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MATERIAL HANDLING RISK ASSESSMENT

RA DESCRIPTION

Material Handling

PROJECT

NDIA Pasenger Terminal

LOCATION

CP 18 Work Areas

DATE: 23-02-12

RISK ASSESSMENT TEAM


NAME

DESIGNATION

Risk Assessment for material handling


Rev No.: Revision 0

SITE REPRESENTATION
SIGNATURE

Page 1 of 15

NAME

DESIGNATION

Date: 20/09/2012

SIGNATURE

DESIGNATION
R/A ORIGINATOR

INITIALS & SURNAME

APPROVED
N/A

Goutam Sarkar

CONTRACT MANAGER
SAFETY MANAGER

Rahman Majumder

OBI REPRESENTATIVE.

YES

NO

YES

NO

YES

NO

SEVERITY

CONSEQUENCE RATING

CATASTROPHIC

5
4
3
2
1

10
8
6
4
2

15
12
9
6
3

20
16
12
8
4

25
20
15
10
5

VERY
UNLIKELY

UNLIKELY

LIKELY

VERY LIKELY

ALMOST
CERTAIN

CRITICAL
SERIOUS
MEDIUM
MINIMAL

LIKELYHOOD
IF NOT
CONTROLLED

COMMENTS

SEVERITY OUTCOME

5
4
3
2
1

FATALITY
MAJOR INJURY / ILLNESS
SERIOUS INJURY / ILLNESS
MINOR INJURY / ILLNESS
NONE OR SMALL FA

RISK RANKING (RR) / PRIORITY FACTOR


POTENTIALLY MINOR / ACTION TO BE TAKEN WITHIN 7 DAYS
SCORE
1-2
POTENTIALLY SERIOUS / ACTION TO BE TAKEN WITHIN 48 HRS
SCORE
3 -6
POTENTIALLY MAJOR / ACTION TO BE TAKEN WITHIN 12 HRS
SCORE
7 - 10
POTENTIALLY CATASTROPHIC / ACTION NEEDED IMMEDIATELY
SCORE
11 - 25

Risk Assessment for material handling


Rev No.: Revision 0

Page 2 of 15

Date: 20/09/2012

RATING
L
M
H
H+

RISK ASSESSMENT
No

TASKS / ACTIVITY

1.

Off loading of glass


crates from flatbed
trailer for storing in
warehouse

HAZARD AND
RISK IDENTIFICATION
Hit by plant and equipment
Causing injury

Load failure
Causing injury and/or
property damage
Toppling of forklift/
telescopic handler
Poor visiblity of operator
Broken Crate

Worst
case
Rating
L S R
3 4 12

EH
S

HS

STARRT briefing
Reverse alarm
Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision

HS

STARRT
Inspection of lifting equipments
Lift plan
Competent rigger
Third party certified operators
Exclusion zone
Banksman
Adequately secured load
Suitable weather condition (wind)
Leveled and firm ground surface
Supervisor and operator must know the weight of the load
before unloading
Broken crates to be additionally supported before
unloading

10

15

PREVENTATIVE & CONTROL MEASURES

2.

Offloading glass
panels from broken
crates

Tilting and falling of glass


crate
Sliding glass panels

12

HS

3.

Transportation
(including loading
and offloading) of

Load failure
Sliding and falling of crates

12

HS

Risk Assessment for material handling


Rev No.: Revision 0

Page 3 of 15

STARRT
Adequate and competant supervision
Use pnumetic glass sucker to handle glasses
Stabilizing crates by additional supports
Secure glassess
Group handling
Eqipment daily check
Inspection of glass suckers by competant person
STARRT
Inspection of lifting equipments
Date: 20/09/2012

Controlled
Rating
L S R

No

TASKS / ACTIVITY

HAZARD AND
RISK IDENTIFICATION

Worst
case
Rating
L S R

EH
S

PREVENTATIVE & CONTROL MEASURES

glass crates to site

4.

5.

Opening of glass
crates in warehouse
for segregation of
glass

Transportation of
segregated glass to
site and offloading

Fall of crates & fall


of glass

Fall of glass

15

12

HS

Transportation of
segregated glass to
work location
(manual)

Manual task
Uneven/
obstructed surface
Slip from hand

HS

7.

