When to Use Forklift Cages and How to Work Safely with ...

02 Jul.,2024

 

When to Use Forklift Cages and How to Work Safely with ...

People say, where there's a will, there's a way. When it comes to working at height, this may not necessarily be a good thing. Often, a lack of appropriate access equipment causes employees to find sub-optimal methods of reaching areas at height. This can be dagerous, reckless and is easily avoided.

When to Use Forklift Cages and How to Work Safely with ...

People say, where there's a will, there's a way. When it comes to working at height, this may not necessarily be a good thing. Often, a lack of appropriate access equipment causes employees to find sub-optimal methods of reaching areas at height. This can be dagerous, reckless and is easily avoided.

There is a wide variety of equipment available for work at height, including fixed scaffolding, tower scaffolds, mobile elevating work platforms (MEWPs), portable ladders, as well as non-integrated work platforms, or man-baskets. While the use of the latter is acceptable in very specific circumstances, it is not usually recommended. In this article we will outline what is a non-integrated work platform, how to work safely with it, and when it's not acceptable to use it as means to access height.

What is a non-integrated work platform? 

A non-integrated work platform, also known as a forklift cage or a man cage, is an attachment that has been built to be used in a conjunction with a forklift truck to elevate people so that they can complete jobs at height. The elevated person has no control of the platform and all movements are controlled by the truck operator. It is very different from an intergrated attachment for a lift-truck, which provides the person in the basket itself with full control - these integrated solutions are pretty rare, with non-integrated baskets being much more common.

Forklift cages are an easy and handy way to access height if you needed to reach a certain area at your factory and had no other means to do so. However, while they are a very cost effective solution, they are also the cause of a substantial number of serious accidents. Since trucks are primarily intended for lifting materials, not people, the HSE has put together a guidance note (PM28) which clearly states the occasions upon which the use of non-integrated work platforms is acceptable. Not complying with the HSE guidance leaves organisations vulnerable to safety failures and liable for any accidents.

When is a man-basket NOT the right tool for the job?

According to PM28, any routine or planned tasks such as work associated with production, periodic maintenance or stocktaking are occasions when it is not acceptable to use forklift cages.  The reason for this is because non-integrated work platforms don&#;t provide as many safety features as purpose-built access equipment, and thus they should not be used on regular or planned basis.

Non-integrated work platforms are not suitable for use on:

  • Trucks that require manual sequencing of the lift/tilt controls to maintain the horizontal position of the working platform while being lifted.
  • Trucks with masts that have erratic movement.
  • Trucks that have a capacity of less than kg unless their stability has been verified by testing.
  • Variable reach trucks that can lift to a nominal height greater than 6m.
  • Pallet stackers with wrap-over type forks.

 

How to safely work from a forklift cage?

Often people need a temporary means for working at height. Occasional use of non-integrated work platforms is acceptable only in exceptional circumstances i.e. non-routine or urgent tasks for which it is impractical to purchase or hire in purpose-built access equipment, as well as any tasks that would otherwise require the use of less safe means. Some examples of cases when you can use a forklift cage are for clearing a blocked gutter, checking on high-level damage to racking suspected of causing an immediate risk or checking on the condition of damaged roof lights.

There are a few steps to follow if the circumstances do indicate the use of a forklift basket. First and foremost, ensuring a suitable truck, compatible with the basket attachment is used to lift the basket. The best way to do this is to consult with a truck manufacturer or supplier. It is also essential that the platform can be securely attached to the truck, making sure the equipment is stable at all times and people in the platform cannot reach hazardous moving parts or the controls on the truck. 

Another very important thing is that the weight of the platform together with it's load of people, tools, materials and everything else carried in it is not more than half of the actual capacity of the truck. The actual capacity constitutes the capacity of the truck when it&#;s equipped with any specified attachments and, when carrying out maintenance work, any items that are placed on the platform that add to its overall weight. The user must ensure that the platform is positively locked onto the truck and that the fork arms on the truck extend fully into the fork pockets of the basket attachment.

Steps for the safe use of non-integrated work platforms:

  • Attach a sign to the platform that specifies on which trucks it can be used.
  • Make sure that all pre-use checks are completed by an authorised person who has received adequate training.
  • Ensure that any tilting mechanism, side shift or any variable geometry attachments are not capable of movement when the working platform is elevated.
  • Ensure the truck operator is at the controls of the truck at all times when the platform is elevated.
  • The truck/working platform combination should only be used on firm, well-maintained and level surfaces.
  • There must be adequate communication between the truck operator and people on the work platform.
  • There should be an agreed system of hand signals in place that everyone involved is trained in the use of.
  • People in the working platform should not stand on the guardrails or lean out of the platform when it is elevated. In cases when people need to lean out of the platform to do work, ensure they wear appropriate personal protective equipment (PPE), which typically consists of a full body harness with lanyard attached to a suitable anchor point.
  • Everyone involved in the process from the truck operator to the people in the platform must be properly trained, which includes not only how to operate the equipment, but also knowing what to do in the case of an emergency and the dangers associated with leaning out of the work platform.
  • The area below the work at height must be segregated from the normal work activity via the use of warning cones, lights, barriers or signs as appropriate.
  • Maintenance is essential and the platform needs to be in good working order, and regularly inspected.

