Safe use of a man-cage

This write-up is done specifically for use by the competent person, when he/she is doing a risk assessment before persons are lifted to work above ground level, through the use of a man-cage to ensure that the cage and machinery are compliant and safe for use. Non-integrated work platforms, or as what we in the field will generally refer to as man-cages, cradles, carriers, work platforms, suspended baskets or personnel cages is a complicated subject on itself. In short, these devices are specially made for the lifting of personnel to work in suspended positions, on hard to reach equipment. Man-cages comes in many shapes and sizes and is used in industry daily, but what very few end-users know is that they are regulated by law, through the Occupational Health and Safety act 85/1993, also referred to as the OHS act. More specific, man-cages is regulated through the Driven Machinery Regulation, DMR 18(8). (See attached examples of man-cages, suspended baskets etc.)

Legislation Definition of a man-cage as per DMR 18

“Man-Cage” means a platform enclosed on all side, whether closed or open at the top, designed to raise and lower persons utilizing a lifting machine, but does not include mobile elevated platforms and suspended access platforms. (Excludes MEWP’s and platforms purpose build or build from scaffolding)

Regulation 18(8)

No user shall require or permit any person to be moved or supported through a lifting machine unless that machine is fitted with a man-cage designed and manufactured according to an approved SANS standard approved for that purpose by an inspector and after a risk assessment has been done.

This points out 3 requirements:

1. The cage must be designed and manufactured to an approved SANS standard 2. The cage must be approved by an inspector of the DOL for the purpose it will be used for 3. A risk assessment must be done every time before it is used, by a responsible person

This is further explained through 6 notes:

(a) Man-cage was known as a cradle or suspended basket. This regulation aims to ensure that persons are lifted safely and work is done safely. The intention is to limit the use of a man-cage as far as possible. The employer must first consider lifting persons with machine/equipment specially designed to lift a person (i.e. cherry picker). If a lifting machine other than the one designed to lift people i.e. forklift or crane can be used to lift persons inside the Man-cages/ cradles or suspended basket. (b) This use of an associated forklift or a crane with a man-cage must be also be approved for a specific site to lift persons, must be approved by an inspector. (c) The scope of such approval shall, as a minimum, include design and safe operation. (d) The use of cradles should in the first instance be avoided by the use of purpose-made equipment. (e) In exceptional instances where the use of cradles can-not be avoided (occasionally) the user must apply for approval from the Department of Labour. (f) Safe working procedures for these activities must be implemented and strictly enforced. Twice the word “inspector” has been underlined for reason that an inspector must approve such man-cage for a specific site.

An inspector is defined in the OHS act as:

“Inspector” means a person designated under section 28 of the OHS act. This designation is given to him/her by the Minister of Labour with certain duties and one of them is to approve the use of a man-cage. Further to this, DMR18 also list certain SANS/EN standards that form part of regulation 18. Four of these specifications is relevant to man-cages/ suspended platforms, as they are the machines normally associated with the lifting of these cages/ platforms. This implies that these lifting machines must be safe for use before one can even attempt to use these machines for the lifting of a man-cage. In certain cases, there are also special instructions given when these machines are used for lifting a man-cage. • SANS 10375 – Inspection and testing of overhead cranes and hoists, (no reference but EN 14502 applicable) • SANS 10388 – The inspection, examination and testing of lift trucks, (no reference) • SANS 19 – The inspection and testing of mobile cranes, (specific reference as well as EN 14502 applicable) • EN 14502 – Cranes – Equipment for the lifting of persons.

SANS 583:2015 Forklift usage

When it comes to the man-cage itself one will find specification SANS 583:2015, Non-integrated work platform for occasional use on lift trucks. Prior to the use of the work platform, a hazard

identification of the equipment, environment and working area shall be performed by the responsible person, and where necessary corrective action shall be taken. In short, a risk assessment must be done taking the following into account.

