Introduction
Lifting plant and equipment can cause accidents if they are used unsafely or poorly maintained. Vehicles falling or rolling off incorrectly positioned jacks or stands, particularly where they are not chocked, are one of the main causes of fatal accidents in motor vehicle repair (MVR).
Working beneath a vehicle is often required to check for faults, servicing and repairs but because these tasks are so common people get used to working under potentially lethal weights. Unfortunately, serious and fatal accidents happen every year even though the dangers and precautions are well known. You must always use the right equipment for the job. Do not be tempted to take short cuts or use inappropriate equipment to lift heavy items.
In particular, you should consider the following issues. More detail can be found in Health and safety in motor vehicle repair and associated industries - HSG261.
Use equipment correctly
Using equipment safely and correctly can reduce the risk of accidents, make sure:
- there are safe working procedures in place when moving heavy loads, particularly when they are raised
- you use the correct pins for axle stands - screwdrivers, nails and bolts are not acceptable
- you use stands on a hard, level surface for example concrete and avoid lifting on sloping ground
- to securely chock wheels remaining on the ground
- that all lifting points for jacks and stands are correct for that vehicle - consult the vehicle manufacturer's handbook for guidance
- you do not exceed the rated capacity (safe working load) of any lifting equipment
- that vehicles are always properly supported - do not rely on jacks alone
Make sure lifting equipment is correctly installed
Make sure the floor and fixings meet the lift manufacturer's specification - if in doubt get specialist advice.
Once installed, the lift must be tested before it is used by a competent person, who will issue a certificate.
Regularly check the fixing bolts with a torque wrench to ensure they remain tight.
Maintaining lifting equipment
Lifting equipment must be maintained and operators trained to use it correctly. For example:
- vehicle lifts need to be kept in good order - follow the manufacturer's instructions and replace consumable items, such as lifting pads, before they become unsafe
- make sure workers evenly balance the lift for different types of vehicle and where major components (for example a gearbox) have been removed - knowing where the centre of gravity is important to prevent cars falling from a vehicle lift
- for 2-post lifts, ensure that the arm locks are fully engaged and secure and that all the lifting pads are positioned correctly before raising the vehicle to full height
Checking and inspecting equipment
Equipment must be checked and inspected regularly.
Vehicle lifts should be thoroughly examined periodically by a competent person, who should issue a 'Report of Thorough Examination'. It is recommended that this is done every 6 months. Although this should identify problems, it is not a replacement for regular in-house checks and maintenance (in the same way that you should not rely on an MOT to keep your vehicle in good order.
Other lifting equipment (for example trolley and bottle jacks, engine hoist, vehicle mounted cranes) should be similarly examined every 12 months by a competent person (and Report of Thorough Examination issued).
Lifting accessories (for example chains and web slings) should be examined every 6 months by a competent person (and Report of Thorough Examination issued).
Other equipment which are critical for safely supporting loads such as props (for cabs and trailers) and axle stands should be inspected every 12 months by a competent person.
Working away from the workshop
When working away from the workshop, make sure:
- the ground is firm and level before raising a vehicle
- to move the vehicle to a safer place, if the area is unsuitable, if the area is unsuitable, before any attempt is made to lift it to undertake any repairs
Propping cabs and tipping trailers
Always prop cabs, trailers that could drop under their own weight.
If there is no prop fitted or if one is fitted but you are unsure it will be effective, then provide your own additional support.
Do not work beneath a vehicle with air suspension unless you prop it first.
Never crawl beneath a vehicle fitted with air suspension unless it is properly supported.
Do not try to adjust the ride height of air suspension for the purpose of recovery or repair.
More information on working under buses and coaches fitted with air suspension is in Safe recovery (and repair) of buses and coaches fitted with air suspension.
Examples of incidents from working under vehicles
Here are some examples of how and why incidents from working under vehicles have occurred.
Car raised on a hydraulic trolley jack - a mechanic was replacing a gearbox with a car raised on a hydraulic trolley jack and 2-wheel removal jacks. The car slipped from the supports, crushing and killing him.
HGV slipped from a hydraulic jack - a trainee HGV fitter, working with an experienced mechanic, was fatally crushed when an HGV slipped from a hydraulic jack. Axle stands were available but not used. An almost identical accident, again involving a trainee working with an experienced fitter, happened 3 years earlier at a different company.
Removing an engine from a vehicle - workers were using a chain block suspended from a gantry to remove an engine from a vehicle. As one turned their back on the raised load, the other moved the gantry, which fell onto their colleagues head, killing them. They were not following a safe system of work.
2-post lift - a car fell off a 2-post lift, killing the mechanic working below. The arms did not lock and the lifting pads were damaged or missing.
Changing coach tyres - a tyre fitter went to change 6 tyres on a school coach parked on a sloping car park. Both rear nearside wheels and one offside wheel had been removed and they were in the process of jacking it up when it fell onto their head and chest, killing them.
No end stops on 4-post lift - a worker was standing at the end of a raised 4-post lift and pulled the car towards them. There were no end-stops on the lift and they were unable to stop the car falling off the lift onto them. They died in hospital from crush injuries. The lift had never been thoroughly examined and tested.
Roadside rescue - an HGV recovery fitter was crushed to death under the air-lifted axle of a tractor unit they were attempting to rescue from the roadside. No supplementary supports were used.