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National Code
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National Code of Practice

Government Gazette
REPUBLIC OF SOUTH AFRICA

Regulation Gazette No. 8158
Vol. 476
Pretoria
18 February 2005
No. 27292

GOVERNMENT NOTICE
No. R. 145
DEPARTMENT OF LABOUR
18 February 2005
OCCUPATIONAL HEALTH AND SAFETY ACT,l993
(ACT NO. 85 OF 1993)

NOTICE OF INCORPORATION

DRIVEN MACHINERY REGULATIONS

Government Notice R.295 of 26 February 1988

I Jace Naidoo designated chief inspector in terms of section 27(1) of the Occupational Health and Safety Act, 1993 and by virtue of the power delegated to me by the Minister of Labour, hereby with the recommendation of the Advisory Council for Occupational Health and Safety, incorporate under section 44(1) the National Code of Practice for Training Providers to Lifting machine operators into Driven Machinery Regulation 18 (11)

NATIONAL CODE OF PRACTICE FOR THE EVALUATION OF TRAINING PROVIDERS FOR LIFTING MACHINE OPERATORS

FOREWORD

This Code of Practice is to provide clarity and direction to all stakeholders directly or indirectly related to the accreditation and provision of training to lifting machine/ I equipment operators in South Africa.

This document incorporates the experience acquired by the Department of Labour, the relevant stakeholders of the industry since 1992.

This Code of Practice provides direction regarding the foundation for training of all lifting machine/equipment operators with the objective of ensuring
standardised training, and safety standards that will impact directly on reducing the risk of injury/death to employees/persons or damage to plant and equipment, inherent in all driven machinery operations and especially when loads are lifted or transported.

Your local office of the Department of Labour, or the ETQA (TETA) is available to assist in clarifying any difficulties in understanding the application of the legislation.

SCOPE

This Code of Practice is to provide clarity and direction to all stakeholders directly or indirectly related to the accreditation and provision of training to lifting machine / equipment / equipment operators in South Africa.

The code of practice sets out the requirements to the accreditation criteria of the authorised body, subject to meeting the South African Qualifications Authority: “Criteria and guideline for providers”.

The Code of Practice requires that all lifting machine/equipment Operators are
trained regardless of the capacity of the lifting machine / equipment by accredited providers.

Further, the code of practice covers the criteria and guidelines for lifting machine/equipment operator facilitators, assessors and providers. Also including the prerequisites for approved learningltraining programmes, facilities and equipment to train an operator to a certain level of competence for a specific type of lifting machine / equipment.

The Authorised Body has been empowered to categorise for purposes of issuing
Certificates of Competence, those lifting machine/equipment falling outside the
specific codes but within the broad classification of lifting machine / equipment.

The Code of Practice sets standards of training and operation and provides
direction and guidance to achieving accreditation and approval as an Accredited
Provider.

For clarity the relevant extract from regulation 18 (11) of the Driven Machinery
Regulations as amended, is appended: Appendix I0.

Where other Occupational Health and Safety legislation is applicable these must be applied.

The authorised bodies shall be consulted by the National Standards Bodies prior to approval of unit standards for operators of lifting machinedequipment.

DEFINITIONS

For purposes of The Code of Practice the following definitions shall apply: -

Accredited Provider
Means a body, which delivers learninghraining programmes, which culminate in
specified National Qualifications Framework standards or qualifications, and
manages the assessment thereof, accredited by an authorised body and approved by the Chief Inspector in terms of the Driven Machinery Regulations.

Accredited Providers shall be one of the following:

a) Sole Proprietor / Legal Entity Training Organisation.
b) In-House Training Division of a company or corporation.
c) Training Division of an equipment supplier company.

Assessment
Means the process of collecting evidence of learner’s work to measure and make judgements about the achievements or non-achievements of specified National Qualifications framework standards and/or qualifications and of this code of practice.

Audit
Means the process undertaken to measure the quality of products or services that have already been made or delivered;

Authorised Body
Means a body accredited in terms of section 5(l)(a)(ii) of the South African
Qualifications Authority Act, 1995 (SAQA Act), responsible for monitoring and
auditing achievements in terms of national standards or qualifications, and to which specific functions relating to the monitoring and auditing of national standards or qualifications have been assigned in terms of section 5(l)(b)(i) of the Act, and hold authorisation by the Chief Inspector in terms of the Driven Machinery Regulation 18.

Board
Means an executive structure of an Authorised Body, in this context ‘Council’ will have a similar meaning.

Certificated Operator
A holder of a valid certificate of competence.

Certificate of Competence

A certificate issued by an accredited provider or authorised body, to a person who has demonstrated competence in a specific category of equipment according to the assessment criteria of the applicable unit standardls and the criteria of this Code of Practice.

Lifting Machine/Equipment Codes
The lifting machine/equipment codes denote the different types of lifting machine / equipment that are covered under this Code of Practice primarily lift-trucks (also known as forklift) and cranes. The unique codes for the different machine types are identified in Appendix 3. See Appendix 12 for typical illustrations.

Management Representative
A person employed by the Accredited Provider to administer and, control the
functionality of the provider in accordance with the provisions of the Code of
Practice.

Moderator
Means the person, body or organisation that is registered by the relevant
authorised body in accordance with criteria established for this purpose by a
Standards Generating Body and that ensures the assessment of the outcomes as described in the National Qualifications Framework Standards andlor qualifications, and this Code of Practice, is fair, valid and reliable.

Quality Management System
Means the combination of documented processes used to ensure that the degree of excellence specified is achieved.

Registered Assessor
Means the person who is registered by the relevant authorised body in accordance with criteria established for this purpose by a Standards Generating Body to measure the achievement of specified National Qualifications Framework Standards or qualifications and the criteria of this Code of Practice, and “constituent assessor” has a corresponding meaning;

Facilitator
Means’a person who facilitates learning processes, activities, manages and
administers assessments.

Regulations
Means regulations as published under the Occupational Health and Safety Act, Act No.85 of 1993) and shall include other relevant legislation.