Safe use

• Ensure that cage has been approved by the Inspector from DOL for this specific task • Ensure that the required certification of the cage is in place • Ensure that the documentation tie up with the data plate of the man-cage which includes name and address of supplier, year of manufacture, type of cage, ID number, tare weight and rated capacity as well as the number of people that it is permitted to carry. • Ensure that the cage and the forklift is compatible. In fact, the cage must have a sign identifying the specific fork trucks on which the work platform may be used • Ensure that the platform is securely attached as per the manufacturer’s specification. This normally include pins behind the heels of the forks as well as a secondary attachment around the fork truck backrest • Ensuring that the screens on the cage provide adequate protection. It should have a full screen at the back to prevent the user from getting any body part into the fork truck mechanical parts. • The moving or supporting of persons in suspended equipment shall only be done under the supervision of a responsible person appointed by the user. • Persons expected to work on platform, truck operators and responsible persons shall be aware of the restricted indicating that they may not be used for production or planned maintenance. • All persons involved with work platforms should be properly trained and given full instructions on safe systems of working with work platforms, including the action to be taken in the event of an emergency and the dangers associated with leaning out of the work platform. • The truck and work platform combination shall only be used on firm, well maintained and level surfaces. Gradients and uneven or inconsistent ground conditions can affect the stability of the truck. • The truck shall not be moved while the work platform is elevated horizontally, however, minor controlled, positional adjustments are acceptable, if they are necessary, to allow the task to be carried

out safely, but preferably the platform shall always be lowered before moving the truck for adjustments in positioning • If the truck and work platform combination is rated for use with the truck stabilizer or axle locking deployed (or both) then they shall be deployed before the platform is elevated. • The working area below the work at height shall be segregated from the normal work activity. Persons and vehicles shall be prevented from approaching the work at height activity. This may be achieved by the use of warning cones, lights, barriers or signs, as appropriate. Where necessary other adjacent operations or activities may have to be stopped. • The path of platform travel shall be clear of hazards, such as storage racks, scaffolding, overhead obstructions, and electrical wires. • The rotation on trucks equipped with rotators shall be deactivated • The lifting carriage and forks shall be secure to prevent them from pivoting upward

Truck operator

• The operator of the truck shall be specifically trained for the use of a work platform.

• The truck operator shall remain at the controls of the truck while the platform is in elevated position and the parking brake shall be applied at all times when the platform is elevated.

Persons occupying the work platform

• Persons occupying the work platform shall remain on the floor and shall not use other means inside the platform to achieve a higher position, for example, stand on the guardrails or use a ladder. • The platform shall be positioned to prevent the need for persons to lean out when carrying out their work. • Special precautions may be necessary to ensure that persons in the platform are not endangered by hazards such as live electrical conductors or overhead travelling cranes. • Overhead protection should be considered where there are risks from falling objects or other overhead hazards. • Al persons occupying the work platform shall be secured to the work platform by means of personal protective equipment applicable to working at heights, including but not limited to, a full body harness. A body-harness, lanyard, or deceleration device (energy absorber) which has sustained permanent deformation or is otherwise damaged shall not be used

• Persons and equipment on the platform shall not exceed the available space. This is normally 600 mm2 for the first person and another 400 mm2 for the second. • The platform shall be lowered to the floor level for persons to enter and exit. Persons shall not climb on any part of the rough terrain lift truck while attempting to enter or exit

Rough terrain trucks

If rough terrain lift truck is to be used to lift persons, the following precautions shall be taken and above those already required • The rough terrain lift truck shall not be operated on a side slope unless the truck is levelled. • The combined mass (weight) of the platform, load, and personnel shall not exceed one-third of the capacity at the related load centre position as indicated on the information plate(s) of the rough terrain lift truck on which the platform is used.

Communication

• Persons shall be lifted and lowered smoothly, with caution, and only at their request, however the platform shall then be moved smoothly and with caution. • There shall be adequate communication between the truck operator and persons on the platform especially when raising and lowering. Hand-held communication devices or a system of signals should be used where communication is difficult. • If a work platform is lifted to a height greater than 4m above the truck operator, or work platform is used in a noisy environment, then it is likely that communication aids will be required. • When using hand signals, SANS 10296 shall apply. • When using hand held communications devices account shall be taken of any foreseeable hazards due to electromagnetic compatibility.

