17. Work equipment

General considerations regarding work equipment

This section provides specific information on some work equipment commonly used in the warehouses and distribution centres of COSENTINO S.A.

As a general rule, all work equipment will have:

  • The CE marking and declaration of conformity or the respective local certification, depending on the country in which it is used.
  • An instruction manual. It will be available to and known by all persons using the respective equipment. It will be written in at least one of the country’s official languages.
  • The equipment maintenance instructions will be strictly obeyed.
  • Maintenance register.

17. a. Bridge crane

  • The bridge crane operator will have theoretical and practical training in accordance with specific local legislation.
  • It is used to transport slabs in the warehouse and during truck loading and unloading processes.
  • Do not exceed the permitted bridge crane load capacity. Bridge cranes with 5t or 8t capacities will normally be used.
  • Before use, check the state of the hoisting equipment, identifying any damage or incorrect operation that could pose a risk to the safety of people and property.
  • The bridge crane must bear the CE marking and have an instruction manual and a certificate of conformity in the local language.
  • Regular inspections will be performed by an authorised entity.
  • Every day, a check will be performed of the state of the hoisting equipment using a standard check-list to detect potential faults or failures affecting safety.

17. b. Slings

Always use canvas slings to prevent damage to the material. Never load slab packages larger than those mentioned above.

  • Before each use, the sling must be inspected to detect faults and its correct identification and specification will be ensured.
  • Unidentified or faulty slings must never be used, it must be taken to a competent person for inspection.
  • During the period of use, checks must be made for faults or damage, including hidden damage due to soiling. These checks must include all hoisting and other accessories used with the sling.
  • In the event of doubt regarding aptness for use or if any of the mandatory marks is missing or illegible, the sling will be withdrawn from service for inspection by a competent person.

Some faults that may affect the suitability of slings for safe and continuous use are listed below:

  • Worn surface: All substantial, localised wear will be critically observed. Local abrasion other than general wear may be caused by sharp edges while the sling is under tension, and may lead to a serious loss of resistance.
  • Cuts: Lengthwise and crosswise cuts, nicks or damage due to wear at the ends, cuts in the stitching or the slots.
  • Chemical attack. Chemical attack causes local weakening and softening of the material.
  • This is indicated by a separation in the form of surface flakes that can be torn off or eliminated by rubbing.
  • Damage due to heating or friction. This is indicated by fibres with a shiny appearance and in extreme cases, the merging of fibres.
  • Damaged or deformed accessories.

Correct use of flat textile slings

  • The sling edges will be protected from friction and abrasion by the load and by the lifting appliance. When providing reinforcements and protection from damage for the edges and/or abrasion as part of the sling, they must be correctly placed. It may be necessary to reinforce it with extra protection.
  • The load will be secured by the sling(s) so that it cannot overturn or fall from the sling during the hoisting operation. The sling(s) must be placed so that the elevation point is directly above the centre of gravity and the load is balanced and stable. The sling may move above the elevation point if the centre of gravity of the load is not below the elevation point.
  • Take care to guarantee personal safety during the lifting operation. People in the danger zone must be warned that the operation is to take place, and if necessary, the zone must be evacuated immediately. (Hands and other body parts must be kept outside the sling, to prevent injury). (ISO 12480-1 standard for planning and directing lifting operations, and implementing safe work systems).
  • A test lift must be performed. The load must be lifted slightly, checking that it is safe and in the appropriate position. This is particularly important with the basket or other loose strangulation elements, where the friction retains the load.
  • If the load tends to tilt, it must be lowered and the accessories repositioned. The lift test will be repeated until the stability of the load is guaranteed.
  • Care must be taken when hoisting to ensure the load is controlled, for instance, by preventing accidental rotation or collision with other objects.
  • Never drag a load in a sling or the sling itself over the ground or a rough surface.
  • The load must be lowered in a controlled manner, in the same way as when it was lifted. Make sure that the sling is not caught when the load is lowered. The load must not be supported by the sling, as this could cause damage, and the sling must not be dragged beneath the load when the load is deposited on it.