Unit Standard
Means the applicable unit standard for operating lifting machine/equipment
registered on the National Qualifications Framework by the South African
Qualifications Authority

DUTIES OF AUTHORISED BODIES

I. The authorised body shall appoint an Accreditation Committee to regulate the accreditation functions under the guidance of an appointed competent person.

2. At least four (4) of the members serving on an Accreditation Committee shall
be subject matter experts relevant to the lifting machine/equipment codes and
training.

3. The accreditation committee shall make final recommendations to the Board
of the Authorised Body for final accreditation approval. After accreditation,
the Authorised Body shall forward a copy of the accreditation certificate and
relevant details of the accredited provider, to the Chief Inspector for approval
under the applicable regulation.

4. The authorised body shall maintain the latest information on the accredited
provider's, and shall forward such listings on request or at least every three
months to the Chief Inspector. The following information fields are to be
included; registered name of provider, postal and physical address, contact
name, contact numbers, and accredited codes.

5. The authorised body shall at the last working day of January of each year or
as may be requested provide the following returns for the previous calendar
year to the Chief Inspector;

a. the number of new accredited providers;
b. the number of routine assessments and audits of accredited providers;
c. the number of certificates of competence issued both new and retrained,
per code of lifting machine / equipment.

6. The authorised body shall conduct periodic audits of accredited providers to
verify compliance to the Code of Practice. Provided that audits shall be
conducted at intervals not exceeding 12 months or as determined by the
Authorised Body to verify compliance to the Code of Practice.

7. The authorised body is empowered to suspend or withdraw the accreditation
of a provider after a fair process for non-conformance with the accreditation
criteria. The Authorised Body shall forthwith notify the Chief Inspector of any
suspension or withdrawal.

DUTIES OF ACCREDITED PROVIDERS

1. Accredited providers shall hold valid accreditation issued by an authorised
body, in terms of the SAQA Act, and approval from the Chief Inspector, in
terms the Driven Machinery Regulation 18, as published under the
Occupational Health and Safety Act 1993.

2. An accredited provider’s management representative shall be responsible for
the implementation and maintenance of a Quality Management System
(QMS).

3. The QMS shall address the “Criteria and Guidelines for providers” (as
published by SAQA) and the following -

a. The management representative’s delegated duties and responsibilities,
including the authorisation of all certificates of competence.

b. The delegation of functions and scope of responsibilities for registered
facilitator/s or assessor/s under the supervision and control of an accredited
provider, to maintain assurance of management’s support for independent
actions and decisions.

c. The accredited provider shall ensure that all assessments are carried out
with integrity. Measures shall be implemented to ensure that the accredited
provider and its staff are free from all pressures; financial or otherwise that
could influence their judgement.

d. A clearly defined written policy and procedure for the resolution of any
conflict that may arise from clients or other parties about the activities of the
accredited provider.

e. The accredited provider shall ensure confidentiality of all information
obtained in the course of its activities. Proprietary rights shall be protected.

f. The accredited provider shall conduct internal moderation on all aspects of
its scope of accreditation. A procedure clarifying whom, when, what and
how regarding the internal moderation process shall be conducted.

FIELD OF ACTIVITY

1. The field of activity and extent of the services for which the provider has been accredited and approved shall be detailed in the accreditation document
issued by the authorised body. An accredited provider shall not provide
training on any lifting machine/equipment code and extent of services other
than those for which the provider holds accreditation and approval.

2. The training provided must lead to the competent operation of the lifting
machine/equipment within the specific code.

3. Where certification is provided by an accredited provider at premises other
than those inspected and approved by the authorised body, then full details of
the facilities and equipment used shall be recorded in the format of the
facilities check sheet as detailed in Appendix 8.

TRAINING SYSTEM DOCUMENTATION

1. The accredited provider will keep available for inspection and audit the
following documentation and information -

a. An approved learning programme for each accredited lifting machine /
equipment code;

b. Learner material or course notes per learning programme, which shall
include safety rules, checklists, load charts and illustrations of machine
components;

c. Theoretical continuous (formative) and final (summative) assessment
documents, including model answers for each lifting machine / equipment
code;

d. Practical assessment documents, including assessment mark sheets for
each category code;

e. Attendance register, with provision for learner and facilitator/assessor
signatures for each day of training;

f. A training register to record all certificates issued and shall include;
certificate serial number, date of issue, recipient’s name, recipient’s
identification number, employer name, lifting machine / equipment codes,
facilitator/assessor’s name and accreditation number;

g. The relevant information required in accordance with SAQAs National
Learner Record Database; and proof of submission to the ETQA;

h. The portfolio of competence of each learner is to include a signed copy of
the learner’s identity document and a copy of the certificate(s) issued; and

i. The evidence of the training register shall be submitted on request and as
specified by the authorised body;

RECORDS AND RETENTION

1. All learner records shall be maintained by the accredited provider for a
minimum period of three (3) years and the records shall be accessible during
this time for inspection by the authorised body and Department of Labour.

2. The authorised body will similarly retain for three (3) years all its relevant
records.

TRAINING COURSE DURATION

1. The accredited provider shall ensure that every learner is granted sufficient
theoretical and practical training to enable the learner to attain the prescribed
competency level according to the assessment criteria of the applicable unit
standard. The training course duration and instruction conditions may vary
according to previous certification of the learner, as indicated below:

2. Learners without prior training or experience applicable to a specific lifting
machine/equipment code -

a. Shall be trained for a minimum of 40 hours, of which a minimum of 50
percent shall be devoted to practical operating instruction;

b. The ratio of learners to facilitator shall not exceed 4:l for theory training;
and

c. The ratio of learners to demonstration/practical training per machine shall
also not exceed 4:l and all operator training must be subject to direct
facilitator supervision.

Notes:

Operators without a valid certificate/carry card shall not operate the
relevant lifting machine/equipment in the working or operating
environment.

Operators of immovable machines (area specific) may be trained/
assessed in the working or operating environment only under the direct
and constant supervision of a facilitator/assessor and the work area is
safe and safeguarded.

Should the operator not meet the prescribed unit standard competency
further training must be arranged, for the learner to achieve the particular
outcome/s.