 

Regulations to be aware of:

  • Under the Health and Safety at Work etc Act employers or people who have control of premises have the duty to ensure the safety of their employees and other people on the premises.
  • According to the Management of Health and Safety at Work Regulations a risk assessment must be carried out before any work at height is done.
  • Non-integrated work platforms can only be used under the exception in the Use of Work Equipment Directive (AUWED 89/655/EC amnded by 95/63/EC) that allows the use of material handling equipment not designed to lift people in exceptional circumstances.
  • When deciding to use a non-integrated or integrated work platform, employers must follow the relevant requirements of the Provision and Use of Work Equipment Regulations (PUWER).
  • The Lifting Operations and Lifting Equipment Regulations (LOLER) requires that lifting operations are properly planned and work is carried out in a safe manner.
  • Under LOLER it&#;s required that all equipment for lifting people, including trucks and work platforms, are thoroughly examined by a competent person at least every six months.
  • All relevant LOLER requirements must be followed for the use of both non-integrated and integrated work platforms.
  • Under the Work at Height Regulations (WAHR) all work at height must be properly planned, organised and the risks controlled.

Non-integrated work platforms do not fall under the Machinery Directive in which a machine is described as &#;an assembly, fitted with or intended to be fitted with a drive system other than directly applied human or animal effort, consisting of linked parts or components, at least one of which moves, and which are joined together for a specific application.&#; Therefore, forklift cages must not be CE marked and there is no free movement of their distribution throughout the EU. 

To find out more about the rules and regulations when using non-integrated work platforms download the HSE's Guidance Note PM28

Do you need to wear a harness when using a forklift cage?

Order pickers are specially designed and built materials handling equipment (MHE) that lift workers up via an elevating platform to allow the picking and/or loading of goods into high vertical shelving.

For businesses that already own a forklift and don&#;t want to purchase an additional order picker and alternative way for workers to be safely lifted is to fit the forklift with a safety cage.

In this post we briefly look at the risk control measures that need to be implemented when using a safety cage on a forklift.

What is a Forklift Safety Cage?

A forklift cage is a safe work platform to raise or lift workers performing occasional or short-duration tasks, where it isn&#;t practical to use more expensive permanent solutions, such as scaffolding or an elevating work platform.

Pre-Lift Forklift Cage Risk Control Measures

Before a worker steps into the safety cage, it is important the operator should perform a trial lift of the empty cage.

This trial lift will check that the cage is secured to the forklifts tynes correctly, that there is a clear vertical path for the cage to travel up and that there is no risk of the cage occupants or the cage itself contacting overhead obstructions such as doorways or working in proximity to overhead power lines.

When workers have entered the safety cage and before lifting commences it is imperative to ensure all workers in the cage are:

  • Aware they must always stay within the bounds of the safety cage. Workers must stand on the floor of the safety cage not on a ladder, rail, or other object
  • Wear a securely connected safety harness
  • Able to safely exit from the safety cage and forklift in the event of a failure in normal operations
  • Are trained to use the cage safely including any emergency procedures, so occupants can be rescued in the event of an accident or breakdown.

Forklift Safety Cage Risk Control Measures

The following risk control measures should be put in place when operating a forklift safety cage:

  • Safety cages should only be installed on a forklift that has been rated for use, with a load data plate that shows it has been manufacturer rated to safely use the cage.
  • The forklift is to be always stabilised on a hard level surface while lifting workers and/or loads.
  • Before lifting commences the forklift operator must ensure that the parking brake is applied, the driver controls are in neutral, and the mast is vertical, and that hydraulic controls are off except for lift and lower capabilities. Tilt functions should not be used.
  • The forklift operator must always remain at the controls during lifting operations, this ensures they do not inadvertently engage controls when accessing / egressing the forklift and that they can lower the cage in the event of an accident or unexpected breakdown.
  • Where possible workers should only enter the safety cage when it is in position ready to lift, it is not recommended to transport workers whilst they&#;re in the cage unless necessary.
  • The safety cages gate is self-locking and is kept always shut the cage is raised up.

Interested in purchasing a forklift safety cage? Contact our sales team on 13 22 54 to discuss available safety cages and other attachments available to increase the versatility of your forklift.