Storage:

  • When not in use, slings will be stored in well-ventilated, dry, clean conditions at room temperature on a shelf, away from heat sources, contact with chemicals, fumes, corrosive surfaces, sunlight or other sources of ultraviolet radiation.
  • Before being placed in the warehouse, the slings must be inspected for damage. Damaged slings must never be returned to the warehouse.
  • When a sling has come into contact with acids and / or alkalis, they must be washed with in water or neutralised using the appropriate methods before storage.
  • Slings that are wetted during use or after cleaning must be hung and left to dry naturally.
  • The slings must be inspected visually at least once a year by a competent person. Registers of these inspections will be kept. Damaged slings must be discarded from service, and never repaired by staff.

Table 3. STEEL SLINGS

SLINGING OF SILESTONE SLABS
STEEL SLINGS (2 slings)
Slab thickness Weight per slab (approximate) Slabs per package Weight of package (kilos)
SILESTONE I ,II and III Standard slab
Dimensions: 305x138cm		 1,2cm
2cm
3cm 		105kg
210kg
310kg 		18
14
8 		1,89Ton
2,94Ton
2,48Ton 		Used with a diameter of 14mm and each has a capacity of 1.8 Tn. About 10cm from the edges their total capacity is 3,05Tn
SILESTONE III Jumbo Slab
Dimensions: 327x163cm		 1,2cm
2cm
3cm 		160kg
270kg
400kg 		18
14
8 		2,88Ton
3,78Ton
3,20Ton 		Used with a diameter of 16mm and each has a capacity of 2 Tn. About 10cm from the edges their total capacity is 4,05Tn

POLYESTER (NYLON) SLINGS Bezabala 3Tn x 5m

SLINGING OF SLABS
Parallel lifting in U basket
Slab thickness Weight per slab (approximate) Slabs per package Weight of package (kilos)
SILESTONE I ,II and III Standard slab
Dimensions: 305x138cm		 1,2cm
2cm
3cm 		105kg
210kg
310kg 		14
14
10 		1,47Tn
2,94Ton
3,1Ton 		Used with a width of 90mm with each sling having a capacity of 3 Tn. About 10cm from the edges their total capacity is 6 Tn.
SILESTONE III Jumbo Slab
Dimensions: 327x163cm		 1,2cm
2cm
3cm 		160kg
270kg 		14
14
8 		2,24Tn
3,78Ton
3,20Ton 		Used with a width of 90mm with each sling having a capacity of 3 Tn. About 10cm from the edges their total capacity is 6Tn.
Dekton 0,8 cm
1.2 cm
2 cm
3 cm 		100 kg
167 kg
250 kg
375 kg 		6
6
10
6 		0.6 Tn
1 Tn
2,5 Tn
2,25 Tn 		Used with a width of 90 mm with each sling having a capacity of 3 Tn. About 10cm from their edges their total capacity is 6 Tn.

USE OF TEXTILE SLINGS:

Use of the following PPE:

  • Safety footwear
  • Helmet
  • Mechanical protection gloves
  • High visibility clothing
  • Mask
  • Protective glasses

Main risks:

Being crushed by falling or overturning slabs.

The crane operator is responsible for checking that no workers are present in the adjacent areas. He will stop the operation and warn any approaching staff to withdraw.

Visual inspection and review of the rocker:

Correct hooking to double anchor hook. Can only be used with a double anchor hook.

Chains and shackles not twisted.

Updated maintenance inspection (check on the plate that it has passed the annual inspection).

Level of wear of connection elements (rings, shackles).


Visual inspection of sling condition:

– Seams, cut threads.

– Top and bottom protections.

– Clamp.

With no protection and clamps, it cannot be used.

Check the state of the slabs; if any are broken or cracked, they must not be handled with slings, use the claw to remove them and put in a safe place.


Grab the package with the slings, pass one through one side. The top and bottom protectors will cover the entire perimeter of the edges of the package.


