In this article
What are FOPS?
FOPS Legislation
Not all FOPS are the same
Which level of FOPS does my machine require?
How do I know what level FOPS my machine has?
How Ideagen Plant Assessor helps to simplify the process
Summary
What are FOPS?
FOPS stands for falling object protective structure. FOPS are operator protective devices designed to protect operators from items that may fall on a piece of earthmoving (or other) machinery when being operated.
Australian Workplace Health & Safety (WHS) legislation mandates the use of the risk assessment process to manage the risks of things falling on operators of powered mobile plant and machinery, and specifically identifies the need to consider the use of operator protective devices in doing so.
FOPS Legislation
The original WHS legislation contained a specific mandatory requirement for a roll-over protective structure (ROPS) and a falling objects protective structure (FOPS) on all types of earth-moving equipment (specified in Regulation 217) and expanded the definition of ‘earth-moving equipment’ to include a wider variety of gear.
Regulation 217 has since been repealed - and while making sense to do this, the downside consequence of this decision was that it put a much heavier onus back upon the risk assessment process. It means that a machinery risk assessment must be undertaken in order to decide whether or when it is necessary to fit FOPS, and to what specification.
This process in itself requires quite a bit of technical knowledge for the person conducting the risk assessment.
Not all FOPS are the same
There are two different levels - level 1 FOPS and level 2 FOPS.
The recognised standard to define the performance requirements for FOPS is ISO 3449:2020 Earth-moving machinery – Falling object protective structures. This standard is referenced in AS 2294.1-1997 Earthmoving machinery – Protective structures general.
ISO 3449 states the following:
- Level 1 impact protection: Impact strength for protection from small falling objects (e.g. bricks, small concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and other construction site services
- Level 2 impact protection: Impact strength for protection from heavy falling objects (e.g. trees, rocks) for machines involved in site clearing, overhead demolition or forestry
ISO 10262:2020 Hydraulic excavators – Operator protective guards includes the same definitions with the exception that excavators under 6000kg are exempt from the requirements of level 2 FOPS.
Which level of FOPS does my machine require?
The practical application is as per these written requirements - that is, it is decided by the task the machine is being used for that will determine the level of FOPS required. Most machines only require a level 1 FOPS.
The following types of machines require a level 2 FOPS:
- Demolition machines
- Forestry machines
- Earthmoving machines used to excavate rock vertically
- Tunneling and underground mining machinery
How do I know what level FOPS my machine has?
It is a requirement of ISO 3449 that each FOPS is labeled with the performance requirements that the structure meets. Therefore, your machine should have marked somewhere on the compliance plate on the structure a reference to ISO 3449 and the level that it meets. If there is no level specifically mentioned, then it is safer to assume it is a FOPS level 1.
Most machines requiring a FOPS also have a roll-over protection structure (ROPS). The ROPS normally incorporates the FOPS. As the labeling requirements for each standard are similar, and they are often in the one structure, and the information is usually on the same compliance plate on the structure.
How Ideagen Plant Assessor helps to simplify the process
Ideagen Plant Assessor have simplified the risk assessment process in regards to technical aspects, making it much easier for inspectors using our software to get it right.
Firstly, we only apply the FOPS questions to the types of equipment that can have the structure - meaning you will not see a FOPS question applied to, for example, a vibrating roller or a paving machine. Then we apply the appropriate questions and provide the right supporting information to allow an inspector to determine the need for a FOPS and the type of FOPS fitted.
Below we outline the FOPS questions, and the relevant information included in the Ideagen Plant Assessor risk assessment, if a FOPS is confirmed present by the inspector:
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Is this item of plant fitted with a falling objects protective structure (FOPS) to ISO 3449 level 1 or ISO 10262 level 1?
- Answer YES if compliance plate states compliance to ISO 3449 or ISO 10262 but not a level
- Answer NO if no FOPS is fitted
- Answer N/A if level 2 FOPS
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To answer this question, you will need to locate the compliance plate which will be attached somewhere on the structure.
Level 1 FOPS - risk information included in an Ideagen Plant Assessor report:
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This item of plant is fitted with a level 1 falling objects protective structure (FOPS). This structure is designed to protect the operator from small falling objects (e.g. bricks, small concrete blocks and hand tools).
Before operating this item of plant, a task-based risk assessment must be conducted to determine the level of FOPS required.
- Level 1 – withstands 1,365 joules (e.g. 20kgs @ 7m drop, 70kgs @ 2m drop) – operations such as highway maintenance, landscaping, and other construction site services
- Level 2 – withstands 11,600 joules (e.g. 200kgs @ 6m drop, 394kgs @ 3m drop) – operations such as site clearing, overhead demolition or forestry
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To answer this query, you will need to locate the compliance plate which will be attached somewhere on the structure.
Level 2 FOPS – Ideagen Plant Assessor question:
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Is this item of plant fitted with a falling objects protective structure (FOPS) to ISO 3449 level 2 or ISO 10262 level 2?
- Answer N/A if no FOPS or level 1 FOPS
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As with the level 1 FOPS question, you will need to locate the compliance plate to answer this question.
Level 2 FOPS – risk information included in an Ideagen Plant Assessor report if FOPS present:
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This item of plant is fitted with a level 2 Falling Objects Protective Structure (FOPS). This structure is designed to protect the operator from heavy falling objects (e.g. trees, rocks).
Care should still be exercised when operating in an area with a risk of falling objects.
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Summary
Operator protective guards, and in particular FOPS, is a relatively complex area of machinery safety. Hopefully, the information above will assist you to understand and manage this key area, and how Ideagen Plant Assessor can help simplify the process for you.
Disclaimer: This information is intended to provide general information on the subject matter. This is not intended as legal or expert advice for your specific situation. You should seek professional advice before acting or relying on the content of this information.
By Founder Paul Dean
Originally published September 2022
Updated July 2024
About the Author
Paul Dean is the Founder of Ideagen Plant Assessor. Paul spent 10 years working in the construction industry, and 5 years in the machinery supply industry where he developed a deep knowledge about mobile plant and machinery compliance. Pauls idea for Plant Assessor was created in 2004 after working in the motor vehicle and machinery auction industry and realising the complexity and lack of standardisation when managing machinery and equipment compliance. Read More.
