Safety Evolution

March 11, 2023
Manufacturers raise the bar on safety to a higher standard.

There are many kinds of bad news phone calls the owner of a rental company, equipment dealer, or equipment manufacturer could receive during a working day. The cancelation of a contract, a valued worker deciding to quit, a regular customer leaving to go with a competitor, equipment being damaged or stolen, a truck or piece of rental equipment in an accident on a jobsite, a lawsuit of some kind.

But the worst is a call that informs the business owner or manager of a fatal accident or serious injury – that a worker has fallen to his death from a mobile elevating work platform. And with all the advances in machine diagnostics, improved performance on jobsites, safer equipment, better and safer accessories and training programs, falls from height are still one of the leading causes of death on construction jobsites, although electrocution has rivaled falls from platforms as the leading cause in recent years.

While the numbers of reported fatalities haven’t strongly decreased in the past decade, there are far more aerial machines in use and more entities reporting the incidents, leading to the sense that the aerial industry’s overall safety record has improved and jobsites are significantly safer today than they were a decade ago. And recordable incidents have declined according to most rental companies and manufacturers.

“Many jobsites have improved their focus on safety and training, and some sites have fantastic safety protocols in place,” says Scott Owyen, director of training, Genie Industries. “They have well-trained and knowledgeable safety officers and supervisors on site that enforce safety rules and manage their programs very effectively.”

“In the last 10 years, the focus on safety, not just in this industry but everywhere, has become even more so,’” says Nate Hoover, director of product management – boomlifts for JLG Industries. “When you look at the automotive industry, for example, many safety devices now come standard in today’s cars, such as airbags, anti-lock braking systems and proximity sensors, to name a few, that were once just options. The same holds true for the aerial industry. MEWP designs not only have come a long way in utility and productivity but also as a safe alternative to other methods of working at height. The updated ANSI A92.20 and CSA B354.6 standards gave impetus for redesign and machine modification resulting in safety as well as productivity improvements. Enhanced stability, higher platform capacities and the inclusion of personal protection devices have been revisited to improve machine safety and efficiency. Today, having MEWPs on job sites is now considered an enhancement to worksite safety.”

Malcolm Early, vice president of marketing for Skyjack, agrees. “While MEWPS themselves have generally always been statistically safe, the way we use MEWPS, and jobsites in general, are certainly safer than they were a decade ago,” he says. “Updates, many stemming originally from ANSI changes, have ensured that MEWPS are being used in a safer manner than they were a decade ago. Load sensing systems, for example, prevent normal machine operation when platform capacities exceed their load rate. Wind force calculations have been expanded as of late, providing a more stringent application for testing. Changes to guardrail system requirements, including heights and solid rails versus hinges or chains, have improved general safety practices and MEWP development.”

“A lot of manufacturers follow jobsite trends, especially when it comes to safety protocols,” says Robby Hagan, senior vice president of sales, Xtreme Manufacturing and Snorkel. “We develop equipment to meet and exceed all safety rules and continue to consult with contractors to understand each application. Most MEWP suppliers also contribute to ANSI to determine safer practices that protect both life and property. Training programs are offered at every level from MEWP manufacturers to equipment rental companies to contractors. Safety is a priority to all, and improvements are shared freely within the MEWP industry.”

Improvements in safety have come about because participants at every level are contributing. The recent ANSI standards that have improved safety procedures were very much motivated by manufacturer involvement. Rental companies have made safety a much greater priority than ever before. Rental companies are far more diligent in making sure customers are thoroughly trained and ANSI standards require them to do site assessments and improve training and customer familiarization. Safer conditions require buy-in from all levels, such as drivers who deliver the machines to jobsites and often are trained to provide familiarization to rental customers. Drivers also are better trained in proper loading and unloading as well as how to secure machines safely for transport. Inspections of jobsites for hazards are now mandated by ANSI regulations.

In many cases, not all, the contractors themselves do a good job in assessing the risks at their jobsites.

