High Risk Work Licence - Reach Stacker (RS) cheat sheet
High Risk Work Licence - Reach Stacker (RS) · Keep the key ideas within reach.
Legislation, standards and duty of care
Reach stacker operation requires a high risk work licence (RS class) under WHS Regulations; operating without a valid licence is an offence.
Primary duty of care: PCBU must ensure health and safety of workers and others, so far as reasonably practicable (WHS Act s19).
Workers must take reasonable care for their own safety and that of others, and comply with reasonable safety instructions (WHS Act s28).
Duty to consult with workers on matters affecting health and safety, including changes to plant or systems of work (WHS Act s47).
Incident notification: notifiable incidents (death, serious injury/illness, dangerous incident) must be reported to the regulator immediately (WHS Act s38).
Design and manufacture duties: plant must be designed to be without risks to health and safety when used for its intended purpose (WHS Act s22).
Importers/suppliers must ensure plant is accompanied by information on its intended use, limitations, and safe operation (WHS Act s25-26).
Records of plant maintenance and inspection must be kept for the period specified in regulations (typically 5 years for registered plant).
Operator competency: only trained, licensed operators may operate; trainees must be supervised by a licensed operator.
Hazard identification, risk assessment and control
Hierarchy of control: eliminate, substitute, isolate, engineering controls, administrative controls, PPE (WHS Regulations s36).
Risk assessment formula: risk = likelihood × consequence; use a risk matrix to prioritise controls.
Common reach stacker hazards: tip-over, dropped containers, collision with pedestrians/vehicles, crush zones, fuel/fire, electrical contact.
Hazard identification methods: workplace inspections, incident reports, worker consultation, task analysis, safety audits.
Control measures for tip-over: load charts, stability limits, ground conditions, speed limits, boom/attachment management.
Pedestrian separation: physical barriers, marked walkways, exclusion zones, high-visibility clothing, spotters.
Hazard reporting: any defect or hazard must be reported immediately to supervisor and recorded in maintenance log.
Dynamic risk assessment: continuous monitoring during operation; stop work if conditions change (e.g., wind, ground collapse).
Reach stacker components, stability and load charts
Stability depends on centre of gravity (CoG) staying within the stability triangle; load moment = load weight × distance from tipping line.
Load chart specifies maximum load at given boom extension and angle; never exceed rated capacity.
Boom extension increases load moment; capacity decreases as boom extends or angle lowers.
Counterweight balances load; adding attachments (e.g., spreader) reduces net capacity.
Tyre pressure and condition affect stability; uneven tyre pressure can cause tipping.
Ground bearing pressure must be adequate; use mats or spreader plates on soft ground.
Wind speed limits: typically cease operations when wind exceeds manufacturer's limit (often 20 m/s or as specified).
Attachments: container spreader, piggyback, or hook; each has specific capacity and use limitations.
Load chart is specific to each machine; never use a chart from another machine.
Pre-operational inspection, maintenance and defect reporting
Pre-start checks: fluid levels (engine oil, coolant, hydraulic oil, fuel), tyre condition/pressure, lights, horn, brakes, steering, boom, spreader, safety decals.
Inspect for leaks, cracks, wear, loose fittings, and damaged hydraulic hoses.
Test controls: boom raise/lower, extend/retract, spreader open/close, steering, brakes, park brake.
Check safety devices: load moment indicator (LMI), reverse alarm, beacon, fire extinguisher, seat belt.
Record inspection results in logbook; report defects immediately and tag out if unsafe.
Maintenance schedule: follow manufacturer's recommendations; keep records of all servicing.
Defect reporting: minor defects recorded and monitored; major defects (affecting safety) require immediate shutdown and repair.
After maintenance, function test all controls and safety devices before returning to service.
Site planning, ground conditions and operating area set-up
Assess ground bearing capacity: concrete, asphalt, compacted gravel; avoid soft ground, trenches, excavations.
Slope limit: typically max 5% (or manufacturer's specification); use level ground for stacking.
