HSE warns of crush risk from powered tilting stabilisers

The Health and Safety Executive (HSE) has issued a safety notice for those involved in lorry loader operations with powered 'tilting' also known as ‘swing-up’ or ‘rotating’ stabilisers.

It says it is aware of three fatal incidents in Great Britain since 2019, where the operator of a lorry loader has been crushed against the bodywork of the vehicle by the retracting leg of a powered tilting stabiliser.

On some lorry loaders with powered ‘tilting’ stabilisers, people can be crushed against the bodywork of the vehicle when the stabilisers are being retracted.

There is a risk of serious injury or death when a powered tilting stabiliser is being rotated to a vertical position, said the HSE.

Those involved in lorry loader operations, it says, should include the crushing hazard from tilting stabilisers in their risk assessments and include appropriate control measures in all lorry loader procedural documentation, such as lift plans.

Tilting stabilisers may rotate either towards the front or the rear of the vehicle, depending on machine design.

On some lorry loaders, stabilisers on opposite sides of the same vehicle may tilt upwards in different directions. 

Rotating tilting stabiliser leg 180° from the vertical foot down to the vertical foot up position

Owners should seek safety improvements from manufacturers

The HSE says that lorry loader owners should seek safety improvements from manufacturers to eliminate or reduce the crushing risk on machines currently in use.

“Consult with your manufacturer at the earliest opportunity to secure reasonably practicable improvements to reduce the risk of crushing within the existing general configuration and certification of the machine,” it said.

For example, it may be possible to install software modifications to prevent the stabiliser from retracting unless the leg is in the vertical stowage position; install interlocks to prevent the stabiliser legs being retracted unless the leg is vertical; or disable the base controls by removing the fixed levers and use only remote controls.

Safe operation

HSE says that users should ensure that their operators are competent, are familiar with the functions of the type of stabiliser fitted and have been trained in correct use.

The following key safety points apply to those involved in lorry loader operations:

• The risk of crushing is increased on the side where the tilting stabiliser rotates towards the operator or levers at the crane base.
• Tilting stabiliser legs should be pinned or locked in the vertical position before the horizontal stabiliser beam is deployed or retracted.
• It is essential that operators fully observe all movements of the stabilisers during deployment and stowage.
• Operators must be made aware that operation of the tilt-up function must be separate from the retraction of the stabiliser beam (operators should not use both functions simultaneously).
• Operators must be fully conversant with the manufacturer's instructions regarding the deployment and stowage of tilting stabilisers. There can be considerable variation between different systems.
• Operators, or others, must not be positioned in (or be required to lean or reach into) danger zones where there is a risk of crushing.
• Where the stabiliser is only partially deployed, the risk is increased. In this case, consideration should be given to repositioning the vehicle to ensure further extension of the stabiliser beam is achievable prior to the tilt-up leg being deployed.
• Where available, remote controls should be used for the operation of stabilisers and the operator should stand in a position suitable to observe the operation but outside of the danger zone.
• All loader cranes with remote-control of powered stabilisers have the option to use emergency fixed levers at the crane base. The emergency fixed levers are only required in the event of remote-control failure, following confirmation that a) the spare remote-control battery does not resolve the issue, and b) the remote-control 'umbilical cord' is inoperable. Fleet owners are advised to ensure that the umbilical cord is always available in the cab and is fit for use. Should the emergency fixed levers need to be used, this guidance applies in the same way as it would to standard controls.

For more advice from HSE and to read the full safety notice, click here.