If only pickups and vans could fly: Vehicle maintenance and the challenge of safely lifting large vehicles on a two-post lift

The use of automotive lifts requires mechanics to work under or near a multi-ton load. Based on consultation with stakeholders, pickups and vans appear to pose problems when raised using two-post above-ground lifts (2PAG lifts), the most common type of automotive lift in garages. The aim of this article is therefore to highlight the work activity performed by mechanics when raising pickups and vans on 2PAG lifts and to describe the factors they take into account to ensure vehicle stability. Data collection took place under actual conditions in five garages. A total of 108 lifting situations were filmed and analyzed, of which nine involved pickups and vans. Using a multidisciplinary ergonomic-engineering approach, the field results were then discussed and compared with measures obtained previously in a controlled environment. The indicators of difficulty identified during the lifting were more prevalent for pickups and vans (89%) than for other vehicle categories (59%). In addition, the total capacity of the lift appears to be an insufficient indicator of safety for this type of vehicle. For example, due to lift-vehicle geometry, the rear lift arms could support around 70% of the total load when a pickup is loaded in the cargo area, with each rear arm potentially exceeding 25% of the lift’s rated capacity. Also, lifting points usually creates a rear overhang that induces rocking, generating load fluctuations of up to 510 kg-force on the front support pads. Recommendations are made for vehicle manufacturers and 2PAG lift manufacturers, as well as for garage personnel. • Pickups and vans present a specific stability challenge when using two-post lifts. • Experimental and field methodologies were used to address the issue. • Lift capacity is an insufficient safety indicator for pickups and vans. • Avenues for prevention are proposed for the various stakeholders involved.