Storage of loose
glasses on site

Fall of glass
Glass hit by
moving plant and
equipment

HS

Risk Assessment for material handling


Rev No.: Revision 0

Lift plan
Competent rigger
Third party certified operators
Exclusion zone
Banksman
Restraining of load
Maintain load capacity of boom truck
Adequate and competent supervision (if training required
it should be covered)

STARRT briefing
Placement of glass crates on firm and level ground
Incline glass crates at an angle (at least 5 degree)
opposite to the side being opened
Structure to support against the inclination
Trained and competent workers
Adequate supervision
Use of glass sucker
Appropriate PPE
Place on A Frame for storage
Load glass secured on A frame
Third party cerfication required for A frame if being
handled by crane
Exclusion zone
Competent Rigger / Banksman
Lift plan
STARRT
Assessmnet of load prior to work
Assessment of movement surface prior to work
Group / machanical shifting if required
PPE
Locate store area away from work activity
Store segregated glass only on A frame
Secure storage area with barricade
Place warning signage

HS

6.

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Date: 20/09/2012

Controlled
Rating
L S R

10

No

TASKS / ACTIVITY

8.

Off loading of
gypsum board
bundle for storage
in laydown

9.

Transportation of
gypsum boards to
site by boom truck
and offloading by
forklift

HAZARD AND
RISK IDENTIFICATION
Glass hit by
pedestrians
Hit by plant and
equipment
Load failure

Load failure
Hit by plant and
equipment

Worst
case
Rating
L S R

EH
S

15

HS

12

HS

PREVENTATIVE & CONTROL MEASURES

Controlled
Rating
L S R

10

STARRT
Align container base with the ramp
Competent forklift operator
Banksman
Reverse alarm & light
Daily checklist completed ( equipment)
Use lifting equipment and accessories appropriate for
weight been lifted
STARRT briefing
Reverse alarm
Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Restraining of load
Maintain load capacity of boom truck
Adequate and competent supervision (if training required
it should be covered)
Inspection of lifting equipments
Lift plan

10. Transportation of
gyspum boards to
work location by
trolley

Toppling of trolley
Trolley run away
Hit permanent
structure
Pinch points
Uneven surface
Interfce with
electrical cables

12

HS

STARRT
Assessment of the load and weight
Use of appropriate trolley
Assessment of load balance
Assessment of material shiftment route
Adequate number of personal
Appropriate PPE
Watchman

11. Off loading

Hit by plant and

12

HS

STARRT briefing

Risk Assessment for material handling


Rev No.: Revision 0

Page 5 of 15

Date: 20/09/2012

No

TASKS / ACTIVITY

HAZARD AND
RISK IDENTIFICATION

ceiling/roof panels
from
container/flatbed
truck for storage in
loaydown

Worst
case
Rating
L S R

EH
S

PREVENTATIVE & CONTROL MEASURES

equipment
Load failure

12. Transportation of
ceiling/roof panels
to site

Load failure
Sliding and falling of panels

Reverse alarm
Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Restraining of load
Maintain load capacity of boom truck
Adequate and competent supervision (if training required
it should be covered)
Inspection of lifting equipments
Lift plan

12

HS

STARRT
Inspection of lifting equipments
Lift plan
Competent rigger
Third party certified operators
Exclusion zone
Banksman
Restraining of load
Adequate and competent supervision (if training required
it should be covered)

STARRT
Assessmnet of load prior to work
Assessment of movement surface prior to work
Group / machanical lifting if required
PPE
STARRT
Align container base with the ramp
Competent forklift operator
Banksman
Reverse alarm & light
Exclusion zone

13. Transportation of
ceiling/roof panels
to work location
(manually)

Manual task
Uneven/
obstructed surface

HS

14. Off loading of


stones/tiles from
container

Hit by plant and


equipment
Load failure

12

HS

Risk Assessment for material handling


Rev No.: Revision 0

Controlled
Rating
L S R

Page 6 of 15

Date: 20/09/2012

No

TASKS / ACTIVITY

HAZARD AND
RISK IDENTIFICATION

Worst
case
Rating
L S R

EH
S

PREVENTATIVE & CONTROL MEASURES

Daily checklist completed ( equipment)

Controlled
Rating
L S R

15. Transportation of
stones/tiles to site
by boom truck and
offloading by forklift

Load failure
Hit by plant and
equipment

15

HS

STARRT briefing
Reverse alarm
Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Restraining of load
Maintain load capacity of boom truck
Inspection of lifting equipments
Lift plan

10

16. Transportation of
stones / tiles to
work locations by
jack pallets

Sliding of load
Failure of hydrolic
control
Uneven /
obstructed shifting
routes
Run away from
ramp

