips, trips and falls), but not
include the integrity of the load, or the Personal Protective Equipment of the personnel. This
guide has been developed to supplement the existing Health and Safety literature currently
available.

Typical example of column lift with runner mounted 3 position gates

Contents and appendices

SECTION PAGE

Selection 5
Training 6
Pre-user checks 7
Environment 7
Cleaning/housekeeping 8
Associated equipment 8
Management responsibilities 9
Rental vehicles 9
Retro fit 9
References and further information 10
IRTE publications 18
Sponsors 20

APPENDICES

Appendix 1 Fall protection 12

Appendix 2 Commercial vehicle handrail selection 17

Selection

Careful consideration should be given to matching the appropriate tail lift to the task it is
required to perform and this should form part of your risk assessment11. Selection includes
not only initial specification but also matching the equipment to the task. Further information
on the selection of tail lifts is provided in the Society of Operations Engineers Specification
Guide for Road Vehicles9 and in Appendix 2.

The selection of fall prevention equipment should be applicable to all tail lift types and these
can be broadly categorised as:

• Column Lift
• Cantilever Lift
• Tuck under Lift
• Retractable Lift.

It should be recognised that these lift types can be used for both goods and personnel, the
fall prevention devices should be selected to suit the operational requirements and must be
applied in all cases.

It is recommended that all open sides of a raised platform should be suitably equipped to
protect against falls. This would be one way of fulfilling your responsibilities under the Work At
Height Regulations 2005.

Fall prevention equipment for operator and goods can be placed into several categories
as listed below. Wherever possible these should form a fixed part of the tail lift, but can be
detachable where its operation makes fixed equipment impractical.

• Safety gates (fixed, folding or detachable)

• Roll stops (integrated into the platform, or an addition to the platform edges)
• Ancillary equipment such as flaps, bridge plates, run up ramps that are able to be
deployed as load restraint
• Safety chains/straps
• Slip resistant surfaces.

Worked examples of the equipment listed above can be found in Appendix 1.

A Selection Check Sheet is included in Appendix 2.

The main standard covering tail lifts is EN 1756-1:2001+A1:2008 Tail lifts. Platform lifts for
mounting on wheeled vehicles. Safety requirements. Tail lifts for goods.

Training

Provision should be made for suitable and sufficient operator training (including agency/
temporary and part time staff) in all aspects of tail lift use, including the appropriate safe
system of work.

The training should include the following key areas:

• Safe operation of the tail lift

• Manual handling hazards associated with type of tail lift, load, associated equipment and
environmental conditions
• Position for the operator when operating the lift - covering solo operation and multiple
operators
• Parking and position of vehicle when using a lift
• Understanding the risks of falls from height – personnel/goods and third parties
• The correct use of the fall prevention equipment (fall prevention should be a specific item
within the training programme/documentation)
• Pre User Checks.

As always the training delivered must be fully documented and include dates and signatures.
Further details covering this subject can be found in Managing work to avoid fall from
vehicles6 and HS(G) 136 Workplace Transport safety14.

Typical example of a column tail lift with fixed safety handrails

Pre-user checks

In addition to the standard pre-user checks that must be carried out in relation to the
operation and safe use of the tail lift, it is essential that fall prevention equipment and the
condition of the platform surface are included within this process. The tail lift operator
and/or the person carrying out the pre user check should be deemed competent for these
inspections. Such inspections are covered by the Lifting Operations and Lifting Equipment
Regulations 1998 (LOLER). More information on the Regulations can be found in the
Approved Code of Practice L113 – safe use of lifting equipment 13.

Documented training should be given to ensure and prove competence. Pre-user checks
should be recorded on a specific document which should be retained as appropriate.

If defects are identified on the pre-user check, these should be reported to a designated
person to ensure that appropriate repairs are carried out within acceptable timescales, so that
the equipment is only ever used in a safe condition.

Defect reports and documentation supporting their rectification should be retained as

appropriate.

Typical example of cassette/cantilever lift with folding ‘P’ gates

Environment

Environmental conditions can adversely affect the safe operation of the tail lift and fall
protection equipment detailed above. The environment should be considered throughout the
risk assessment, selection and training process.

Examples of environmental issues to consider would include:

• Weather
• Location of delivery point (e.g. High St, warehouse yard)
• Gradient
• Slip resistance of lift surface and operator footwear5, 7, 8.
Cleaning/housekeeping

The operators should be aware that they are responsible for ensuring any spillage that may
prevent the safe use of the tail lift and fall prevention equipment, or reduce the slip resistance
of the platform surface, should be removed before the equipment is used (using the
appropriate risk assessment and safe systems of work).

Typical example of a slide away tail lift with folding ‘p’ gates and 3 way folding ramps

Associated equipment

As with the careful selection of the tail lift equipment, equal care should be given to the
selection of all ancillary equipment that can be used on the platform forming part of the load
or mechanical handling devices used by the operator, e.g.