3. Operators with previous certification -

a. Operators previously 'certified under the Driven Machinery Regulations
whose certificates have expired or are due to expire, shall be subject to recertification training. Provided the re-certification route for an expired
certificate is only applicable if the original certificate expired within a
maximum period of 90 calendar days. The re-certification training shall
comprise a minimum of 4 hours theoretical instruction with special focus on
safety and I-hour practical training and assessment under a ratio of 1 :I
instructor/assessor supervision.

b. The ratio of learners to facilitator shall not exceed 4:l for theory training;
and

c. The ratio of learners to demonstration/practical training per machine shall
also not exceed 4:l and alloperatortraining must be subject to direct
facilitator supervision.

Notes:

Operators without a valid certificate shall not operate the relevant lifting
machine/equipment in the working or operating environment.

Operators of immovable machines (area specific) may be trained/
assessed in the working or operating environment only under the direct
and constant supervision of a facilitator/assessor and the work area is
safe and safeguarded.

The I-hour practical training and assessment period must include sufficient practical preparationltraining of the operator before any assessment.

Should the operator not meet the prescribed unit standard competency further training must be arranged, for the learner to achieve the particular outcome/s.

ENTRANCE QUALIFICATION CONDITIONS

1. All learners of whatever status must be physically capable of performing
without difficulty the tasks involved in operating the lifting machine/equipment
for which they are to receive training or re-certification training and are at
least 18 years of age.

2. Before commencing training or re-certification training every learner shall
provide the accredited provider with the following:

a. A declaration from the employer confirming the physical and psychological
fitness of the learner to undergo the intended training;

b. An optometrist's certificate confirming the learner has adequate day and night vision, and depth perception (e.g. Purdue University standard vision test No. 3): Provided that a valid Professional Driver’s Permit can also be accepted in lieu of the optometrist certificate and physical fitness of the learner to undergo the intended training; and

c. Shall wear the required personal protective equipment as prescribed by the
employer under the General Safety Regulation 2 of the Occupational Health
and Safety Act.

3. All new entrants intended under this code will require to hold at least a
General Education and Training Certificate Grade 9 (Std 7 - equivalent ABET

ACCREDITATION REQUIREMENTS FOR PERSONNEL

1. Every application for accreditation must demonstrate that the organisation has in the employ persons holding the criteria and qualifications for the appointment as management representative, registered facilitator/assessor.

2. Every accredited provider shall appoint in writing a full time employee as a
management representative.

3. Every accredited provider shall appoint in writing all registered facilitators/
assessors.

Management Representative

1. The management representative shall be empowered with the necessary authority to ensure that the provisions of the Code of Practice are implemented and maintained.

2. The accredited provider shall within 7 days notify the authorised body in
writing regarding any changes to the management representative.

Registered Facilitator

A registered facilitator is a person holding registration by the authorised body
having complied with the following -

a. Holding a valid certificate of competence for each lifting machine / equipment code in which instruction is given: Provided that in cases continuous training for a particular lifting machine / equipment code the recertification criteria as an certificated operator may be relaxed / lapsed by the Authorised Body but limited to a maximum period of three (3) years; The duration of initial training for a facilitator shall be at least the same as for a novice operator plus documented 120-hours practical experience.

b. Demonstrating competence in the following unit standards for providing training as evaluated by the authorised body;
I. Coach Learners - numbered 9926
ii. Prepare Learning Aids - numbered 9953
iii. Facilitate Targeted Skills Development - numbered 9956

c. Knowledgeable of this code of practice; and

d. Who is under the supervision and control of an accredited provider

Registered Assessor

A registered assessor is a person holding registration by the authorised body
having complied with the following -

a. Demonstrating competence in the following unit standards for providing assessment as evaluated by the authorised body;
i Plan and Conduct Assessments - SAQA ID 7978 or as amended.

b. Knowledge of this code of practice;

c. Demonstrate subject expertise in the category being assessed; and

d. Have a valid certificate of competence.

e. Conduct assessments under the auspices of an accredited provider.

4. In the event of personnel vital to the performance of the accredited provider
leaving their employment, accreditation shall be suspended for the specific codes until the accredited provider can prove by assessment that the replacement staffs meet the requirements.

TRAINING FACILITIES AND COURSE REQUIREMENTS

1. The following facility requirements are to be provided for training -

a. Lecture and practical training facilities; and

b. Suitable audio-visual equipment in accordance with the NQF approved
Learning MateriaVProgramme which may include:
i. Overhead Projector;
ii. Video cassette recorder and Monitor or similar; or
iii. Flip Chart or White Board.

LEARNING PROGRAMME REQUIREMENTS FOR ALL CATEGORIES

1. The accredited provider shall ensure that -

a. The approved learning programmes for the lifting machine/equipment codes
offered must be aligned to Appendix 1 & 2 of the National Code of Practice and to the applicable unit standard/s;
b. Each learner receives a condensed learner handbook, which includes
component illustrations, safety rules, load charts and checklists;
c. The practical and theoretical assessment tools aligned to the unit
standard/s; and
d. Demonstrate the revision of learning programmes to reflect any changes in
the applicable units standard/s and this code .of practice, within 90 days of
the gazette date or published date.

CERTIFICATION

1. A certificate of competence and a carry card is only valid for a period of 24
months, from the date of issue.

2. A certificate of competence must include the following information:

a. name and logo of the accredited provider or authorised body;
b. address of accredited provider;
c. accreditation number of provider;
d. certificate identification or serial number;
e. identification of Act and Regulation;
f. initials and surname of operator;
g. identification number of operator;
h. lifting machine code, code description of equipment, attachments and capacity;
i. registratiqn number of Learning Material;
j. restrictions of operation;
k. registration number of facilitator and assessor;
l. unit standard number and credit value;
m. date of issue and expiry date; and
n. authorising signature.

3. A carry card must be issued upon certification or re-certification and must
include the following information:

a. name and logo of the accredited provider or authorised body;
b. certificate identification or serial number;
c. initials and surname of operator;
d. identification number of operator;
e. lifting machine code, code description of equipment, attachments and
capacity;
f. restrictions of operation;
g. registration number of facilitator and assessor;
h. date of issue and expiry date; and
i. authorising signature.