Fit the clamps correctly at both sides to adjust the load and ensure it is properly balanced.


Lift the package slowly to check that the slinging is correct. If you observe any failure or anomaly, lower the package and correct the problem.


Respect the safety distance when handling slabs, do not stand in the danger zone.

The safety bars will always be in place when slinging/unslinging the package.


Put the safety bars in place before depositing the package.

17. c. Rocker

Always use the rocker to prevent unexpected shifting of the load.

Work settings

General method of use

  • Always operate with the rocker hanging from the hook of the crane or pulley gear.
  • Make sure the mooring points (rocker ring and lower points for picking up the load, such as hooks, shackles, etc.) operate safely and that the dimensions and capacities of each element are appropriate for the load and the methods used.
  • Use the useful length of the rocker that is most suitable for the load to be lifted.

It is always best to work with vertical pull movements

– Couple the crane hook or pulley to the top rings of the rocker.

– Raise the rocker (unloaded) to facilitate the mooring of the load with the lower cables.

– Moor the load with the lower cables.

–  Check that the rocker is moored securely to the load and lift the load slightly above the ground.

– After checking that all the operations have been performed correctly and there is no risk to people or the load, or to the facilities, lift the load and move it to its destination.

Precautions

  • Make sure this equipment is always used in accordance with the accident prevention guidelines.
  • Store the rocker in a stable manner to prevent it from accidentally overturning.
  • Make sure that the above processes are complied with in full and that all users of the rocker have read this manual carefully.
  • Ensure that the rocker is only used by authorised staff.
  • Perform a visual check before each use of the rocker.
  • Never use the rocker above people, regardless of whether it is empty or under load.
  • Do not use the rocker as a methods for transporting people.
  • Make sure that the rocker load capacity is not exceeded.
  • Other precautions

– Check that the crane and the pulley tackle are in good conditions of use. Never user the crane to make side pull movements.

– Check that none of the nuts or screws are loose.

– Check that there is no wear, deformation or any problem affecting safety when using the rocker. In the event of doubt, contact the manufacturer’s technical inspection service.

– Check that the rating plate of the rocker has not become detached.

17. d. Pressure clamps

  • Do not carry goods that weigh more than the maximum load established for the clamp: 1 slab as the general norm (scissor clamp) and a maximum of 2 slabs with the crocodile clamp (Iremar/Insemac).
  • The clamps must have the CE mark approval.
  • Follow the instructions set out in the manufacturer’s manual.
  • Perform all maintenance work correctly.
  • Handle the slabs with the utmost care and take every precaution as they approach their final destination.

Load capacity depending on the type of tool

Main types of clamp used.

Table 1. PS “red-crane” classification clamp

Slinging of Silestone slabs Number of slabs per clamp
1,2 cm 1 slab
2
3

Table 2. INSEMAC/IREMAR crocodile clamp

Slinging of Silestone slabs Number of slabs per clamp
1,2 cm 2 slabs
2
3

Tabla 3. ABACO, AARDWOLF, GALESKY, etc… other crocodile clamp

Slinging of Silestone slabs Number of slabs per clamp
1,2 cm 1 slab
2
3

Safety instructions

a) For the crocodile clamp:

  • Take all the European safety guidelines into consideration and the instructions for using hoisting elements.
  • Permission to work with the “crocodile” clamp will only be given to trained, competent persons. They must be familiar with the manual and the safety instructions.
  • Do not grip the clamp when it is being lifted or lowering heavy items – danger of entrapment.
  • Do not use the clamp to overturn the slab in a horizontal position or lift it from that position, as the clamp could break.
  • Always keep the rubber surface clean, free of oil and dry.
  • Only lift parallel slabs, not conical ones.
  • Never exceed the gripping thickness specified for this clamp (60mm).
  • Do not exceed the maximum lifting weight.
  • Only lift homogeneous slabs that are firm and not broken.
  • The “crocodile” clamp must only be used for stone slabs, not for materials such as metal and glass, or fragile, dangerous materials.
  • Keep the safety and informative labels clean and legible.

b) General safety instructions for using hoisting tools

Important! To protect people against accidents, it is important to consider several general safety instructions.