Reference List

There is a wide variety of equipment available for work at height, including fixed scaffolding, tower scaffolds, mobile elevating work platforms (MEWPs), portable ladders, as well as non-integrated work platforms, or man-baskets. While the use of the latter is acceptable in very specific circumstances, it is not usually recommended. In this article we will outline what is a non-integrated work platform, how to work safely with it, and when it's not acceptable to use it as means to access height.

What is a non-integrated work platform? 

A non-integrated work platform, also known as a forklift cage or a man cage, is an attachment that has been built to be used in a conjunction with a forklift truck to elevate people so that they can complete jobs at height. The elevated person has no control of the platform and all movements are controlled by the truck operator. It is very different from an intergrated attachment for a lift-truck, which provides the person in the basket itself with full control - these integrated solutions are pretty rare, with non-integrated baskets being much more common.

Forklift cages are an easy and handy way to access height if you needed to reach a certain area at your factory and had no other means to do so. However, while they are a very cost effective solution, they are also the cause of a substantial number of serious accidents. Since trucks are primarily intended for lifting materials, not people, the HSE has put together a guidance note (PM28) which clearly states the occasions upon which the use of non-integrated work platforms is acceptable. Not complying with the HSE guidance leaves organisations vulnerable to safety failures and liable for any accidents.

When is a man-basket NOT the right tool for the job?

According to PM28, any routine or planned tasks such as work associated with production, periodic maintenance or stocktaking are occasions when it is not acceptable to use forklift cages.  The reason for this is because non-integrated work platforms don&#;t provide as many safety features as purpose-built access equipment, and thus they should not be used on regular or planned basis.

Non-integrated work platforms are not suitable for use on:

  • Trucks that require manual sequencing of the lift/tilt controls to maintain the horizontal position of the working platform while being lifted.
  • Trucks with masts that have erratic movement.
  • Trucks that have a capacity of less than kg unless their stability has been verified by testing.
  • Variable reach trucks that can lift to a nominal height greater than 6m.
  • Pallet stackers with wrap-over type forks.

 

How to safely work from a forklift cage?

Often people need a temporary means for working at height. Occasional use of non-integrated work platforms is acceptable only in exceptional circumstances i.e. non-routine or urgent tasks for which it is impractical to purchase or hire in purpose-built access equipment, as well as any tasks that would otherwise require the use of less safe means. Some examples of cases when you can use a forklift cage are for clearing a blocked gutter, checking on high-level damage to racking suspected of causing an immediate risk or checking on the condition of damaged roof lights.

There are a few steps to follow if the circumstances do indicate the use of a forklift basket. First and foremost, ensuring a suitable truck, compatible with the basket attachment is used to lift the basket. The best way to do this is to consult with a truck manufacturer or supplier. It is also essential that the platform can be securely attached to the truck, making sure the equipment is stable at all times and people in the platform cannot reach hazardous moving parts or the controls on the truck. 

Another very important thing is that the weight of the platform together with it's load of people, tools, materials and everything else carried in it is not more than half of the actual capacity of the truck. The actual capacity constitutes the capacity of the truck when it&#;s equipped with any specified attachments and, when carrying out maintenance work, any items that are placed on the platform that add to its overall weight. The user must ensure that the platform is positively locked onto the truck and that the fork arms on the truck extend fully into the fork pockets of the basket attachment.

Steps for the safe use of non-integrated work platforms:

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  • Attach a sign to the platform that specifies on which trucks it can be used.
  • Make sure that all pre-use checks are completed by an authorised person who has received adequate training.
  • Ensure that any tilting mechanism, side shift or any variable geometry attachments are not capable of movement when the working platform is elevated.
  • Ensure the truck operator is at the controls of the truck at all times when the platform is elevated.
  • The truck/working platform combination should only be used on firm, well-maintained and level surfaces.
  • There must be adequate communication between the truck operator and people on the work platform.
  • There should be an agreed system of hand signals in place that everyone involved is trained in the use of.
  • People in the working platform should not stand on the guardrails or lean out of the platform when it is elevated. In cases when people need to lean out of the platform to do work, ensure they wear appropriate personal protective equipment (PPE), which typically consists of a full body harness with lanyard attached to a suitable anchor point.
  • Everyone involved in the process from the truck operator to the people in the platform must be properly trained, which includes not only how to operate the equipment, but also knowing what to do in the case of an emergency and the dangers associated with leaning out of the work platform.
  • The area below the work at height must be segregated from the normal work activity via the use of warning cones, lights, barriers or signs as appropriate.
  • Maintenance is essential and the platform needs to be in good working order, and regularly inspected.

