NRMCA Safety Series 7

Pre/Post shift inspections Operating the loader Maintenance of the loader Always Lockout/Tag out/Try equipment that is being maintained Moving Materials Moving Heavy Objects Sedimentation pond cleanout Driving the Loader Summary

 Front-end loaders are vital to the RMC industry  Average cost is $150,000  One large RMC producer reported maintenance costs for a 3-year period was $2.34 million dollars  Take care of the equipment 3

 Front-end loaders have been involved in occupational deaths at ready mixed concrete facilities  Damage to company trucks  Damage to plant equipment  Damage to suppliers of aggregate and cement 4

5  Pre-Shift inspection at the start of the day  Follow company procedures for documenting pre/post shift inspections  If a problem occurs during hours of operation, assess on an individual basis

7  Generally divided into 5 sections: 1. Approaching the loader 2. Checking engine compartment 3. “Circle for Safety” 4. Check cab area 5. Final inside cab inspection – with engine running

8  Section 1: Approaching the loader  Look for any visible sign of leaks:  Engine and hydraulic oil  Coolant, gear lube, water, etc.  Check for broken head lights, mirrors, front, side or rear glass  Check to see if loader is leaning to one side or the other

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11  Section 2: Checking Engine Compartment  Oil and coolant  Fans and fan belts  Air compressor  Alternator  Hydraulic fluid and power steering fluid  Radiator  Hood latches  Look for any other fluids that may be leaking

12 Start Here Section 3

13  Air Pressure – varies from loader to loader (25 psi – 40 psi) and tire to tire.  Reference your loader Operations and Maintenance manual for details  Tire Inspection  Proper tire inflation will help increase the life of the bucket blade by keeping the blade even while on the ground  Proper tire inflation will help prevent rollover  If tires are leaking ballast, have fixed immediately

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Broken Step 19 Loader Pre-Shift Inspection

20  Section 4: Check Cab Area  Ladders – always use 3-points of contact  Handholds  Loose/unsecure objects  Start engine  Oil pressure and fuel gauge  Gauge lights and headlights  Emergency brake  Other emergency equipment

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22  Section 5: Inside the Cab Inspection – with engine running  All gauges and horn  Windshield wipers  Backup alarm  Emergency brake  Seat belt  PPE  Mirrors  Completed pre-shift insp form while engine is warming

23  Loader operator should check the emergency brake for adjustment immediately after starting the loader  Safety equipment for your loader includes seat belt (mandatory use), portable fire extinguisher, back up alarm and strobe light.  Ensure portable fire extinguisher is charged

24  Only company authorized and trained personnel can operate the loader – check your operator list for details  Pre-shift inspection must be completed daily and signed off by a Plant Manager when an item needs to be corrected  Document and fix deficiencies

 Loader Operators should be well versed in company refueling procedures  Ask your supervisor how to document fuel used per company SOPs 25

 Any employee performing maintenance on the loader shall follow their company’s equipment- specific procedure for lockout/tagout/tryout 26

 If you have to raise the bucket for repairs, always use jacks to support the arm and chock the tires 27

28  Guards, safety appliance warning devices (back-up alarms) or any other device shall not be removed for any purpose except when making immediate repairs, lubrications or adjustments.  All devices must be replaced immediately upon completion of the work

1. Seat belt is always worn 29

30 2. Operators must be familiar with the Loader Operations Manual from the manufacturer 3. No one can ride in the cab, on the side, back or in bucket 4. The bucket shall not be used to raise or lower personnel 2. The time has come. If you do not have a ladder at your plant, you need to talk to your Area Manager and get one. 5. When using the loader to back up, place transmission in reverse and wait a few seconds for personnel to react

31 6. Slow down and sound the horn before going around blind corners 7. Never allow anyone to walk underneath a raised bucket 8. Never exceed the rated loader lifting capacity 9. Safe speed is determined by the operator and conditions

Inclines or side slopes  Operators must drive the loader forward up the grade. The loader must then also be driven down the incline in reverse.  If you encounter a side slope, you must squarely approach the slope and do not attempt drive sideways on the slope

 Use caution when operating loaders around power lines  Contact with power lines can lead to electrocution  It’s a good idea to find a safe place, raise the bucket all the way and measure how high it goes! 33

 Loaders have areas of limited visibility Be Careful 34

 Always park loader in the same spot  Clean and well lit to help deter theft or vandalism  It is also a good way to help spot fluid leaks 35

 Always enter aggregate stockpiles squarely  Reduces wear on the loader  Maximizes bucket capacity  Keeps weight balanced 36

 Always carry materials in the “low” position until ready to dump.  Maximizes visibility and loader stability  Always drive up the incline and back down the incline 37

38  Loader used for moving heavy objects  Returned concrete turds, blocks, motors, etc.  Never exceed the loader lifting capacity  Consult the loader Operations Manual for your loader for specific model  Hoisting cables, suspension cables and attachments shall be inspected prior to use and at least monthly

 Always inspect chain hook points prior to use 39

 Vertical Hitch – loading with the load suspended on a single leg or the sling 40

 Choker Hitch – loading with the sling passed through one eye and suspended by the other 41

 Basket Hitch – loading with the sling passed under the load and both ends on the hook or a single master link 42

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44  When using chains, wire ropes or slings; always inspect the lifting mechanism prior to use and at least monthly.  The loader will move into position:  Another employee will attach the load to the loader bucket and move back 20 feet in case the chain, wire rope or sling breaks and the load falls. Employees shall communicate via radios or hand signals  Chains and wire ropes can also be slung with enough force to kill a person

45  Today we covered:  Pre shift inspections  Operating the loader  Maintenance of the loader  Always Lockout/Tag out/Try equipment that is being maintained  Moving Materials  Moving Heavy Objects