• Pallets
• Roll Cages8, 10
• Pallet Trucks15
• Sack Barrows
• Dock Levellers.

Further information can be found within the references.

Management responsibilities

Along with all the accepted responsibilities contained within LOLER and the Provision and
Use of Work Equipment Regulations 1998 (PUWER)12, equal importance must be given to
fall prevention equipment provision, use, training, maintenance and thorough examination.
Further information can be found in the operator’s handbook supplied with the tail lift, guides
from the Society of Engineers9, and HS(G) 136 - Workplace Transport Safety14.

Rental vehicles

The selection criteria detailed above must be applied to the procurement of rental vehicles.
Appropriate training must be carried out and operators made aware of any differences
between equipment types. Pre-user checks may need to be amended, but must be carried
out.

Retro fit

The decision to undertake retro fitting should be governed by the outcome of risk
assessments. Cost of retro fitting, while important, must not overcome the outcome of the
appropriate risk assessments. It is recommended that retro fitting of fall protective equipment
is carried out in conjunction with the equipment manufacturer, wherever possible, and should
meet the requirements contained within this guide.

Typical example of a column lift with 3 sided fall protection and 3 way folding ramps
References and further information

1. Falls from Vehicles case studies

http://www.hse.gov.uk/fallsfromvehicles/casestudies.htm

2. Preventing Falls From Vehicles - An industry guide – Freight Transport Association

http://www2.fta.co.uk/information/otherissues/workplacesafety/falls.pdf

3. HSL Research Report – rr437 - The underlying causes of falls from vehicles associated
with slip and trip hazards on steps and floors.
http://www.hse.gov.uk/research/rrpdf/rr437.pdf

4. Access
http://www.hse.gov.uk/fallsfromvehicles/access.htm

5. Footwear
Selecting the right footwear to avoid falls from vehicles
http://www.hse.gov.uk/fallsfromvehicles/footwear.htm

6. Managing work to avoid fall from vehicles

http://www.hse.gov.uk/fallsfromvehicles/wpt05.pdf

7. Slips and Trips

http://www.hse.gov.uk/slips/research.htm

8. Research Reports

A study of the slip characteristics of metal flooring materials

http://www.hse.gov.uk/research/rrpdf/rr534.pdf

Safety of roll containers

http://www.hse.gov.uk/research/rrpdf/rr009.pdf

9. Tail Lifts

Guides from The Society of Operations Engineers

http://www.soe.org.uk/publications/guides.html

Tail Lift – Specification Guide for Road Vehicles

Tail Lift Operators – a simple guide

10
References and further information

10. Manual handling

Manual handling Assessment

http://www.hse.gov.uk/pubns/indg383.pdf

Roll cages and wheeled racks in the food and drink industries: Reducing manual
handling injuries
http://www.hse.gov.uk/pubns/fis33.pdf

11. Five steps to risk assessment

http://www.hse.gov.uk/pubns/indg163.pdf

12. L22 – Safe use of work equipment – Provision and use of Work Equipment Regulations
1998 – ISBN 978 – 0 7176-6295-1.

13. L113 – safe use of lifting equipment – Lifting Operations and Lifting Equipment
Regulations 1998 – ISBN 0-7176-1628-2.

14. HS(G) 136 - Workplace Transport Safety – ISBN 0-7176-6154-7.

15. HS(G) 6 – Safety in working with lift trucks – ISBN 07176-1781-5.

16. Information sheet WPT06 – Delivering safely: Co-operating to prevent workplace vehicle
accidents
http://www.hse.gov.uk/pubns/wpt06.pdf

11
Appendix 1 - Fall protection

The following list shows methods of protecting against falls from height. The list is not
exhaustive and other methods may be used which achieve an equivalent level of safety.

For illustrative purposes, different methods are shown on different types of tail lift mechanism.
The methods are not intended to be exclusive to that type and in most cases can be
transferred from one type to another. It is intended that handrails or guards be deployed
before the platform is used for (un)loading or for access.

Runner Mounted Handrails – permitting side (un)loading

The handrails may be turned through 90o or 180o.

12
Appendix 1 - Fall protection

Drop-in Interlocked Handrails – not permitting side (un)loading

The platform can be deployed from a stowed position without the handrails in place. The
lifting and lowering of the fully deployed platform is prevented until the handrails are in place.

Platform Mounted Handrails – not permitting side (un)loading

The handrails are permanently attached to the platform.

13
Appendix 1 - Fall protection

Platform Mounted Handrails - permitting side (un)loading

The handrails are attached to the platform and may be turned through 90o or 180o.

Platform Mounted Guards - permitting side (un)loading

The guard can also act as a side (un)loading ramp.