SANS 19:2004 Mobile crane usage

This SANS specification has a section especially pertaining to the “Inspection, testing and examination of cranes for lifting Persons and suspended baskets as per annexure A and E” Which in short means that a risk assessment must be done, and the following must also be in compliance above any other specifications also applicable.

Report of thorough examination

The report of thorough examination shall state the crane and carrier have been thoroughly examined for the purpose of lifting persons. This means that before a cradle is attached to a mobile crane, the crane must be approved for use by the competent person through a proper risk assessment.

General

Cranes and other equipment used to lift persons and the personnel carrier shall be thoroughly examined either at least every six months or in accordance with a written scheme of thorough examination. • Check to ensure that the crane has an RCI/L with an appropriate duty for personnel lifting (i.e. half the rated capacity for lifting other loads). • Check to ensure that the crane is equipped with a motion-control system that brings motion to rest automatically when the controls are released. • Check to ensure that the crane is equipped with an appropriate anemometer or other device to monitor in-service wins speeds. This is intended to ensure that personnel carriers are not use in wind speeds in excess of 7 m/s. (25km/h) • Check to ensure that any crane equipped with a winch has power lowering. Cranes with free-fall ability shall not be used to lower and raise persons unless the free-fall facility has been locked out. • Check to ensure that load-bearing hydraulic cylinders are fitted with load-hold valves (over-center valves) to stop movement in case of hose rupture or pipe fracture. Cranes only equipped with simple check or hose rupture valves shall not be used for the lifting of persons. • Carry out a functional check to determine whether the crane control system is able to provide a smooth transition of the carrier. The control shall be such that the carrier can proceed gently and the working speed shall not exceed 0, 5 m/s during all motions. • Check to ensure that means are provided so that, if the power supply or control system fails, the carrier can be positioned to enable access/egress without risk. • Measure the wire rope used for hoisting and lowering the carrier. The wire rope shall have a diameter of at least 8 mm.

Man-cage/Carrier/cradle

• Visually check to ensure that storage accommodation for equipment, including any emergency egress equipment (for example safety harness, lanyard), is provided in the carrier. • Visually check to ensure that the carrier is marked with the number of persons that may be carried and the maximum load that may be carried. • Check to ensure that no doors in the carrier open outward and that doors can be securely fastened. • Visually check to ensure that the carrier has hand rails, mounted in positions that do not trap hands, to provide security for persons. • Visually check to ensure that the carrier sides are such as to prevent persons or materials from falling from the carrier. • Visually check to ensure that any attachment points for safety devices such as harnesses are secure and undamaged. • Visually examine the structure of the carrier. It shall be free from damage, corrosion, cracks and other imperfections. • Visually check any mechanism provide to ensure that the floor of the carrier remains horizontal. It shall be free from damage, leaks, corrosion and wear.

• Visually check the carrier for unique identification mark and record this on the report thorough examination.

Bosun’s Chair

• Visually examine both primary and secondary suspension points. They shall be free from damage, corrosion, cracks and other imperfections. • Visually examine the seat structure for damage, security and contamination. • Visually examine the seat belt(s) for damage, contamination, security of their fixings and correct operation.

Harnesses

• Visually check any safety devices such as harnesses and lanyards for integrity and completeness • Visually examine the harness for signs of cuts, abrasion, damaged stitching or contamination • Check the harness for correct operation of all buckles, adjuster, fasteners, etc. • Visually examine both primary and secondary suspension points. They shall be free from damage, corrosion, cracks and other imperfections. • Check the age of the harness to determine whether it is within the age range recommended by the manufacturer

Pre-use checks on Crane

Before using the crane for lifting persons and suspended baskets, check to ensure that the following requirements have been complied with. • The hoist ropes are free of kinks and other obvious defects, • A means has been provided to prevent the carrier attachment from becoming detached from the hook; • Multiple part lines are not twisted around one another, there is no slack in the wire ropes and all ropes are properly seated on drums and on sheaves

Pre-use checks on Carrier

• The carrier, suspension system, attachment points and any carrier motion controls shall be checked before use by the appointed person/crane supervisor. The checks are to identify conditions that have been specifically indicated by the carrier manufacturer, or competent person as potentially creating a hazardous operating condition. • The checks shall cover at least those items listed in annex E, and the form shall be signed by appointed person/crane supervisor. Any conditions found to be unsatisfactory shall be corrected before persons are lifted.