“On some jobsites where it’s a national or even an international contractor, they have specific safety professionals who are very diligent in enforcing safety criteria above and beyond the standards of OSHA,” says Gary Crook, vice president of engineering, MEC Aerial Work Platforms. “They hold themselves to a higher standard. But we know there are smaller operations and subcontractors and they’re trying to keep their costs down and they don’t do the full amount of training for people or risk assessment that would otherwise avoid some dangerous situations. But a risk assessment and a pre-planning of the tasks to be done, mitigation of the hazards, the means to respond in the event of an emergency, all those activities can greatly improve the safety of the overhead job. “

New safety products and accessories

Manufacturers continue to make their products safer. Although RER was not able to reach every aerial manufacturer for this article, here is a look at what some manufacturers have done to make safer products.

Skyjack

“Safety has always been important to the Skyjack team,” says Skyjack’s Early. “For example, the XStep was developed to safely provide operators with an additional 19 inches (48cm) of jobsite access. The most recent IPAF Global Safety Report cited falls from the platform to be among the most common type of incidents leading to death – a finding that has remained consistent over the last decade. Paired with the relatively common practice of operators standing on railings to gain more height, it became clear that a tool to allow increased reach in a safe manner was needed. The design and height of the top railing on the XStep, as well as entry and exit via the locking gate, ensures operators have the same degree of security as a conventional platform.

“The changes required by ANSI 92.20 provided Skyjack with an opportunity to deliver greater insights on MEWP usage and utilization by providing richer and industry-specific data. As a result, Skyjack introduced its ELEVATE telematics solution back in 2018. Part of Skyjack’s digital product suite, ELEVATE Live brings interactive pre-use inspection lists and familiarization materials to jobsites through a simple QR code. No apps to install, no login credentials, just point and click. Through this, operators have all essential information about the machine they’re using right at their fingertips. Safety is everyone’s responsibility, and a large part of jobsite safety is education and ensuring operators, supervisors, and general contractors know what safe use looks like. We’re evolving how we get our message out to ensure easy access.”

Snorkel

“We have developed short MEWP ‘tailgate’ videos on our Snorkel website that are available to everyone for free,” says Hagan. “These videos are used often and are designed to be brief and to the point. We have an OEM service & support team that travels within their territories to visit with customers and assist with mechanical issues, as well as to conduct onsite safety and familiarization training. We bring our safety culture to the customers to educate as many operators and mechanics as possible.”

Genie

“Safety is the most important thing we do at Genie, and it has been throughout our more than 55 years in business,” says Owyen. “If you look at our current machines, design enhancements such as platform load sense, dynamic terrain sensors, indoor/outdoor ratings, etc., will assist the operator by minimizing the likelihood of the operator reaching a condition of instability in certain situations. However, proper training is still crucial to the safe operation of any MEWP.

“Genie also has done a remarkable job of observing operators on the job and asking them what their biggest challenges are in getting the job done safely. The result has been a series of options and accessories that are designed to increase operator productivity while decreasing the possibility of the operator performing an unsafe act.

“For example, the Genie Lift Guard Fall Arrest Bar was designed to allow an individual to exit a Genie boom at height while being attached to a single lanyard anchor point that traverses the entire width of the platform, allowing the individual to move freely around outside the platform without the need to move the lanyard from anchor point to anchor point. This provides for 100-percent tie-off and enhanced freedom of movement.  

“The new, extra-large 13-foot (4 meter) platform provides the ability to get more work done, faster and more comfortably by enabling operators to access a much larger working area quickly and easily, reducing the number of times needed to stop and reposition the machine.

“The Genie Lift Tools Access Deck for booms and scissor lifts provides operators with a secondary surface to work from, elevating them 22 inches (0.56 meters) above the platform floor. Attached to the platform mid-rail, this additional access enables operators to get into restricted spaces to increase productivity.

“There are many other accessories available such as the Genie Lift Tools Panel Cradle, Pipe Cradle, Material Carrier and more that are designed to increase productivity and safety on the job. A full list of these can be accessed at https://www.genielift.com/en/aerial-lift/boom-scissor-a+ccessories.