  • Read the manual carefully before using the tool.
  • Make sure the manual is always available in the place where the tool is used.
  • Permission to work with this type of tool will only be given to trained competent persons.
  • The tool must be used in a way that poses no danger to anyone.
  • Use safety equipment such as helmets, gloves and safety footwear.
  • Lift loads formed by two parts only if they are joined as a single unit.
  • Never leave a load hanging without supervision.
  • Lift the load only to the necessary height.
  • Do not stand beneath the load or let other people do so.
  • Move the load slowly so that it does not sway.
  • People working with tools must control possible faults.
  • Tool connections or parts must never become detached.
  • The tool must be left in a place where it cannot fall, overturn or slip.
  • Leave the tool in a place where it is protected from outdoor conditions or aggressive substances.
  • Do not use the tool if it is damaged or does not function correctly.
  • Tool inspections or repairs will only be made by qualified persons.

Handling:

Lower the “crocodile” clamp over the load until the slab can be picked up with the entire rubber surface, with the clamp positioned at the top part of the material.

Warning!

Grasp the slab at the centre of gravity!
Then release the red latch and lift the slab.

Warning!

¡Before lowering the slab, make sure the clamp is not pressing or resting on any part, as this could cause the clamp to open before the material is deposited – Risk of accident!

Inspection and maintenance

Before using it for the first time and at least once a year, the clamp must be checked by a qualified person (visual and functional inspection).

In the event of damage or special situations that could affect the clamp operation, an extraordinary inspection should be made.

If necessary, change the clamp parts, using only original spares.

We recommend using the “crocodile” clamp for a period of 5 years and then replacing it in full. (Obviously, this will depend on the use and maintenance of the clamp).

Clamp for lifting Dekton 8 mm and 12 mm slabs

Due to their physical characteristics, the Dekton slabs may break when lifted with normal crocodile clamps, thus posing a serious safety risk.

In this respect, another type of clamp must be used for these slabs that provides a larger gripping surface:

Manufacturer: TECNOCAT 21, S.L. Model: P-21

General safety instructions:

Pay attention!

The following general instructions must be followed to the letter.

  • Check the work area before using the machine:

– Keep work areas clean and tidy.

– Do not use the machine if the area is wet or damp.

– Make sure the work area is well lit.

– Moderate lighting requirements: 200 lux.

– Do not use the machine near flammable liquids and/or gases.

– Keep people not related to the work away from the machine, especially its dangerous areas.

  • Wear the appropriate working clothes:

– Do not wear loose apparel, jewels, ties or elements that could be caught by moving parts. Long hair must be tied back.

– When handling glass, wear gloves to protect from mechanical risks, safety footwear and a helmet to protect from falling objects, and the appropriate
clothing.

  • Do not remain too long in the radius of action:

– Avoid adopting postures or positions that cause fatigue and rest your feet firmly on the ground, maintaining a balanced posture at all times.

– Make sure that no-one is standing within the machine danger zone before it is started up.

– Do not use the machine to carry people or loads.

  • Do not overload the machine:

– The hoisting system used to grasp the machine must be safe and appropriate for executing heavy work.

– Do not use the machine to perform work for which it is not intended to be used.

  • Always remain alert:

– Observe your work. Use your common sense.

– Do not work with the machine when you are tired.

  • Operating hoisting equipment and accessories:

– Respect the prohibition to operate hoisting equipment and loads above or near people and work areas.

– It is advisable to limit the load operation areas by putting up signs in the passageways where the loads are to be transported.

– Respect the prohibition to allow persons not involved in transporting the loads to operate in the areas used for moving them.

– Use the hoisting system correctly, making smooth movements and without exceeding the load capacity.

– Transport suspended loads in areas with good visibility.

Safety measures that must be taken by users.

The operator will check the following aspects of the machine:

– The correct general condition of the clamp.