EN 14502-1:2010 Cranes – Equipment for the lifting of persons. Suspended baskets

This standard deals with suspended basket for use in lifting operation of persons with machinery which is not designed for lifting of persons.

General safety requirements and protective measures

• Suspended baskets shall be manufactured from material specified as being incombustible. So, no wooded floors and must be protected against corrosion. • The parts where persons are intended to stand shall have a minimum free-standing height of 2m. • When there is a possibility where falling objects can be a hazard, the basket shall be provided with a roof that will prevent a 20mm sphere from passing through.

Load lifting attachments

• Suspended baskets shall be attached to the carne hook with flexible load lifting attachments consisting of steel wire rope slings or chain slings with a safety factor of at least 8 x (weight of basket + rated capacity) for chain slings and 10 x (weight of basket + rated capacity) for wire rope slings • When hanging from the hook, the vertical distance between the basket and the crane hook shall never be less than 3m • Steel wire rope shall be made from spliced eyes or crimped ferrules, both with thimble eyes. Wire rope grips (crossby clamps) shall never be used. • The slings shall be fitted is such a way that they can only be removed with tools • Chain sling to be attached with hammerlocks or shackles that is secured in such a way that it complies with the above point

Access and exist

• Any gate provided for must open inwards, upwards or sideways and return automatically to the closed position, and shall be fitted with a self-engaging latch. • It is also recommended that the cage gate be fitted with a lock that automatically locks once the cage is lifted, and can then not be opened.

Anchorage for personal protection equipment against fall from a height

• Al persons occupying the work platform shall be secured to the work platform anchorage points by means of personal protective equipment applicable to working at heights, including but not limited to, a full body harness. • The length between the anchorage points and the harness shall be fixed such that the operator is restrained within the basket at all times. (Note: this is not explained in SANS 19 so the user may use a standard lanyard or deceleration device (energy absorber))

Instruction manual

The manufacturer of the basket shall provide an instruction manual with the minimum information that also draw attention to national legislation, in our case the OHS act DMR 18.8.

Information to the user

• The combination of crane and suspended basket shall only be operated by people trained in the safe use of the equipment

• All work to made under controlled conditions by an appointed person • The required equipment to perform a rescue shall be available throughout the lifting operation • Baskets shall not be used in adverse weather conditions • Guide ropes is recommended but u may not be air hoses or electrical cables Information to the crane driver • All movements should proceed gently at low speeds • The crane driver shall always be present and 2-way communication shall exist between the driver and the persons in the basket and no other work shall be done by the driver or the signaler during this time.

Information to the personnel using the basket

• Fasten safety harnesses as prescribed • Secure tools and material against displacement, tipping and falling out • Ensure in keeping body parts within the basket during operation • Do not stand on the sides at all • Ensure that basket is on an even grand when exiting or entering

Special requirements related to the work from a suspended basket.

• When electrical welding is conducted from the basket, special care shall be taken to earth the basket in order to protect the carne and its ropes from becoming conductors of electricity

Markings

Ensure that the documentation tie up with the data plate of the man-cage which includes: • Name and address of supplier, • Year of manufacture, • Type of cage, • ID number, • Tare weight, • Rated capacity, • Number of people that it is permitted to carry.

Source of information OHS act 85/93 DMR 18 SANS 103:2015 SANS 19:2004 EN 14502-1:2010

+27 (0) 21 556 0498, +27 (0) 82 490 5453, joseph@bluecranes.co.za, www.bluecranes.co.za