4. No person shall operate any equipment covered by this Code of Practice without a valid certificate of competence required by the applicable regulation
published under the Occupational Health and Safety Act or any other applicable Act.

5. Any certificate of competence or any other certificate intended for use within
the scope of this code of practice, without a validity period or are older than 24 months of the date of issue shall be considered void. See clause Training Course Duration for certificates issued 24 months prior to the publication of this Code of Practice.

APPENDIX 1 :
APPLICABLE LIFT-TRUCK STANDARDS


Assessment Criteria for Learner Achievements

1. The following assessment criteria are to be demonstrated by the learner on
completion of a course applicable to the lifting machine cod.es category Lift
Trucks - Refer also to the applicable unit standard(s)

a. Theoretical knowledge and the safety rules applicable to the lifting machine
and the work environment or as found in a typical work environment;

b. Correctly identify and state the purpose of all controls and main components. Including the completion of a checklist prior to using a lifting machine and state any actions that are required on the discovery of a defect or suspected fault. Apply the correct start up procedure for the lifting machine and the use of all the lifting machine/equipment controls correctly;

c. Correctly read and understand the lifting machine / equipment information
plates. Be conversant with and able to apply load charts, load centres and
de-rating factors;

d. Have the ability to competently operate the lifting machine correctly,
identify, select, pick up, transport and stack the load at various levels whilst
passing through an obstacle course without making contact with any of the
obstacles;

e. Show a capability to undertake the correct method of operating on inclines
(ramps); and

f. Prove to be conversant with various types of pallet construction and the
storage and retrieval requirements of each type.

Criteria for Learners not achieving outcomes

I. Any learner who does not achieve the outcomes for certification on a designated day, the accredited provider may afford the learner a further opportunity after on-site training and before a further attempt is undertaken.

2. In cases where the outcome/s are not achieved on the second attempt a new
assessment date must be set with further appropriate training.

3. In the case of a third unsuccessful attempt to achieve the outcome/s, remedial interventions with the employer must be applied if further attempts are to be considered.

Equipment Requirements:

1. The accredited provider shall ensure that the following equipment is available
for the duration of the training and assessment -

a. A lift machine in good working order applicable to the code, which shall
include a load chart and a valid load test certificate in accordance with the Driven Machinery Regulations 18 or original equipment manufacturer specification;
b. An obstacle course to adequately train and assess the competence of the
operator performing the assessment criteria as described above and the
requirements of the applicable unit standard. The standard obstacle course
used for lift truck operators is found in Appendix 1.2 The practical training
area for a lifting machine shall be flat with a minimum size of +/- 300 square
metres. Further, it is recommended that the obstacle course area be under
cover; and
c. The relevant attachments and equipment (test loads) for the operation of the lift machine. It is permissible for the physical facilities to be provided by the client organisation.

Learning Programme Subject Matter - Lift Trucks
1. The following subject matter, where applicable, shall be included in the
learning programme applicable to lifting machines under the category lift
trucks -

a. The identification and knowledge of principle components, functions and
operations;
b. Understand safety rules and best practices applicable to operating environments and emergency situations;
c. The procedures to conduct pre-operational checks, start-up and shut down operations and the operation of all controls;
d. The principles and rules applicable to load charts, de-rating, load-centres and capacity ratings and plates;
e. The hazards and safety rules regarding the refuelling of the lifting machine as applicable to diesel/petrol, electrical supply (battery), liquefied petroleum gas or any other fuel;
f. The importance and requirement for maintaining lifting machine logbooks and reports;
g. The standards regarding the manoeuvring of the lifting machine, within
the standard obstacle course, confined stacking gangways, and on inclines / ramps;
h. The practices of determining the mass of different loads, understanding
the hazards applicable to the load and ensuring stability during any
operation; and
i. The standards for loading and off-loading from racks at various heights, and into and from trucks and boxcars.

Theoretical Examination for Lift Truck Operators

1. The theoretical examination must consist of a minimum of 40 questions aimed
to assess the learner’s achievement of the outcomes of the applicable unit
standard.
2. Illiterate or semiliterate learners may be assessed by means of a verbal test in
the presence of a witness. The theory test sheet used in such cases is to be
endorsed as a verbal test.
3. The format of the theoretical questions is optional, but it is recommended that
a combination of YeslNo and multiple-choice questions be used. The
requirement for written explanatory type answers is not recommended.
Practical Tests for Lift Truck Operators.

1. The practical test is to be so organised to assess the operator’s competence
and proficiency in achieving both the unit standard and assessment criteria
standards as set out above. Further, any unique competencies required of
the operator should be included in the practical test.

Marking of Assessments

1, Only a registered assessor shall perform assessments.

2. The minimum assessment topics / criterion are set out under the assessment mark sheet, Appendix 7. Each topic / criterion are assigned penalty points for each occurrence of non-compliance or error, which are to be totalled by the assessor to determine the level of competence.

3. The total penalty points earned may not exceed the following -

a. A maximum of 30 penalty points scored under the pre-start and preoperational assessment topicskriterion, excluding any critical items; and

b. A maximum of 50% of the total scored penalty points calculated by 6
penalty points per 1 minute of operational assessment time (driving time).
i.e. duration of practical driving of 15 mins the maximum penalty points
should not exceed 15mins*6*50% = 45 or 20mins*6*50% = 60

4 Learners must demonstrate competence on the critical knowledge (theory)
assessment before being allowed to participate in the skills (practical)
assessment.

APPENDIX 1.1 :
Standard Obstacle Course for Lift Truck Operators.


The standard lift truck course and procedure was developed to standardise the
assessment of operators and thus ensuring an equitable benchmark regardless of location. The obstacle course tests the competence of the operator through
various generic manoeuvres. Modifications to the obstacle course maybe
necessary depending on the lifting machine and accessories fitted.

Stacking Heights

See drawing / sketch Appendix 1.2 for the minimum physical heights required.
Critical Dimensions

1. Procedure to determine dimensions marked “X”. Refer to drawing / sketch
Appendix 1.2. Park the lift truck at right angles to the racking with the forks or
pallet touching the rack. Whilst in the stationery position turn steering wheel
to the full lock position. Move the truck to a 45-degree position. Stop the lift
truck and measure a distance of 300 mm from the corner of the counter weight
(or furthest projecting part) to the opposite racking. Please note that this
procedure should be repeated for the opposite side as the turning radius
differs on some lift trucks.