“Operator training also has continued to evolve, thanks in part to Genie’s focus on continuous improvement and the new ANSI and CSA standards. The new requirements set forth in the standards, such as the need for safe use plans, risk assessments, rescue plans, and supervisor training have enhanced the training content dramatically. All our training courses were updated to the new standards in 2019, including our Genie Lift Pro online operator training courses. Since their initial release, Genie Lift Pro online courses have trained over 100,000 individuals to safely operate MEWPs and telehandlers. Our classroom-based operator training and train-the-trainer courses trained nearly 1,000 individuals in 2022 alone and we are seeing an even bigger uptick in 2023.”

JLG

“We incorporate technology into our equipment and design our safety accessories and protective solutions to mitigate job site risks before they occur,” says Hoover. “And our solutions are designed to enhance safe work practices at height while maintaining productivity, especially for operators working close to objects or tight quarters.

“Here are some examples of our accessories and equipment improvements that contribute to safe work at height:

“JLG SkyGuard technology offers enhanced control panel protection to reduce the risk of being caught between hazards on the job. The SkyGuard SkyLine, a slim design, is standard on most new JLG boom lifts.

“In North America, the ANSI/CSA standards require that MEWPs are equipped with load-sensing and tilt-sensing technology to make sure operators remain within the capacity limits of the machine. JLG machines have proprietary built-in sensor technology that is advanced enough to recognize when the machine is back within its rated load capacity, enabling operations to resume work. For tilt sensing, JLG machines are equipped with a system that disables boom and drive functions if the incline surpasses the rated operating incline limit.

“JLG’s optional SkySense enhanced detection system uses strategically placed object detection sensors to provide operators with an added level of awareness of their immediate surroundings. When a machine is in use, the sensors establish warning zones and stop distances in the machine’s direction of motion. As the machine approaches the zone limits, audible alerts notify the operator, increasing the protection of people and property.

“JLG also offers new technologies that enhance machine operation. For example, recent advancements in machine leveling technology have been developed to address safely working on uneven terrain. For example, self-leveling (for boom lifts) and variable-tilt and QuikLevel Advanced (for scissor lifts) are technologies designed to adjust the machine’s chassis to the ground conditions, rather than prepping the ground conditions for the machine.

  • With self-leveling technology, the JLG 670SJ self-leveling boom lift is engineered to continuously and automatically level itself on slopes up to 10 degrees, even when driving at full height.
  • With variable-tilt technology on JLG slab scissor lifts, sensors monitor both the weight in the platform and the machine’s tilt to determine the allowable work envelope. The machine then notifies the operator, before raising the machine, about how high they can elevate, removing the guesswork that often results in having to descend and try again.
  • QuikLevel Advanced is an option on JLG rough-terrain scissor lifts. This feature allows the stowed scissor to level on side slopes up to 4.5 degrees, then elevate and drive at full height under certain conditions.

“Digital technologies also enhance job site safety, and the use of mobile apps is becoming more prevalent on job sites. Especially if they improve the operator’s experience with the machine before work begins. An example of this is the JLG augmented reality app, which can enable users to scan the MEWP’s safety decals to get the current information on ANSI standards’ requirements, as well as to see an overlay of a specific machine’s control panel with explanations of its functions before machine operation.

“Another example is the JLG mobile control app, which offers remote control of select model scissor lifts through their phones without tethering to the machine. This allows users to maneuver around obstacles while maintaining a safe distance from the machine, position it into areas with low clearance and load or unload it from a truck without the need for an operator in the platform or walking next to the machine.

“In addition to our accessories and equipment advancements, training is essential to supporting the industry and for our equipment operators to be safe and successful on the job. We offer a variety of standards-compliant training, including:

  •  Service and equipment training online through JLG University or in person at the JLG training center and proving grounds;
  • Train-the-Trainer courses to teach participants how to train MEWP operators;
  • AccessReady e-learning modules for operators and supervisors;
  • AccessReady XR virtual reality training that provides real-time interaction and true-to-life job site scenarios.

“We have also taken a couple of unconventional approaches to educating the industry. For example, we provide a full library of safety-related content on the JLG #DirectAccess education and information site, offering equipment owners and operators another resource to learn more about best practices for safe work at height and to better understand the impact of safety on the industry.”