– The correct state of the tightening plate cork surface. This element must have no cuts or cracks that could prevent it from gripping the load correctly.

17. e Racks, binary racks and safety bars

Type A racks

This type of rack is designed to permit the loading and transporting of stone material that must be handled once cut into slabs of a variable thickness.

The rack is supplied separately, and there must be at least two racks for loading it (one at each end of the slab).

The maximum weight admitted for each pair of racks has been calculated based on their geometric characteristics, starting with a specific mean weight of 2,400kg/m3 of stacked material.

Specificities of the equipment

In principle, it is clear that the primary condition for using these elements is based on the common sense of the handler. Even so, a series of minimum safety criteria are provided that must be considered by the person handling the product.

  • The person handling it must adjust the distance between the racks by an indirect measurement and never suspend the piece.
  • The rack must not be adjusted by hitting or pushing it when it is loaded (regardless of the load).
  • There must be a difference of no more than two slabs between both sides of the rack.
  • A structural tube will always be housed as a stop in the first opening of the support skid from the last slab deposited and the verticality of the slab will be achieved by using the appropriate wooden chocks, preventing the tube from bending.
  • The support surfaces must be properly cleaned, removing all dirt, sludge or grease that could reduce the friction coefficient.
  • Never load slabs on the stop of the rack skid.
  • This type of rack must not be used to transport loads on trucks with open-gate trucks without using the appropriate fastening systems.
  • Free space between the slabs must be avoided, as in addition to reducing loading space, this creates an inappropriate positioning angle that could break the slabs. Bear in mind that the slab must not be positioned at an angle with an inclination less than 85º.
  • Special care will be taken when loading with the bridge crane and slings, especially when the slings are removed, to prevent accidental hooking on sharp edges that could cause the assembly to collapse.
  • The racks will be separated a minimum distance that is half the length of the slab, with 1/4 of the length being the maximum projection.
  • Care will be taken to ensure the passageways parallel to the sides of the racks are kept free of material and have a passage width that is sufficient.

Binary systems

The instructions set out in the manufacturer’s manual will be respected, in addition to the load capacities and inclination of the slabs.

  • They will always bear the CE marking or equivalent certification mark, depending on the country where they are used.
  • They will have a declaration of conformity and a load test certificate.
  • The information on the use and load limits will be known by all the warehouse staff.

Mode of use

  • The rack and all other accessories must support the load that is to be borne.
  • Try to start loading the rack at the central part.
  • It is advisable to use this rack anchored to the deck.
  • Place the rack in an uncluttered area, away from areas where there are people moving about.
  • Take the slabs to the rack carefully, without making any sudden movements, and once in place, try not to touch them and protect them from knocks.

Controls

  • Make a visual inspection of the rack before each use.
  • Make sure there are no deformations, wear or damage.
  • No part of it must have any permanent deformations and the screws tha anchor it to the floor must not be loose.
  • Have the equipment controlled by a competent inspector at least every 12 months.

Precautions

  • Do not use a rack that has no rating plate.
  • The load limits indicated by the manufacturer will be respected in full.
  • Slabs that are not sufficiently rigid may bend lengthwise and break, or crosswise and slide downward.
  • Inform your supervisor of any problem arising in the equipment.

Transfer racks

This rack is used as an implement for forklifts, for transporting the slab from a bridge crane area to another parallel one.

It will have the CE marking, an instruction manual and the declaration of conformity.

Mode of use

  • The rack and all other accessories must support the load that is to be borne.
  • Place the rack in an uncluttered area, away from areas where there are people moving about.
  • Take the slab to the rack carefully, without making any sudden movements, and rest it on the rack at an angle of less than 15º with the vertical plan.
  • Once in place, try not to touch it and protect it from accidental knocks.

Controls

  • Make a visual inspection of the rack before each use.
  • Make sure there are no deformations, wear, warping or damage.
  • No part of it must have any permanent deformations and the screws that anchor it to the floor not be loose.
  • The equipment must be inspected every 12 months by a competent inspector.