2. Chicane aisles are to be constructed in such a manner that the loaded lifttruck will have only 100mm clearance at all critical points when passing
through the chicane.

3. The maximum clearance allowed between pallets or other objects when
stacking is 75mm for both width and height distances.

4. The distance from chicane to the test racking position is to be twice the length of the lift truck. Allow the operator two opportunities to align lift-truck in the test aisle before performing the first task.
Test Route Preliminaries

1. Before testing may take place, the facilitator must complete the test route
twice to ensure that it is practical and to familiarise himself with the sequences
and the pallet positions.

2. A marking control sheet must be used, see Appendix 7 for a recommended
sheet. The sheet is to be completed during the assessment to record faults as
and when they occur.

3. It is important to walk all learners through the route explaining both the
requirements of the practical test and the criteria and method of marking.

4. As a safety measure, ensure that no other persons including other learners
are in the immediate vacancy of the obstacle course, during the actual
assessment of a learner.
Practical Test Procedure

1. The learner is to perform the following whilst being assessed -

a. At the parked position carry out, without the use of a written checklist, the
pre-operational checks required for the lift-truck, which is to be used during
the assessment;
b. Answer 5 questions regarding the pre-operational checks;
c. Mount the lift-truck and carry out the start-up and operational checks;
d. Drive to station "A" and pick up the pallet;
e. Drive forwards through the chicane and deposit the pallet at station "B" at the high level;
f. Drive to station "C" and collect the pallet at eye level;
g. Drive to station "D" and deposit at the low level;
h. Drive to station "B" and collect the pallet at the high level;
i. Drive to station "C" and deposit at the eye level;
j. Drive to station "El" and collect the stillage** at the eye level;
k. Drive to station "E2" and deposit the stillage" at the eye level;
l. Drive to station "D" and collect the pallet at the low level;
m. Drive in reverse through the chicane;
n. Drive to station "A" and deposit the pallet within the identified position;
o. Drive to "Park" position and park correctly; and
p. Perform close down checks.

Note -

a. ** Stillages maybe substituted with a stack of pallets that is packed within a maximum tolerance of 50 mm on a minimum of two sides.
b. Where training and practical assessments are conducted on machines restricted to particular areas (i.e. warehouses), this must be conducted in a clearly demarcated area, by means of danger tape or barriers.
c. In the case of order pickers (Code 8 & 9) the word "pallet" shall be interpreted to describe a parcel or component.

Close Down Checks
The normal close down checks associated with the completion of the days work is to be carried out and any problems reported.

APPENDIX 1.2:
Sketch/Layout of Lift Truck Assessment Course

(prior to the accessment)


APPENDIX 2 :
APPLICABLE CRANE STANDARDS


Assessment Criteria for Learner Achievements

1 .The following assessment criteria are to be demonstrated by the learner on
completion of a course applicable to the lifting machine codes category Cranes
- Refer also to the applicable unit standard

a. Theoretical knowledge and the safety rules applicable to the lifting machine
and the work environment or as found in a typical work environment;

b. Correctly identify and state the purpose of all controls and main components. Including the completion of a checklist prior to using a lifting machine and state any actions that are required on the discovery of a defect or suspected fault. Apply the correct start up procedure for the lifting machine and the use of all the lifting machine controls correctly;

c. Correctly read and understand the lifting machine information plates. Be
conversant with and able to apply load charts, range diagrams, load moment indicator’s (LMI) load and de-rating factors;

d. Have the ability to competently operate the lifting machine correctly using
all its operating functions, identify loads, hoist, transport and position the load in a safe manner;

e. Show a capability to undertake the correct method of operating the crane in
various operating positions, for example on inclines; and

f. Proof to be conversant with various hand signs used to hoist and position a
load.

Criteria for Learner’s not Achieving Outcomes

1. Any learner who does not achieve the outcomes for certification on a
designated day, the accredited provider may afford the learner a further
opportunity after on-site training and before a further attempt is undertaken.

2. ln cases were the outcome/s are not achieved on the second attempt a new
assessment date must be set with further appropriate training.

3. In the case of a third unsuccessful attempt to achieve the outcome/s, remedial interventions with the employer must be applied if further attempts are to be considered.

Equipment Requirements:
1. The accredited provider shall ensure that the following equipment is available
for the duration of'the training and assessment -

a.A lift machine in good working order applicable to the code, which shall
include a load chart, range diagrams, load moment indicator (LMI) and a valid
load test certificate in accordance with the Driven Machinery Regulations 18 or
original equipment manufacturer specification. Further suitable;
b.A course to adequately train and assess the competence of the operator
performing the assessment criteria as described above and the requirements of
the applicable unit standard, and
c.The relevant attachments, lifting tackle for rigging a variety of loads and
suitable loads for the practical operations. It is permissible for the physical
equipment and facilities to be provided by the client organisation.
Additional Entrance Qualification Conditions

1. An appropriate drivers licence for the particular vehicle;

2. Shall be wearing protective footwear (steel toe-capped); and

3. As from the final approval date of the Code of Practice, all new entrants intended under these categories shall hold a General Education and Training Certificate Grade 10 (Std 8), or National Qualifications Framework level 2 (Maths and English) or equivalent.

