Many manufacturing facilities - especially chemical companies and food processing plants – use overhead hoists to lift material up to an elevated work platform instead of using a lift truck. This is the traditional method of lifting super sacks up to the processing platform where they can be dumped into hoppers. Other facilities may use a traditional lift truck to lift the material up, but then will use an overhead hoist to access the material once they are on the platform. This is a common method of emptying drums of ingredients off of a pallet.
Both of these areas typically create environments where employees are working around the ledges of these elevated platforms. In these scenarios a proactive guarding solution should be installed.
When you are looking to secure these areas, it’s important to keep these things in mind:
If the operation requires overhead access then the safety device must be designed to integrate with the machinery that is being used: for instance, integration with an overhead crane used to lift super sacks up to the platform, or a vacuum hoist that is used to unload material off of a pallet. This means that the safety device in place cannot interfere with this operation so the safety gate shouldn’t have any overhead mechanics. Instead it needs to provide a clear path to move the material through this area.
If the operation requires overhead access is this required at both the ledge and above the pallet drop area? If a forklift is lifting material up to the ledge and a hoist is being used to unload the material then the overhead access is only needed on the operator’s side.
Do the employees have access to the pallet drop area? If so the area in which they are working must feature a safe environment at all times. This means all ledges on elevated areas in which they are walking and working must be protected.
Our Open Top Safety Gate is ideal for securing these areas. This dual-gate system protects workers on elevated areas; when the ledge-gate is open, allowing material to be delivered or loaded, the rear-side gate is closed, protecting workers from falling off the ledge. When the rear-side gate is raised to access the pallet, the ledge-side gate closes. The gates are interconnected off to the side with no overhead mechanics, which creates a safe work environment without restricting the access overhead.
This solution is also ideal when tall pallets are being loaded up to the area. The same concept of keeping the overhead access applies so these tall pallets can be moved through the area.
We’ve created a video that shows how our Open Top Safety Gate works, which you can view here.
Facility safety has been moved to top of mind for many managers, as in August, OSHA increased fines for safety violations involving employee injury. Increased fines are not the only reason to implement safety measures - employee health and the risks they face on the job must also always be considered.
There are often areas in warehouses, distribution centers and manufacturing facilities that pose risks to employees that stand out immediately; open elevated platforms that get a lot of employee foot traffic is just one example. However, there are often other areas that pose risk that are unidentified, and therefore, unprotected. Leaving areas unprotected not only expose risks to employee health, but also to violation of federal OSHA codes, and as a result, significant fines.
Almost every facility has the following three areas - have you made sure that they are secure?
1. Pallet drop areas on elevated structural platforms, or mezzanines, in which pallets are being loaded by a lift truck or AGV
Any opening on elevated platforms where employees are working expose them to the risk of falling. All openings in the railing on levels in which employees work should be secured. Often these areas are “protected” with chains or single gate systems like lift-out barriers, but those devices do not meet current ANSI standards, are often left open or do not provide the protection needed to prevent employee injury. To ensure OSHA compliance and meet ANSI standards, secure these areas with dual-gate systems.
2. Picking areas, empty pallet bays or tote return bays on multiple level pick modules
Any facility with multiple level pick modules has a variety of openings on the elevated levels for picking or for empty pallet/empty tote return bays. Just like the openings on a mezzanine, the areas on a pick module where there is access to the exposed ledge should be secured with dual-gate system. This ensures there is a barrier in place between the picker and the ledge while they are working the pallet, and while the bay is being replenished. Another major source of fall-related incidents occurs where the empty pallets or empty totes are stacked so they can be removed by the lift truck. These areas should also be secured with a dual-gate system so a barrier is always there to provide fall protection. There are many options for safety gates designed specifically for rack systems so there are solutions even if space is limited or there is a tight aisle restricting egress; rack-supported versions of these gates will attach directly to the pallet rack to maximize space and provide a rugged connection. Ideally these fall protection solutions should be designed into the system, but solutions can be retrofitted into an area already operational. Either way these areas need to be secured, and proactively securing them before an incident occurs, will prove to be a valuable investment
3. Pallet flow bays
It’s not uncommon for employees to enter the lanes of pallet flow bays. While these areas are not specifically designed for employee access, ledges do need to be secured in the instances that it happens – there have been documented instances of employees entering the lanes of pallet flow bays to retrieve a fallen box or square a pallet, or to signal the lift truck operator below. Some of these instances have resulted in fatalities. To avoid these scenarios, the ledges of flow lanes should be secured with a physical barrier.
One of the two main methods of securing these areas is the use a self-closing pallet swing gate, which swings open when the lift truck loads a pallet into the lane, and then swings closed once the pallet flow down the lane. The gates must be designed so they do not swing outward, creating a fall protection barrier. This is a valid solution; however, you want to make sure the gate system you are installing was designed specifically for the application of loading multiple pallets into a system. There are a number of considerations that must be considered.
(1) It needs to be able to withstand the abuse of the lift truck constantly loading pallets through the gates, as well as the 200 pound lateral force of a person pushing the gate outward.
(2) It should be designed with a solid panel to make for an easy transition for the pallet onto the flow lane.
(3) The pallet flow system should also be designed so the pallet flow lane is long enough so the last pallet loaded into the system can travel far enough down the lane to allow the gate to close when the lane is full. This is easier if bi-parting gates are used so the pallet doesn’t have to travel as far before the gate closes.
The key to success with this solution is to use a gate designed specifically for pallet flow applications, and not to simply install a swing gate that may have been designed for personnel egress or for staged pallets on a mezzanine. A gate designed for pallet flow will better integrate with system and maintain a safe environment without impeding on production.
Another solution, and often the way to create the safest environment, is to use a dual-gate system to secure the entire lane. The safety device should be made deep enough to accommodate all the pallets on the lane so there would be a gate at the ledge and a second gate at the end of the lane; the gates would be counterbalanced and interconnected so when one gate is open, the opposite side is closed. This accomplishes two purposes: one, it ensures there is always a barrier between the picker and ledge, and two, it keeps the picker a safe distance from the pallets while they are being loaded into the lane. This is also the ideal solutions for the empty pallet return bays where the pallets flow towards the ledge to be removed. With a dual-gate system securing these bays, you will always have a safe environment
It’s easy to miss an area that needs protection; make sure to conduct facility safety checks in order to recognize risks and mitigate them with safety solutions and reach out to professionals in the industry for assistance. The ProGMA, which is a safety guarding group of the MHI is a valuable resource.