Overview
General plant operations encompass a broad range of specialist equipment used across construction sites that falls outside the core earth-moving, lifting, piling and demolition categories. This CPD module covers mobile elevating work platforms (MEWPs), telescopic handlers, masted forklift trucks, concrete pumps, crushers, screeners, draglines, skip handlers, and loader/securer operations. Operators must hold the appropriate CPCS category card for each machine type and demonstrate current competence through the renewal test and CPD requirements.
Key Knowledge Areas
Mobile Elevating Work Platforms (MEWPs)
MEWPs are used extensively for safe working at height and fall into three main types: scissor lifts (A25), boom-type platforms (A26) and mast climbers (A27). Operators must understand the specific characteristics and limitations of each type, including maximum platform height, safe working load, wind speed limits and ground bearing requirements. Pre-use checks must cover all safety systems including guardrails, emergency lowering, outriggers and tilt sensors. The Work at Height Regulations 2005 require that MEWPs are only used when the risk assessment identifies them as the most suitable means of access.
Telescopic Handlers
Telescopic handlers (A17) are versatile machines used for material handling, and the suspended loads variant (A17E) permits lifting operations. Operators must understand the load-moment relationship — as the boom extends, the machine’s lifting capacity reduces. Stability is affected by ground conditions, gradient, boom configuration and attachment weight. Approved attachments must be used in accordance with the manufacturer’s instructions, and operators must be aware of the different operating characteristics when fitted with forks, buckets or lifting hooks.
Forklift Trucks
Masted forklift trucks (A14) are a staple of construction logistics. Operators must understand load centre distances, maximum fork height capacities, and the risks associated with travelling with raised loads. Pre-use checks must cover mast operation, fork condition, hydraulic systems and braking. Pedestrian segregation is critical in forklift operating areas, and designated traffic routes should be established and maintained.
Concrete Pumps
Both truck-mounted boom concrete pumps (A06) and trailer-mounted concrete pumps (A44) require specific operational knowledge. Operators must understand pipeline pressures, boom reach limitations, outrigger setup requirements and the hazards of concrete line blockages. Cleaning and maintenance of pipelines is a high-risk activity requiring strict adherence to safe systems of work. Proximity to overhead power lines must be assessed before deploying boom-type pumps.
Crushers, Screeners and Loading Equipment
Crushers (A42) and screeners (A43) are used for processing demolition and excavation materials on site. Operators must understand feed rates, product sizing, dust suppression requirements and the hazards associated with blocked or jammed machinery. Skip handlers (A39), loader compressors (A41) and loader/securer operators (A49/A50) handle specialist loading and transport tasks requiring knowledge of load restraint, vehicle stability and STGO regulations where applicable.
Dragline Operations
Dragline equipment (A05) is used for excavation in waterlogged or soft ground conditions where conventional excavators cannot operate safely. Operators must understand bucket control, swing radius hazards and the specific ground bearing requirements of the dragline setup.
Safety Considerations
All general plant operations require thorough pre-use checks at the start of each shift. Operators must ensure that the correct category-specific training and assessment has been completed before operating any machine. Pedestrian-plant segregation, appropriate PPE, and clear communication with ground personnel are essential across all equipment types. Risk assessments and method statements must address the specific hazards of each machine, including overhead obstructions, underground services, ground conditions, and environmental factors such as wind speed and visibility. Emergency procedures, including machine shutdown and evacuation, must be understood and practised.
Exam Tip: Questions on general plant operations often focus on the specific limitations and hazards of each machine type. Know the key safety features and pre-use check requirements for MEWPs, telescopic handlers and concrete pumps. Understand the stability factors that affect telescopic handler operations and the wind speed limits for MEWP use. For crushers and screeners, focus on blockage clearance procedures and dust suppression requirements.