4. Conditions 1 and 3 do not apply to wall / pillar mounted jib cranes

Recommended Learning Programme for Cranes


1. The following subject matter, where applicable, shall be included in the
learning programme applicable to lifting machines under the category cranes -

a. The identification and knowledge of principle components, functions and operations;
b. Understand safety rules and best practices applicable to operating environments and emergency situations;
c. The procedures to conduct pre-operational checks, start-up and shut down
operations and the operation of all controls; The Learner/operator shall
provide the assessor with a duly completed daily inspection list for the particular. crane and recognise and report any possible defects.
d. The principles and rules applicable to load charts, range diagrams, load
moment indicators (LMI) de-rating, and load-centres, at various jib / boom
extension, counterweight mass, outrigger positions, and quadrant configurations;
e. The hazards and safety rules regarding the refuelling of the lifting machine
as applicable to dieseVpetrol, electrical supply (battery), liquefied petroleum gas or any other fuel;
f. The importance and requirement for maintaining lifting machine logbooks
and reports;
g. The standards regarding the manoeuvring of the lifting machine in various
environments and conditions, especially with reference to wind loading;
h. A thorough knowledge of the standard hand signals and communication
methods used between ground staff and operators; and
i. The practices of determining the mass of different loads, understanding the
hazards applicable to the load and ensuring stability during any operation,
this includes knowledge of lifting tackle, rope reeving; (Basic slinging)
Theoretical Examination for Crane Operators

1. The theoretical examination must consist of 40 questions aimed to assess the learner’s achievement of the outcomes of the applicable unit standard.
2. Illiterate or semiliterate learners (only currently certified) may be assessed by means of a verbal test in the presence of a witness. The theory test sheet
used in such cases is to be endorsed as a verbal test.
3. The format of the theoretical questions is optional, but it is recommended that a combination of Yes/No and multiple-choice questions be used. The
requirement for written explanatory type answers is not recommended.
Practical Tests for Crane Operators.

1. The practical test is to be so organised to assess the operator’s competence
and proficiency in achieving both the unit standard and assessment criteria standards as set out above. Further, any unique competencies required of the operator should be included in the practical test.

Marking of Assessments

I. Only a registered assessor shall perform assessments.
2. The minimum assessment topics / criterion are set out under the assessment mark sheet, Appendix 7.2. Each topic /criterion are assigned penalty points for each occurrence of non-compliance or error, which are to be totalled by the assessor to determine the level of competence.
3. The total penalty points accumulated may not exceed the following -

c. A maximum of 30 penalty points accumulated under the pre-start and pre-operational assessment topics / criterion, excluding any critical items; and

Learners must demonstrate competence on the critical knowledge (theory)
assessment before being allowed to participate in the skills (practical) assessment.

Practical Assessment

Pre-Start procedure
In the parked position, the learner shall carry out, without his daily operator
checklist, the specific pre-start checks required for the code of crane used.

Start up procedure
Perform the start -up procedure and functional checks. These checks shall include the operation of all the controls for the various crane movements.

Verbal Theory Questions
Answer five (5) verbal questions based on the safety aspects of the above
procedures.

To determine competence on the pre start and start up assessment the learner
shall not incur more than 20 penalties, excluding the critical items per the
assessment tool.

Operational Procedure Assessment
Perform a series of actions designed to show operator competence and
understanding of the principle manoeuvres involved.

Mobile Jib Cranes (including Tower Cranes)
Practical assessment shall include a prepared pre lift plan, set up, lifting and
manoeuvring the load over and about objects to test the various operating skills required. The operator shall safely lift a load of at least 10% of the crane capacity over the side quadrant of the crane and deposit the load over the rear quadrant. The duration of the practical assessment including pre-start, start up, operational and close down procedures should be at minimum of one hour per operator. The results of the assessment are to be recorded on an assessment document, which allows for the recording of operational faults at each stage, which are to be noted and the final assessment calculated.

Overhead cranes
Practical assessment shall include the preparation of a lift and manoeuvring the
load over and about objects to test the various operating skills required. The
operator shall lift a load of at least 10% of the crane capacity and deposit the load in three different positions. The duration of the practical test including start up, operational and close down procedures should be at least a half an hour per operator.

Close down procedure
Perform the close down procedure on completion of the operation and complete the necessary documentation on the specific machine code.

The results of the assessment shall be recorded on a standard form (refer to
Appendix 7.2, which allows for the operational faults at each stage to be noted and the final score calculated.

A maximum of 50 penalty points are permissible on a combined score for all
practical assessments detailed above, in order to be declared competent.

APPENDIX 3 :
LIFTING MACHINE CERTIFICATION CODES


Forklift Codes
For illustrations of typical codes refer to Appendix 12


VNA = Very Narrow Aisle
NA Narrow Aisle
WA Wide Aisle

SPECIAL NOTE: Accreditation to SAQA unit standard CFH 17 does not equal
accreditation to all of the above codes.

Attachments & Special Equipment

A Side-shift
B Single Pole
C Carton or Paper Roll Clamp
D Crane Hook
E Push-Pull / Slip Sheet Equipment
F Load Rotator
G Wire Guidance System
H Load Extender Pantograph
I Rotating Mast (Order Picker)
J Tilting Bucket
K Tandem Forks
L Container Vanning and Devanning
M Container Handling
U Lifting Cradle (Personnel Cage)

Code Specification on Competency Certificates


Accrediting Organisations are required to annotate certificates to clearly identify the machine category, code number and description. The description only where it significantly differs from the basic code description: i.e. code F11 (Bell Three
Wheeler/Front End LoaderExcavator with ForWgrab attachment)

Special Cases

In the case of additional or new attachmenus, the learner will be required to under go retraining and assessment to include the attachmenus. Refer also to Training Course Duration.
CRANES CODES
For illustrations of typical codes refer to Appendix 12



Note that several SAQA approved unit standards cover the above codes.
Providers must ensure that they are accredited on the relevant unit standards
linked to these codes.

Attachments and Special Operations

P Fly Jib (Lattice)
Q Boom Extension (Hydraulic)
R Counterweight Options
S Tandem Lifts
T Special Categories
U Lifting Cradle (Personnel Cage)
V Rail Mounted
X Steam driven
Y Spreader
Z Grab / grapple

Code Specification on Competency Certificates

Accrediting Organisations are required to annotate certificates to clearly identify the machine category, code number and description. The description only where it significantly differs from the basic code description.

Special Cases

1. It is a pre-requisite that the operator of specialised equipment will be
certificated in a basic category applicable to the special machine in question.