12

HS

17. Off loading of steel


frames/GI channels
from open top
container/ flatbed
trailer

Fall from height (


from top of
container)
Hit by plant and
equipment
Load failure

15

HS

10

18. Transportation (
including loading

Load failure
Hit by plant and

STARRT
Assessment of the load and weight
Use of appropriate jack pallet / trolley
Assessment of load balance
Assessment of material shifting route
Adequate number of personal
Appropriate PPE
Watchman
Wooden angle stand for handling , transporation &
storage of tiles & stones
Scheduled maintainance of equipment
STARRT
Use of secondary fall protection
Use of secured platform (Podium ladder) for opening
container top
Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Appropriate and certified lifting equipment
STARRT briefing
Reverse alarm

Risk Assessment for material handling


Rev No.: Revision 0

12

HS

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Date: 20/09/2012

No

TASKS / ACTIVITY

HAZARD AND
RISK IDENTIFICATION

and off loading by


forklift) of steel
frames/ GI
channhels to site by
boom truck

equipment

Worst
case
Rating
L S R

EH
S

PREVENTATIVE & CONTROL MEASURES

Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Restraining of load
Maintain load capacity of boom truck
Inspection of lifting equipments
Lift plan

Controlled
Rating
L S R

19. Transportation of
steel frames/GI
channhels to work
location

Toppling of trolley
Trolley run away
Hit permanent
structure
Pinch points
Uneven surface
Interfce with
electrical cables

12

HS

STARRT
Assessment of the load and weight
Use of appropriate trolley
Secured load by tying to the trolley
Assessment of load balance
Assessment of material shifting route
Adequate number of personal
Appropriate PPE
Watchman

20. Transportation of
ducts to site / work
location

Sharpe corners
Manual lifting

HS

STARRT
Assessment of load and weight
Appropriate PPE including anti abrasive gloves
Use of group lifting

21. Off loading of


conduit pipes from
container/flatbed
trailer

Hit by plant and


equipment
Load failure

12

HS

STARRT
Use of secondary fall protection
Use of secured ladder (podium)
Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Appropriate and certified lifting equipments

Risk Assessment for material handling


Rev No.: Revision 0

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Date: 20/09/2012

No

TASKS / ACTIVITY

HAZARD AND
RISK IDENTIFICATION

Worst
case
Rating
L S R
3 4 12

EH
S

HS

STARRT briefing
Reverse alarm
Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Maintain load capacity of boom truck
Inspection of lifting equipments
Lift plan

PREVENTATIVE & CONTROL MEASURES

Controlled
Rating
L S R

22. Transaportation and


offloading of conduit
pipes to site

Load failure
Hit by plant and
equipment

23. Transportation of
conduit pipes to
work location
(manually)

Sharpe edge
Manual lifting

HS

STARRT
Assessment of load and weight
Appropriate PPE including anti abrasive gloves
Use of group lifting

24. Off loading cables


from flatbed trailer
by crane

Load failure
Hit by plant and
equipment

12

HS

STARRT briefing
Banksman / Rigger
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Maintain load capacity
Inspection of lifting equipments
Lift plan

25. Transportation of
cables to site and
offloading by Boom
truck

Load failure
Hit by plant and
equipment

12

HS

STARRT briefing
Reverse alarm
Banksman
Competent workforce
Adequate supervision
Maintain load capacity of boom truck
Inspection of lifting equipments
Lift plan

26. Transportation of
cables to work

Uncontroled load
Hit pedestrian or

HS

STARRT
Isolation of the area by barricading

Risk Assessment for material handling


Rev No.: Revision 0

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Date: 20/09/2012

No

TASKS / ACTIVITY

HAZARD AND
RISK IDENTIFICATION

location by rolling of
cable drum

Worst
case
Rating
L S R

EH
S

PREVENTATIVE & CONTROL MEASURES

structures
Pinch point
Manual task

Watchman
Controlled group lifting
Trained and competent manpower
PPE

Controlled
Rating
L S R

27. Off loading panel


boards

Load failure
Hit by plant and
equipment

12

HS

STARRT briefing
Reverse alarm
Banksman
Competent workforce
Adequate supervision
Maintain load capacity of boom truck
Inspection of lifting equipments
Lift plan

28. Transportation of
panel boards to
work location by
jack pallet

Sliding of load
Failure of hydraulic
control
Uneven /
obstructed shifting
routes
Run away from
ramp

12

HS

Load failure
Hit by plant and
equipment

12

EHS

STARRT
Assessment of the load and weight
Use of appropriate jack pallet / trolley
Assessment of load balance
Assessment of material shifting route
Adequate number of personnel
Appropriate PPE
Watchman
Scheduled maintainance of equipment
STARRT briefing
Reverse alarm
Banksman
Competent workforce
Adequate supervision
Maintain load capacity
Exclusion zone
MSDS
Spill kit available
Inspection of lifting equipment

