Integrity of plant

It is a legal requirement that the structure of the quarry plant is designed and maintained. Some plant which uses water may be particularly subject to corrosion. This plant had access on both sides of the conveyor which is a good idea. Unfortunately the structure supporting the walkways was severely corroded. Note the missing parts of the angle flange on each support. Make this part of one of your workplace inspections. Are there areas of the plant that are showing signs of corrosion or vehicle damage?

The cross bracing has been removed and others have corroded away. This will seriously affect the stability of the plant. Any modifications must be approved by a structural engineer and cross bracing must be maintained. A structural survey should be regularly carried out as part of the quarries maintenance scheme.

The legs of this plant have rusted through and others are misshapen either from corrosion or being struck by vehicles. Again these must be maintained and a structural report obtained when ever damage is done.

The supporting stringers of this conveyor have rusted away and fallen. This has affected the stability of the conveyor and the supporting frame for the return rollers has also corroded away. Examine your plant as part of your inspections.

This hopper is showing extreme corrosion and was still in use at the time this photograph was taken. Again regular inspections and monitoring will pick up these defects before they cause problems.

Wooden structures are also liable to rot. This photograph is of a wooden walkway.

A close up shows the extent of the rot

This plank was used to stand on while carrying out maintenance. It had been left under the plant for a number of years. When the person stood on it, it broke and he fell on to the concrete standing severely injuring his back.

Corrosion and cracking is not limited to fixed plant. The chassis of this dumper has failed due to lack of maintenance. Drivers have been killed and injured when chassis have failed and the dump truck bodies crushed the cabs. Chassis of dumpers should be included in the maintenance scheme.

Whenever work is to be carried out underneath hydraulic equipment it must be supported. Dump trucks are provided with two forms of support. The first is a solid support such as this, which the body is lowered onto before work commences.

The other is the pin system where pins are placed in to the sockets at the back of the truck. Part of the daily inspection scheme should include checking that these devices are functional

Here eyes have been pulled out of the skip when the body has been powered down with the pins in position. This machine should not be used until repairs have been carried out. In 2000 two drivers were killed when the skips fell on them as they worked beneath unsupported skips.

Before jacking vehicles always ensure that the jacking points are used and that the correct lifting equipment is used.