2. Where lifting machine/s are in use that are reasonably considered to be a
"one off” type and where no experience in their use is available. The
manufacturer/supplier of the lifting machine will train the operator and issue a
certificate of training. This can be accomplished by sending the learner/
operator to the supplier or the supplier sending a qualified instructor to the
learner/operator. In such cases full course details must be made available to
the relevant authorised body and the operator will be required to do a
theoretical examination set by the to authorised body. The authorised body
will issue the results of the theoretical examination to the operator’s employer.

APPENDIX 4 :
GENERAL EXPLANATORY NOTES


These form part of the provisions of the Code

This appendix contains explanatory notes, which should be taken into account
when additional clarity maybe required.

1. Accreditation of accredited providers will remain valid whilst no nonconformances are recorded during annual audits. If any non-conformances
are recorded the accredited provider will have 30 days of the audit date to
correct and provide any explanations, which may be required.

2. The responsibility of the accredited provider shall go beyond simply carrying
out training and assessments but shall include applying measures to ensure
that the standards of training and assessments are maintained at all times.

3. An accredited provider may operate as a training organisation on a client’s
premises. The registered facilitator shall ensure that sufficient equipment and
facilities are available at the client‘s premises to undertake and complete the
training programme to ensure the required level of competence. In all cases a
record (refer Annexure 8) must be kept of the facilities and equipment used at
the premises for inspection during audits. Any special circumstances such as
the absence of suitable equipment to perform the practical tests required
should be recorded and the certificate issued may require limitation endorsements.

4, Copies of all assessment papers and practical test marking sheets are
required to be kept for each certificate of competence issued for audit purposes.

5. A composite organisation involved in the direct sale of equipment and which
has sufficient staff to perform accredited provider functions shall obtain
accreditation and shall be required to demonstrate the following:

a. That adequate safeguards are in place to isolate certification staff from
those involved in the other aspects of the organisation to ensure that no
pressures are brought to bare which may influence registered facilitator’s
and assessor’s judgement;

b. The organisation has a clearly defined policy for the resolution of conflict
that may arise;

6. Accredited providers requiring registered facilitators to use alternative course
material, to their own proprietary material, must be able to demonstrate to the
authorised body that they are conversant with the material and able to use it
effectively.

7. An organisation applying for accreditation, as an accredited provider must
provide written approval for the use of the course material submitted unless it
is clearly entirely of its own origination

8. Where conditions and/or equipment are insufficient to be able to assess an
operator's performance under all types of situation then any certificate must
be limited accordingly.

9. In the case of the client's only requirement is for the operator to load and off
load road vehicles then the certificate of competence must be limited in either
of the following manner:

a. "Whilst in the employment of the Client"; or
b. "For loading and off loading road vehicles only"

The second alternative is preferred, as this will adequately represent the operator's competency if the certificate of competence is presented to another employer.

10. Hoists, and block and tackle could be classified under code 30, (Overhead
Cranes) and the certificate shall be restricted as such.

APPENDIX 5 :
APPROVAL OF ACCREDITED PROVIDERS


These form part of the provisions of the Code of Practice

1. The approval of an accredited provider by the authorised body shall be
conditional upon the following:

a. Meeting the Criteria & Guidelines of this code of practice and as specified
by SAQA;

b. Should an accredited provider lose its accreditation it shall automatically
lose its approval by the regulatory authority; and

c. A schedule of fees adjusted annually in terms of the SEIFSA indices for
labour may be charged lfor accreditation by the authorised body.

d. Payment within 30 days on submission of invoice for audit fees;

APPENDIX 6 :
RETURNS FROM ACCREDITED PROVIDERS


1. Accredited providers are required to provide the following:

a. Internal verification procedure/s documentation as requested;

b. Monthly returns of certificates of competence issued according to each
code; The format of these returns should be in accordance with the SAQA
National Learner Record Database for learner achievements in accordance
with the NQF.

c. Access to training material and other records as required for the efficient
auditing of this code of practice and SAQA standards; and

d. Submission of corrective action reports for non-compliance or any other
matter effecting accreditation.

APPENDIX 7.1 :
LIFT TRUCK OPERATOR ASSESSMENT MARK SHEET


ACCREDITED PROVIDER:
CANDIDATE: DATE:
I.D. NUMBER: MACHINE TYPE:
MACHINE MAKE: MACHINE CODE:
COMPANY: CAPACITY:
PRE-START CHECKS(Delete items not specific to the test machine or conditions)
Personal Protective Equipment for the work environment
{May include hardhats, overalls, thermal suits, goggles, earplugs as applicable}



PRE-OPERATIONAL TESTS


Total Items Unchecked

* Omission to check any one of these items would constitute the learner / operator not being yet competent of the Pre-start checks and Preoperational
test.

THEORY TEST QUESTIONS (group )
1 4
2 5
3

Penalties
Total items unchecked from Pre-start and Operational Assessment:
: x2 = *
* Maximum 20 penalties

TOTAL PRE-START AND PRE-OPERATIONAL PENALTIES

PRACTICAL OPERATING ASSESSMENT
(Delete items not specific to the test machine)
Penalties
Forks Bind on Entry/Vithdrawal -:x5=
Forks not central under Load -:x5=
Load not at Heel of Forks -:x5=
StacWDe-stack with Mast Tilted -:x5=
Fails to StacWDe-stack Correctly -:x5=
Fails to Apply ParWHandbrake -:x5=
Fails to Place in Neutral -:x5=
Fails to Position Mast for Travel -:x5=
Fails to Position Forks for Travel -:x5=
Places Body Outside Cabin -:x5=
Bump Side of Course -:x10=
Fails to Look in Direction of Travel -:x5=
Selects Wrong Control / direction -:x10=
Shunts to Stack / Un-stack -:x1=
Shunts to negotiate Chicane -:x1=
Fails to Release ParWHandbrake -:x5=
Fails to hold steering wheel during travel -:x10=
Shunts to Stack / Un-stack -:x5=
Shunts to negotiate Chican -:x5=
Fails to Release ParWHandbrake -:x5=
Fails to hold steering wheel during travel -:x5=
Accelerates erratically -:x1=
Brakes erratically -:x3=
Uses Controls roughly -:x5=
Hands on Controls -:x5=
   
