Working at Height Procedures – Asphalt Silos and Plant  

New Policy 03/04/25

Review Date 03/04/26.

1. Purpose

This procedure ensures that all work at height is conducted safely, in compliance with UK regulations, and minimises the risk of falls, injuries, and fatalities.

2. Scope

Applies to all personnel carrying out work at height, including but not limited to:

• Using MEWPs (Mobile Elevated Work Platforms), or fixed platforms.

• Installing or maintaining HDS equipment on silos and plant at asphalt plants and quarries.

• Installing / deinstalling site equipment on asphalt pavers and rollers (GPS on roofs).

3. Legal Requirements

This procedure complies with:

• The Work at Height Regulations 2005

• The Health and Safety at Work Act 1974

• Provision and Use of Work Equipment Regulations (PUWER) 1998

• The LOLER regulations, or Lifting Operations and Lifting Equipment Regulations 1998.

4. Responsibilities

• Managers: Ensure risk assessments are completed, appropriate equipment is used, and workers are trained.

• Workers: Follow safe working practices, use fall protection equipment, and report hazards.  Conduct inspections and ensure compliance.

5. Risk Assessment and Planning

Before any work at height is carried out, a Risk Assessment must be conducted to identify hazards associated with the task and the environment. This includes, but is not limited to, assessing:

• Working platforms (e.g., fixed working platforms, MEWPs, ladders).

• Weather conditions.

• The type of work being performed (e.g., installation, maintenance).

6. Planning the Work

Method Statement (RAMS):
A detailed method statement must outline how the work will be carried out safely, including:

• Equipment to be used (e.g., MEWP, ladders).

• Fall protection measures (e.g., guardrails, harnesses).

• Emergency rescue procedures.

 7. Permits to Work

Prior to any work at height being carried out, the asphalt plant or quarry may need to implement a Permit to Work (PTW) to ensure compliance with UK health and safety legislation. It is the asphalt plant/quarry's responsibility to determine if a PTW is required for specific tasks involving work at height, particularly for activities such as accessing silos, plant equipment, or elevated platforms. If a PTW is necessary, it must be issued before work commences, ensuring that a thorough risk assessment is completed and appropriate control measures are in place. The asphalt plant/quarry must verify that all personnel involved are suitably trained, competent, and equipped with the necessary fall protection and safety systems. Furthermore, the PTW process helps ensure that safe access and egress routes are in place, and that the work environment is secure. The asphalt plant/quarry is also responsible for monitoring adherence to PTW conditions throughout the duration of the work and keeping accurate records

8. Competency and Training

Training:

 Ensure all workers involved in working at height are trained and competent to perform their tasks. This includes:

·        Work at Height Awareness Training.

·        IPAF Certification (for MEWP operators).

·        Manual Handling Training (for lifting tools or equipment).

·        First Aid and Emergency Rescue Training.

·        Ongoing Competency Checks:

Regularly check and refresh competencies.

9. Personal Protective Equipment (PPE)

All personnel working at height must wear the appropriate PPE:

• Helmets with chin straps to protect against head injuries from falling objects.

• Full Body Harnesses with attached lanyards secured to suitable anchor points.

• Non-slip Footwear to prevent slipping.

• High-visibility Clothing.

10. Equipment and Tools

Inspection and Maintenance:

All equipment, including harnesses, lanyards, and MEWPs, must be inspected before use. Equipment that shows signs of wear or damage must be removed from service.

·        Pre-use checks for all equipment.

·        Document and maintain records of inspections.

Tools and Materials:

Only lightweight tools and materials should be taken up to the working height, such as small tools, brackets, cables, and hand tools. These should be stored securely in tool trays or with tool lanyards.

11. Working at Height Safety Measures

• Guardrails and Toe Boards:
  Fixed working platforms must have suitable guardrails and toe boards to prevent falls.

• Anchor Points:
  Ensure that all fall arrest systems are securely attached to certified anchor points.

• Harness Use:
  When working at height, workers must wear harnesses and secure them to the MEWP, platform, or any other safe anchorage point.