14
Appendix 1 - Fall protection

Runner Mounted Parallelogram Handrails – Two-side protection - permitting side

(un)loading.

Parallelogram handrails attached to a runner and designed to drop into slots on platform.
After platform has been fully lowered, handrail on delivery side can be raised to enable side
unloading.

Corner Post Mounted Handrails – Two-side protection – not permitting side

(un)loading.

Handrails attached to corner posts of vehicle and designed to be set in either lateral or
longitudinal orientation. Handrails are slotted so that each handrail has to be lifted before it
can be swung into position.
15
Appendix 1 - Fall protection

Runner Mounted Handrails – Three-side protection - not permitting side (un)loading

Runner Mounted Parallelogram Handrails – Three-side protection - not permitting

side (un)loading.

16
Appendix 2 - Commercial vehicle handrail selection

Lift Type
Column Tuck away Cantilever Retractable
Handrail Type

Runner Appendix 1.1 Side unloading Yes No No No

Drop In Appendix 1.2 No Side Yes Yes Yes Yes

Platform Appendix 1.3 No Side unloading Yes No Yes Yes

Platform Appendix 1.4 Side unloading Yes No Yes Yes

Platform Appendix 1.5 Side unloading Yes No No No

ramps

Runner Appendix 1.6 No Side sides Yes No No No

Corner Appendix 1.7 No Side Yes Yes Yes Yes

Runner Appendix 1.8 No Side platform Yes No No No

Runner Appendix 1.9 No Side mounted Yes No No No

Note:
It may be possible to retrofit certain gate types to existing lifts depending on dimensions and
geometry, but advice should be taken from the lift manufacturer.

Some of the No’s above could be Yes’s, but would require a more complex technical design
solution.

17
IRTE publications

Maintenance Supplier Assessment

The IRTE’s maintenance supplier assessment guide is

aimed at those who contract out the maintenance of their
fleet. It advises on best practice procedures to ensure the
maintenance facilities of workshops used are adequate for the
type and number of vehicles undergoing work.

Coupling or Uncoupling and

Parking of Large Goods
Vehicle Trailers

The IRTE code of practice

is aimed at managers,
supervisors and trainers but
has good advice for everyone
who has responsibility for the
safety of large goods vehicle
and drivers.

‘Wheel Loss - No Longer a

Mystery’ booklet

This guide explains the

mechanisms of wheel loss and
provides helpful best practice
guidance to assist those
specifying and maintaining
commercial vehicles to reduce
wheel loss incidents.

IRTE Guide to Tipper Stability

Essential guidance for those wishing to implement best

practice when operating tipping vehicles or tipper trailers.

To order any of these publications visit

www.soe.org.uk to download a copy or contact the
technical services department at [email protected] or
telephone 020 7630 1111.
IRTE publications

A Best Practice Guide towards Tachograph Systems Compliance

Tachograph
Systems In this indispensable guide, Senior Tachograph Consultant,
Compliance Gordon J F Humphreys, explains what firms need to do to
protect their Operator’s Licence.

Roadworthiness Guide

This guide is intended to

assist vehicle operators and
managers, regardless of fleet
size to improve their vehicle
maintenance controls and
standards.

A simple guide for Tail Lift

Operators

This guide provides some basic

information and highlights the
user’s legal responsibilities
in the use, maintenance and
examination of tail lifts.

Tail Lift - Specification Guide

for Road Vehicles

Guidance for manufacturers,

specifiers, installers, suppliers
and users of tail lifts as to the
safety issues associated with
tail lift installations.

Roadworthiness: Industry Best Practice for PCV

(Passenger Carrying Vehicles)

Produced with leading industry bodies, this guide gives advice

on best practice so all passenger carrying vehicle operators
can improve their vehicle maintenance controls and standards.
IRTE would like to thank the working group who produced this guide and the
manufacturers and organisations who support its contents.

Tony Whitehouse Ventura Network Distribution / NEXT
Simon Eskriett and Ian Forman DEL Equipment UK Ltd
Adrian Bremner Boots UK Ltd
Shirley Duncalf 3663
Martin Farrand Petit Forestier
David Agg Ratcliff Palfinger Ltd
Alan Honig Ross and Bonnyman
Chris Lay Dhollandia Tail Lifts
Chris Macrae FTA
Steve Biddle RHA
Darren O’Donnell Coca Cola Enterprises Ltd
Steven Bannon Brakes
Jim Corbridge HSE
Robert Hudgell HSE
Richard Catley C M Downton Ltd
Calvin Miles DHL

SOE, IRTE Professional Sector,

22 Greencoat Place, London SW1P 1PR ISBN 978-0-9555685-3-4
Tel: 020 7630 1111 Fax: 020 7630 6677
Website: www.soe.org.uk Email: [email protected]

Registered Charity No. 1081753

Registered in England Company No. 3667147 9 780955 568534