Exclusion zones: barricade area around reach stacker operation; account for boom swing radius and load drop zone.
Pedestrian and vehicle separation: designated walkways, crossings, mirrors, spotters, speed limits.
Lighting: adequate illumination for night operations; avoid glare.
Overhead hazards: power lines (maintain safe distance, typically 4.5 m for low voltage, more for high voltage), structures, cranes.
Weather: wind, rain, visibility; stop if conditions unsafe.
Site traffic management plan: one-way systems, parking areas, loading zones.
Load handling, stacking and container/attachment selection
Know load weight and CoG; never exceed load chart capacity for the configuration.
Container spreader: ensure twist locks fully engaged; check container condition (damage, holes, loose doors).
Stacking: stack containers squarely, max stack height per manufacturer/site rules; ensure bottom container sound.
Load security: use twist locks, lashing or other securing methods as required.
Boom angle and extension: keep load close to machine, avoid sudden movements, use smooth controls.
Travel with load low: keep load near ground, tilt back slightly, avoid rough terrain.
Attachment selection: use correct spreader for container size (20ft, 40ft, etc.); ensure attachment rated for load.
Communication with spotters: use agreed signals, maintain visibility, stop if signal unclear.
Communication, signals, spotting and pedestrian/vehicle separation
Standard hand signals: stop, raise, lower, extend, retract, dog everything (clench fists).
Only one designated spotter should give signals; operator must obey stop signal from anyone.
Radio communication: use clear, concise language; repeat back critical instructions.
Maintain eye contact with spotter; if lost, stop until re-established.
Pedestrian separation: use barriers, walkways, and high-visibility clothing; never allow pedestrians in operating zone.
Vehicle separation: establish traffic flow, use mirrors and cameras, sound horn at blind spots.
Blind spots: use mirrors, cameras, and spotters; never rely solely on mirrors.
Emergency signals: agreed distress signal (e.g., continuous horn) to alert others.
Emergency procedures, incident response and shutdown
Emergency stops: know location of emergency stop button; use for immediate hazard.
Fire: use fire extinguisher (dry chemical) for fuel/electrical fires; evacuate if uncontrollable.
Tip-over: stay in cabin, brace, do not jump; after stop, shut down, evacuate if safe.
Hydraulic failure: lower load immediately if possible; do not stand under load.
Incident response: secure scene, provide first aid, notify supervisor, preserve evidence, report to regulator if notifiable.
Spill response: contain fuel/hydraulic spills with spill kit; prevent entry to drains.
Shutdown procedure: park on level ground, lower attachment, apply park brake, neutral gear, shut down engine, remove key.
After incident: do not operate until inspected and cleared by competent person.
Shutdown, securing, parking and post-operational checks
Park on level, stable ground away from traffic and hazards; apply park brake.
Lower boom and attachment to ground, relieve hydraulic pressure.
Engine off, remove key, lock cabin; follow manufacturer's shutdown procedure.
Post-operational inspection: check for leaks, damage, loose parts; report defects.
Refuel safely: engine off, no smoking, use appropriate funnel, avoid spills.
Secure machine: lock doors, set anti-theft devices, chock wheels if on slope.
Record hours and fuel usage; complete logbook entries.
Clean machine: remove debris, especially around engine and hydraulic components.
Environmental and fuel/handling safety considerations
Fuel storage: use approved containers, store away from ignition sources, bunded areas.
Refuelling: engine off, no ignition sources, avoid static electricity, use grounding if required.
Spill prevention: use drip trays, absorbent materials; report spills immediately.
Waste disposal: hydraulic oil, filters, batteries must be disposed of according to environmental regulations.
Emissions: keep engine well maintained to reduce exhaust emissions; avoid idling.
Noise: use hearing protection if noise exceeds 85 dB(A); maintain mufflers.
Dust: use water suppression or dust masks when operating in dusty environments.
Environmental incidents: report to supervisor and environmental authority if required.