Low falls whilst filling tankers

Introduction

The Samlesbury, Inbev UK site near Preston employs 520 people and is operational 24 hours per day, 7 days per week all year round.

The site brews various beers and lagers. As well as the brewing facility, the company also bottle the product and produce promotional packaging. The product is also stored on site and distributed by Inbev's own fleet of vehicles. There are normally 50 - 70 tanker movements per week.

Accident description

Three low falls accidents occurred in the tanker loading bay, when staff were connecting and disconnecting the hoses at the back of the tankers. Although railings were provided on each side at the rear of the tanker (see figure 1), the accidents had occurred due to staff tripping over the hoses and falling from the rear of the tanker.

Business costs and benefits

• Of the three accidents, one member of staff was badly injured and was off work for four months. Uninsured losses (resulting from lost time for example) were approximately £10000 and the accident cost in total around £31000. The other two accidents, whilst being less serious, had the potential for similar cost.

• Following the accidents, the company decided to improve safety for employees and a raised loading bay was constructed which permits the tankers to be reversed up to the deck. This allows staff to work at the same level as the tanker for most loading operations (see Figure 2). The loading bay cost £8000 to design and a further £42000 in materials and construction.

Reducing risk of falls

Risk of falls from vehicles during the loading and unloading process can be reduced through:

• Removing the working at height risk and the need to step down from the vehicle.
• Providing railings fitted at the correct height around working areas.
• Anti-slip coatings on pedestrian surfaces reduce slip and hence fall hazard.
• Ensuring sufficient light in the vicinity of the loading area.
• Adopting a work system for drivers that does not encourage the loading/unloading process to be rushed.

• 
  Figure 1 - tanker in original position in loading bay.
• 
  Figure 2 - tanker in the loading bay.