Suspending Loads Over Workers in the Wind Farm Construction Sector

Photo credit to Boom Logistics

SUSPENDING LOADS OVER WORKERS IN THE WIND FARM CONSTRUCTION SECTOR

Author: Workplace Health and Safety Queensland

Workplace Health and Safety Queensland (WHSQ) has recently identified several issues around the lifting of loads over workers in the wind farm construction sector. WHSQ is concerned about the use of mobile cranes to lift tower sections on wind turbines while riggers are standing under the load. The lifting of loads over people creates exposure to serious injury or death and should only be done when it’s safe to do so, and other systems of work that eliminate the need for workers to be situated under suspended loads are not reasonably practicable to implement.

Section 219 of the Work Health & Safety Regulation in relation to suspending loads over persons states:

219 PLANT THAT LIFTS OR SUSPENDS LOADS

(1) This section applies in relation to plant that is used to lift or suspend persons or things.

(2) The person with management or control of plant at a workplace must ensure, so far as is reasonably practicable, that the plant used is specifically designed to lift or suspend the load.

(3) If it is not reasonably practicable to use plant that is specifically designed to lift or suspend the load, the person must ensure that—

(a) the plant does not cause a greater risk to health and safety than if specifically designed plant were used; and

(b) if the plant is lifting or suspending persons, the use of the plant complies with section 220.

(4) The person must ensure that the lifting and suspending is carried out—

(a) with lifting attachments that are suitable for the load being lifted or suspended; and

(b) within the safe working limits of the plant. (5) The person must ensure, so far as is reasonably practicable, that no loads are suspended or travel over a person unless the plant is specifically designed for that purpose.

(6) The person must ensure, so far as is reasonably practicable, that loads are lifted or suspended in a way that ensures that the load remains under control during the activity.

(7) The person must ensure, so far as is reasonably practicable, that no load is lifted simultaneously by more than 1 piece of plant unless each piece of plant used to lift the load is specifically designed to lift a load.

When it is not reasonably practicable to perform a lifting operation at wind farm construction sites other than for a worker to be positioned under a suspended load, the following matters apply:

⊲ Plan the lift:

• Select the right crane for the job (more than adequate capacity for the working radius, sufficient boom length etc.)

• Ensure lifted loads are well within the working load limit of the selected crane at identified operating radii, develop procedures for multiple crane lifts

• Ensure any process involving work under a suspended load is

The lifting of loads over people creates exposure to serious injury or death and should only be done when it’s safe to do so

only carried out where all other options are exhausted, and workers are positioned under the load at the last possible moment (for joining of tower sections where the tower section is close to its final position a short distance above the existing tower. Workers must remain in a safe location, for example, underneath a tower access platform, until it is safe to be positioned under the load).

• A system must be in place to ensure worker’s safety in case of a failure (load is positioned 100mm over a structure that, should the load fail, it would come to rest on the structure and not place the worker at risk).

⊲ Develop effective emergency procedures – consideration should be given to the location of the closest emergency services (including consultation with the nearest branch prior to work commencing to ensure an effective response), the possible need for an on-site rescue team and trained medical staff (paramedics), method of the rescue of workers (particularly workers at height), the method of communication given the work location (UHF vs VHF radios), the ability of emergency rescue teams to access the location;

⊲ Ensure all required documentation is prepared before starting work (WHS management plan, safe work method statements, plant inspection and maintenance documentation etc.)

⊲ Use appropriately trained and qualified workers - training and experience in the task, high-risk work licences, competency (including where multiple crane lifting operations are being performed)

⊲ Lifting equipment must be in good condition and maintained (consider the ability of lifting equipment to maintain security of the load in case of a failure)

⊲ Cranes should be in good condition and maintained in accordance with the manufacturer’s instructions

If the lift is going to take a long time, it’s important to check the forecast to ensure the wind does not pick up and exceed the maximum wind speed during the lift.

⊲ Use effective communication between workers involved in the task (crane operator and riggers) - consideration should also be given to the communication method given the work location (type of radio)

⊲ Check that weather conditions are adequate for the task and monitor conditions to ensure that a change in weather does not adversely affect the lifting operations. This includes ensuring the maximum wind speed for the lift is not exceeded (including wind gusts) and ensuring good visibility can be maintained (during rain or fog). Also, anemometers on all cranes in this sector are important so the crane operator can ensure the maximum wind speed is not exceeded. If the lift is going to take a long time, it’s important to check the forecast to ensure the wind does not pick up and exceed the maximum wind speed during the lift.

⊲ Crane stability – set up the crane in accordance with the manufacturer’s instructions, and ensure adequate ground conditions (a crane operating pad certified for the actual working pressures of the crane outriggers/tracks for the loads being lifted, including where any changes due to weather could affect the integrity of a certified crane operating pad), adequate lifting capacity of the crane at identified working radii, level ground due to the typically high centre of gravity of loads lifted for wind turbine construction

⊲ Conduct a prestart assessment of the work area and conditions, including consultation with the workgroup in relation to the task

⊲ Only workers involved in the activity should be allowed in the lift zone

⊲ Ensure adequate controls for falling objects - for example, tool and equipment lanyards and clearly identified exclusion zones

⊲ Always ensure safety latch on crane hooks and lifting slings are used and are in good condition.

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