MEC Aerial Work Platforms

For MEC, the Extra Deck, which it introduced two years ago and the Leak Containment System, which it introduced about four years ago have been the most important safety launches, according to vice president of engineering Crook.

“With the Leak Containment System, it solves the problem of diapers that has been an industry headache,” says Crook, referring to the practice of wrapping diapers around engine parts to protect against leaks. “Diapers really are a band-aid to preventing oil leaks on the floor, particularly on sensitive jobsites. When they are first fitted, if well fitted, they might capture a few leaks, but after not many hours or days, they rub on the floor and they get torn. In reality, are they stopping an oil leak? The answer is mostly no. The real problem is when they wrap them up around the side of the scissors and they cover up the controls, which is the emergency stop, the normal lowering of the controls of the machine, and in some cases, they actually cover up the emergency lowering device. There are safety implications. The leak containment was an idea to integrate and have these self-contained stainless-steel trays.

“The LCS would not only capture the oil in the reservoir, but it would give you an early warning that a leak was beginning. Our thinking was that is almost invisible to the user, and they wouldn’t have to do anything special. They have a product that meets the requirements of guaranteeing no leaks on sensitive jobsites. But it doesn’t interfere with the machine, it doesn’t need maintenance or intervention by a technician under normal circumstances, unlike diapers that if they last a month, it’s amazing. It’s not that the diapers are an expense themselves, but it’s a waste of a skilled technician going to a jobsite and spending time and money on something that’s not really necessary.”

MEC also added its Extra Deck, which gives the worker an extra 20 inches of height enabling them to get inside ceiling areas and not have to stand on mid-rails to reach those areas. “In most cases, workers who stand on mid-rails are well-meaning workers just trying to do their job as best they can and there’s this overhead area and they can’t get the whole platform up there and they just want to get the job done so they stand on the mid-rails. Most of the time they get away with it, but when it doesn’t work out, they can slip. It might lead to a lower leg injury from bruising or there’s a real risk of a serious fall. The idea of the Extra Deck is that if the device can’t be deployed and retracted inside 10 seconds, they’re probably going to do what they’ve always done, which is to stand on the mid-rails. But it can be done within 10 seconds and it’s safe and convenient. It can even be used as a workbench for them or even a safe seat when they take a break.”

Equipment Safety Systems

“In recent years, the rapid integration of secondary guarding systems on booms lifts has been a significant advancement in MEWP safety,” says Andrew Delahunt, global business development manager of Equipment Safety Systems. “However, the development of secondary guarding for scissor lifts has proved more challenging to find a solution that does not restrict the machine’s productive purpose.

“In response to this challenge, Australia-based Equipment Safety Systems (EQSS) has developed and successfully introduced OverWatch, an industry-first, human-centric secondary guarding solution for scissor lifts. With a LiDAR sensor at its core, OverWatch detects the operator’s position and movements, and then intervenes only when safety is compromised. It does not interfere with normal operation of the scissor lift, instead it continuously monitors the operator’s position using an infrared light beam. The system can determine when an operator has moved abruptly or is in a dangerous position, either of which will immediately stop the lift.

“It features a small sensor that attaches to the scissor lift control box. This is paired with a powerful processor running advanced sensor AI fusion algorithms to track both operator movement and machine movement, to identify when a cutout is required. 

“OverWatch is designed for the equipment rental industry and is quickly gaining traction in the U.S. and worldwide. It is a robust, unobtrusive, and cost-effective secondary guarding solution that fits any scissor lift and requires only a simple one-time calibration. It works on all jobsites and in all weather conditions and has been widely adopted in Australian rental fleets and on construction sites. Recently, Haulotte integrated OverWatch as an option on its latest generation of electric scissor lifts, available globally.”

Don’t forget telematics

While industry participants know well that spreading safety awareness has a long way to go, much progress has been made and efforts to improve safety practices are ongoing.

“Further developments will most certainly improve aerial safety,” says Early. “Advancements in telematics will continue to improve safety as machine diagnostics and maintenance schedules can be further optimized and monitored. Telematics developments also allow rental houses to continue to ensure that machines are being operated in a safe manner.”