• No Leaning or Overreaching:
  Workers must avoid leaning over edges or overreaching while working at height.

12. Safe Access and Egress

• Ladders/Stairs:
  Ensure safe access to working platforms using fixed stairs or ladders with handrails. Always maintain three points of contact when climbing.

• Exclusion Zones:
  Set up exclusion zones around the base of the working platform to prevent personnel from entering hazardous areas.

13. Weather Conditions

Adverse Weather:

Work at height should be suspended during extreme weather conditions such as high winds, rain, snow, or icy conditions.

Wind speeds should be checked before work begins and should not exceed manufacturer limits for equipment.

Cease work if weather conditions worsen unexpectedly.

14. Emergency and Rescue Procedures

Rescue Plans:
Develop a clear rescue plan that includes details of how to safely evacuate a worker in the event of a fall or emergency. This should involve trained personnel and appropriate rescue equipment.

Communication:

Ensure that all personnel have access to communication devices (e.g. mobile phones) in case of emergencies.

See Annex A

15. Documentation and Reporting

Risk Assessments and Method Statements:
Document and obtain approval for all risk assessments and method statements before starting work at height.

Incident Reporting:
All incidents, near misses, or unsafe conditions should be reported immediately to managers. Investigate and take corrective actions to prevent recurrence.

ANNEX A

Rescue Plan – Working at Height on a MEWP or Fixed Platform

1. Task Overview

This rescue plan applies to all work conducted at height using a Mobile Elevated Work Platform (MEWP) or a fixed platform. It ensures a safe and effective response in case of an emergency, including operator incapacitation, equipment failure, or entrapment.

2. Emergency Contact & Communication

• A mobile phone must be kept on and fully charged at all times while working at height.

• The asphalt plant/site management must be informed of the work and kept updated on progress.

• A check-in procedure will be followed, with the operator required to confirm safety at regular intervals.

3. Rescue Procedure

Scenario 1: Operator Incapacitated or Trapped in the MEWP

• The trained ground-based personnel will use the MEWP’s ground-level emergency descent controls to safely lower the platform.

• If a second operator is present in the MEWP, they will attempt to safely lower the platform using onboard controls.

• If emergency controls fail or the operator is unresponsive, emergency services will be contacted immediately (999).

Scenario 2: MEWP or Fixed Platform Failure

• The operator will attempt to troubleshoot the issue using the platform’s controls.

• If unsuccessful, the trained ground-based personnel will deploy manual override/lowering systems.

• If manual lowering is not possible, emergency services will be contacted.

Scenario 3: Fall Arrest Activation (If Fall Protection Equipment is Used)

• If the operator is suspended in a harness, they must minimise movement to reduce the risk of suspension trauma.

• The ground-based personnel must act immediately to lower the MEWP or access the operator via an alternative means (e.g., ladder or rescue equipment).

• If immediate descent is not possible, emergency services will be contacted.

4. Lone Working Considerations

• A second operator is recommended but not always available.

• If no second operator is present, the site must have a designated, trained person on the ground who can operate emergency descent controls.

• If this is not possible, the work must not proceed until an alternative rescue plan is in place.

5. Training & Competency Requirements

• The MEWP operator must be IPAF trained and certified.

• Any ground-based personnel responsible for rescue must be trained in emergency lowering procedures.

• If fall arrest equipment is used, operators must be trained in suspension trauma risks and self-rescue techniques.

6. Emergency Services & Response Time

• If a situation arises where descent is not possible, emergency services must be contacted immediately.

• The site location and emergency access points must be known to all personnel before work begins.

7. Rescue Equipment Available On-Site

• MEWP emergency lowering system (tested before use).

• Fall arrest harnesses (if required).

• First aid kit available on-site.

• Emergency contact list.

8. Key Responsibilities

• MEWP Operator – Ensure all controls are functional before use and maintain communication.

• Ground-Based Personnel – Be familiar with emergency descent controls and assist in an emergency.

• Site Management – Ensure a safe system of work and confirm rescue procedures are understood.

Joe Charlesworth

Director - Highway Data Systems Ltd

03/04/25