Precautions

  • Always use the safety bars.
  • Never use a rack with no rating plate.
  • In long loads, the support length of the rack must be at least approximately 1/3 of the support base length.
  • Slabs that are not sufficiently rigid may bend lengthwise and break, or crosswise and slide downward.
  • Inform your supervisor of any problem arising in the equipment.

Automated transfer carts

Their function is the same as the previous equipment, to transfer slabs from from a bridge crane area to another parallel area. In this case, the transport involves the use of an automated transfer cart guided by rails.

The equipment will have the CE marking and declaration of conformity or equivalent certificate, depending on the respective country.

The instruction manual will be available to and known by all operators.

Always use the safety bars.

The equipment will have redundant safety systems to prevent entrapment or collisions.

• Emergency stop systems using push buttons or cables.

• Movement / stop sensors.

• Acoustic warning during movement.

• Vertical signs warning of the risk of becoming trapped / hit.

• Markings and painted signs with danger warnings.

Use the tool and chock designed for the task.

Always use at least these PPE. (Respiratory protection is mandatory in places where the level of exposure to silica dust is higher than the legally-established values).

The operator must first ensure that the two safety bars are in place.

Open the slabs with the lever tool and put the chock in place.

The slabs are sloping inward, without touching the safety bars.

From the slab end position, facing the driver, he gives the signal to move forward.

The forklift driver must not move forward if the worker is not positioned at the end of the slab and facing him.

Once the claw is in the centre, the operator approaches and puts the clamp in place.

He opens the lock.

The operator returns to his position at the end of the slab.

Then the driver of the forklift can lift the slab.

The operators grasps the slab with his hand to accompany it to the container.

17. g Cosentino delivery truck

In accordance with local legislation

  • Drivers must have the respective vehicle driving licence valid for driving vehicles included in this category in the country where they work.
  • The truck will have a road permit and accident insurance.
  • All the necessary technical inspections will be made on the vehicles.
  • The jib crane will pass all inspections and maintenance determined by the manufacturer in the instruction manual made available to the driver.
  • The loading surface will be built with non-slip materials.
  • Loading racks with anti-tip systems such as safety bars will always be used.
  • Protection will be provided against the risk of falling to a different level by installing swing gates along the entire platform perimeter.
  • By installing practicable gates throughout the perimeter of the platform.
Workplace: Marble/Silestone warehouses
Job: Warehouse shipment operator Warehouse operator:		 PPE MANDATORY: WHEN THE RISK IS PRESENT:
RISK PREVENTION/PROTECTION
Falls to different levels.
From the truck or forklift.
  • Use the ladder to climb into and out of the truck. Never jump from the truck to the ground.
  • Do not climb onto the forklift prongs. Avoid this unsafe action.
  • Use the equipment available for lifting people (certified basket).
Falling materials when unloading and operating the bridge crane.
  • Regular check to ensure the hoisting equipment hooks are fitted with safety latches.
  • Do not pass under or stand beneath suspended loads or carry loads above persons.
  • Do not overload cranes.
  • Check the hoisting equipment regularly.
  • All hoisting elements will be checked daily and any that fail to pass the inspection will be rejected. Hooks, cranes, cables and slings will have the CE marking. Reject and replace any element without this marking.
  • Use elements that protect against sharp edges and the possibility of steel cables accidentally breaking.
  • Do not allow the crane to be operated by unauthorised persons.
Being hit by motionless objects, by materials in passageways and in narrow corridors.
  • Keep passageways free of obstacles.
  • Make sure work areas and passageways have sufficient space for people to move about easily.
  • Keep work areas clean and tidy.
Being trapped by materials transported by cranes and fixed elements (walls, packages of material, sides of trucks, machines).
  • Hoisting and maintenance equipment will be moved slowly, leaving sufficient space between people and fixed objects, staff will not stand near areas where loads are moved.
  • Hoisting equipment will only operated by specialised staff who are properly trained.
  • No unauthorised staff will remain in areas where load are moved.
  • The equipment will be inspected regularly, following the manufacturer’s instructions.