CLOSE DOWN CHECKS (PARK)  
Fails to Place in Neutral -:x2=
Fails to Set Park Brake -:x2=
Fails to Set Mast and Forks -:x2=
Fails to Shut off Gas -:x2=
Fails to Operate Diesel Cut Out -:x2=
Fails to Switch Off -:x2=
Fails to Remove Key -:x2=

2 TOTAL OPERATING AND CLOSE DOWN PENALTIES

TIME PENALTIES

The assessor is to complete the course to establish a fair time (minimum 15
minutes) and then add 50% to establish the maximum time to complete the
operational and close down (park) assessment.
Maximum time permittedMinutesSeconds
Duration of operating assessmentMinutesSeconds

3 TIME PENALTIES (5 penalties for every 60 seconds above the maximum)


Summary of Penalties

1 PRE-START AND PRE-OPERATIONAL
2 OPERATING AND CLOSE DOWN
3 TIME
   
TOTAL PENALTIES

Note
The total penalties for competency should not exceed 50% of the sum of the
duration of the operational and close down (park) assessment in minutes,
multiplied by 6. i.e. maximum time permitted = 20 mins X 6 = 120 X 0.5 = 60

Result:
COMPETENT NOT YET COMPETENT

Assessor: Registration No:
Signature: Date:

I the undersigned acknowledge that the process and results were explained to me and I accept the outcome of the assessment.

Signature/Mark of Learner:


APPENDIX 8 :
ACCREDITED PROVIDERS FACILITIES RETURN

FACILITIES CHECK SHEET (Appendix 8)
The accredited provider is to complete this document, to record and describe any premises at which certification is offered that has not been inspected and approved by the accreditation issuing authorised body ie client’s premises
  Question Remarks
1 Full physical address details of
the premises, including name of
organisation, street address,
suburb/industrial area, city/ town
and the location of the practical
training / test route area at
premises
 
2 Lifting machine code/s and
description/s for which training is
offered at the premises
 
3 Description of equipment used and identification number of equipment  
4 The lifting machine capacity or
rating
 
5 Description of any attachments
fitted to the lifting machine
 
6 A general description of the
duration training, re-certification
done and test route used at the premises
 
7 Describe any limitations to the
training and test route that may
deviate from the standard routes
set out in the code of practice for
a specific lifting machine code
 
8 Describe any inherent dangers
prevalent in the use of the lifting
machine at the premises.
 
  Signature of Client Signature of facilitator


APPENDIX 9 :
ACCREDITED PROVIDERS FACILITIES CHECK SHEET


PROVIDER :
Address:
Postal Code:
Managerial Representative:
Telephone No:

Learninn Programmes Offered Codes Reqistration No.







List and Addresses of Satellite or "In House" Centres







Facilities
Lecture Rooms No Size
Seating Flipcharts
V.C.R.’s O/H Projector
Othorator Simulator (optional)
Plan of Test Area Yes/No
Area for TestingmXm
Covered/Open
Noise levelDistractions
Rest RoomsAblution Facilities
Access to the above-mentioned Equipment:


ForkliftTrucks Cranes
Pallets Slings
Racking Chains
Containers Dummy loads
Ramps Crates
Dock levellers Steel Sections
Box Cars Attachments

Administrative

Attendance Register
Training Records
Register of Learners

Registration Certificates of Training Centre

Registration Certificates of Facilitators/Assessors

Registration Certificates of Courses

Insurance Indemnity (optional)

Recommendation of Auditor







Signed Date

Approved by Date

Confirmed with Department of Labour Date


APPENDIX 10:
The following legislation and definitions relate to to this Cope of Practice

Occupational Health and Safety Act,1993 (Driven Machinery Regulations.)
Regulation 18 (1 1)


The user shall ensure that every lifting machine is operated by an operator
specifically trained for a particular type of lifting machine: Provided that in the case of a lift truck with a lifting capacity of 750 kg or more and jib-cranes with a lifling capacity of 5000 kg or more at minimum jib radius, the user shali not require or permit any person to operate such a lifting machine unless the operator is in possession of a certificate of training, issued by a person or organization approved for the purpose by the Chief Inspector.

[Date effective 01 October 1993 - G.N.R.2483 of 4 September 1992]

DEFINITIONS
Lifting Machine means a power-driven machine designed and constructed for
raising or lowering a load or moving it in suspension, and includes a block and
tackle, hoist, crane, lift truck orjib crane, but does not include an elevator,
escalator, goods hoist or builders hoist.

Jib crane means any crane of which the load is supporfed by a projecting
horizontal or inclined member, known as a jib.

Lift truck means a mobile lifting machine but does not include-
(a) a vehicle designed solely for the purpose of lifting or towing another vehicle;
(b) a mobile earthmoving machine; or
(c) a vehicle designed solely for the removal of a waste bin;

Lifting Tackle means chain slings, rope slings, hooks, shackles, swivels, spreaders or similar appliances.

APPENDIX 11 :
MANAGERIAL RESPONSIBILITIES


1. The person legally responsible for ensuring that the provisions of the
Occupational Health and Safety Act and Regulations of 1993 are implemented
on behalf of the employer is the Chief Executive Officer (C.E.O.).

2. In the case of a company without a board of directors or a closed corporation, the Owner will be the C.E.O.

3. In the case of a State department, the C.E.O. is the Director-General, not the
Minister. [Section 76 offhe OHS Act, 1993].

4. It is therefore incumbent upon the C.E.O. that proper information, instructions, training and supervision, as far as practicable are provided for the health and safety of employees. [Section 8 (e) of the OHS Act, 1993].

5. The necessary enforcement measures to assure the health and safety of
employees are effected through a chain of command structure.

6. All lifting machine operators must be informed about what they are allowed to do. [Secfions 8(j) and Section 37(1)(b)].

7. The C.E.O. must ensure that a health and safety management system is in
place to give effect to the provisions of the Act and regulations.

8. Anyone delegated by the C.E.O. to perform certain duties regarding
information, instructions, training and supervision for employees, through the
management chain of command structure and who omits to do so is
contravening the Act and regulations and may be prosecuted.

APPENDIX 12: ILLUSTRATIONS OF LIFTING MACHINE CODES

CODE DESCRIPTION

 

 
 
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