 

Regulations to be aware of:

  • Under the Health and Safety at Work etc Act employers or people who have control of premises have the duty to ensure the safety of their employees and other people on the premises.
  • According to the Management of Health and Safety at Work Regulations a risk assessment must be carried out before any work at height is done.
  • Non-integrated work platforms can only be used under the exception in the Use of Work Equipment Directive (AUWED 89/655/EC amnded by 95/63/EC) that allows the use of material handling equipment not designed to lift people in exceptional circumstances.
  • When deciding to use a non-integrated or integrated work platform, employers must follow the relevant requirements of the Provision and Use of Work Equipment Regulations (PUWER).
  • The Lifting Operations and Lifting Equipment Regulations (LOLER) requires that lifting operations are properly planned and work is carried out in a safe manner.
  • Under LOLER it&#;s required that all equipment for lifting people, including trucks and work platforms, are thoroughly examined by a competent person at least every six months.
  • All relevant LOLER requirements must be followed for the use of both non-integrated and integrated work platforms.
  • Under the Work at Height Regulations (WAHR) all work at height must be properly planned, organised and the risks controlled.

Non-integrated work platforms do not fall under the Machinery Directive in which a machine is described as &#;an assembly, fitted with or intended to be fitted with a drive system other than directly applied human or animal effort, consisting of linked parts or components, at least one of which moves, and which are joined together for a specific application.&#; Therefore, forklift cages must not be CE marked and there is no free movement of their distribution throughout the EU. 

To find out more about the rules and regulations when using non-integrated work platforms download the HSE's Guidance Note PM28

Do you need to wear a harness when using a forklift cage?

Order pickers are specially designed and built materials handling equipment (MHE) that lift workers up via an elevating platform to allow the picking and/or loading of goods into high vertical shelving.

For businesses that already own a forklift and don&#;t want to purchase an additional order picker and alternative way for workers to be safely lifted is to fit the forklift with a safety cage.

In this post we briefly look at the risk control measures that need to be implemented when using a safety cage on a forklift.

What is a Forklift Safety Cage?

A forklift cage is a safe work platform to raise or lift workers performing occasional or short-duration tasks, where it isn&#;t practical to use more expensive permanent solutions, such as scaffolding or an elevating work platform.

Pre-Lift Forklift Cage Risk Control Measures

Before a worker steps into the safety cage, it is important the operator should perform a trial lift of the empty cage.

This trial lift will check that the cage is secured to the forklifts tynes correctly, that there is a clear vertical path for the cage to travel up and that there is no risk of the cage occupants or the cage itself contacting overhead obstructions such as doorways or working in proximity to overhead power lines.

When workers have entered the safety cage and before lifting commences it is imperative to ensure all workers in the cage are:

  • Aware they must always stay within the bounds of the safety cage. Workers must stand on the floor of the safety cage not on a ladder, rail, or other object
  • Wear a securely connected safety harness
  • Able to safely exit from the safety cage and forklift in the event of a failure in normal operations
  • Are trained to use the cage safely including any emergency procedures, so occupants can be rescued in the event of an accident or breakdown.

Forklift Safety Cage Risk Control Measures

The following risk control measures should be put in place when operating a forklift safety cage:

  • Safety cages should only be installed on a forklift that has been rated for use, with a load data plate that shows it has been manufacturer rated to safely use the cage.
  • The forklift is to be always stabilised on a hard level surface while lifting workers and/or loads.
  • Before lifting commences the forklift operator must ensure that the parking brake is applied, the driver controls are in neutral, and the mast is vertical, and that hydraulic controls are off except for lift and lower capabilities. Tilt functions should not be used.
  • The forklift operator must always remain at the controls during lifting operations, this ensures they do not inadvertently engage controls when accessing / egressing the forklift and that they can lower the cage in the event of an accident or unexpected breakdown.
  • Where possible workers should only enter the safety cage when it is in position ready to lift, it is not recommended to transport workers whilst they&#;re in the cage unless necessary.
  • The safety cages gate is self-locking and is kept always shut the cage is raised up.

Interested in purchasing a forklift safety cage? Contact our sales team on 13 22 54 to discuss available safety cages and other attachments available to increase the versatility of your forklift.

Reference List

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  1. Commission for Occupation Safety and Health. (). Guidance Notice Working Safely with Forklifts. www.commerce.wa.gov.au. Retrieved December 2, , from https://www.commerce.wa.gov.au/sites/default/files/atoms/files/working_safely_with_forklifts_0.pdf
  2. Safe Work Australia. (, July). General Guide for Industrial Lift Trucks. www.safeworkaustralia.gov.au. Retrieved December 2, , from https://www.safeworkaustralia.gov.au/system/files/documents//industrial-lift-trucks-general-guide.pdf