29. Off loading fire


proofing materials
by forklift
/telehandler

Risk Assessment for material handling


Rev No.: Revision 0

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Date: 20/09/2012

No

TASKS / ACTIVITY

HAZARD AND
RISK IDENTIFICATION

Worst
case
Rating
L S R
3 3
9

PREVENTATIVE & CONTROL MEASURES

Controlled
Rating
L S R

HS

STARRT briefing
Banksman
Competent workforce
Adequate supervision
Inspection of lifting equipment

12

EHS

STARRT
Assessment of the load and weight
Use of appropriate jack pallet / trolley
Assessment of load balance
Assessment of material shifting route
MSDS
Spill kit available
Adequate number of personal
Appropriate PPE
Watchman

HS

Scheduled maintainance of equipment


STARRT briefing
Banksman
Competent workforce
Adequate supervision
Inspection of lifting equipment

15

HS

STARRT briefing
Banksman / Rigger
Competent workforce
Adequate supervision
Inspection of lifting equipment
Lift plan
Completion of daily equipment checklist
Exclusion zone

10

30. Transportation of
fire proofing
materials to site by
truck

Load failure
Hit by plant and
equipment

31. Transportation of
fire proofing
materials to work
location

Sliding of load
Failure of hydrolic
control
Uneven /
obstructed shifting
routes
Run away from
ramp

32. Loading of terrazzo


sand bags on to
boom truck and
offloading of site

Load failure
Hit by plant and
equipment

33. Transportation of
terrazzo sand bags
to work location by
crane

Load failure
Hit by plant and
equipment

Risk Assessment for material handling


Rev No.: Revision 0

EH
S

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Date: 20/09/2012

No

TASKS / ACTIVITY

HAZARD AND
RISK IDENTIFICATION

Worst
case
Rating
L S R

EH
S

PREVENTATIVE & CONTROL MEASURES

Controlled
Rating
L S R

34. Transportation of
terrazzo chemical
drums to site by
truck and offloading
by forklift

Load failure /
displacement
Hit by plant and
equipment

15

EHS

STARRT briefing
Inspection of pallets integrity
Securing load with straps
Banksman
Competent workforce
Adequate supervision
Inspection of lifting equipment
MSDS
Spill kit

10

35. Transportation of
terrazzo chemical
drums to onsite
storage area/ work
location by jack
pallet

Sliding of load
Failure of hydraulic
control
Uneven /
obstructed shifting
routes
Run away from
ramp

12

EHS

STARRT
Assessment of the load and weight
Use of appropriate jack pallet / trolley
Assessment of load balance
Assessment of material shiftment route
Adequate number of personal
Appropriate PPE
Watchman
Wooden angle stand for handling , transporation &
storage of tiles & stones
MSDS & spill kit

Scheduled maintainance of equipment


STARRT briefing
Reverse alarm
Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Maintain load capacity
Inspection of lifting equipments

36. Offloading of water


proofing sheets

Risk Assessment for material handling


Rev No.: Revision 0

Load failure
Hit by plant and
equipment

12

HS

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Date: 20/09/2012

No

TASKS / ACTIVITY

HAZARD AND
RISK IDENTIFICATION

Worst
case
Rating
L S R
3 3
9

EH
S

HS

STARRT
Assessment of the load and weight
Use of appropriate trolley
Secured load by tying to the trolley
Assessment of load balance
Assessment of material shifting route
Adequate number of personal
Appropriate PPE
Watchman

PREVENTATIVE & CONTROL MEASURES

Controlled
Rating
L S R

37. Transportation of
water proofing
sheets to work
location

Toppling of trolley
Trolley run away
Hit permanent
structure
Uneven surface
Interfce with
electrical cables

38. Offloading conveyor


parts

Load failure
Hit by plant and
equipment

15

HS

STARRT briefing
Reverse alarm
Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Maintain load capacity
Inspection of lifting equipments

10

39. Transporting
conveyor parts to
site by flatbed trailer
and offloading by
crane

Load failure
Hit by plant and
equipment

15

HS

STARRT briefing
Banksman/ Rigger
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Maintain load capacity
Inspection of lifting equipments
Lift plan

10

40. Transportation of
conveyor parts to
work location by
forklift / pallet trolley

Load failure
Hit by plant and
equipment

12

HS

STARRT briefing
Reverse alarm
Banksman
Exclusion zone (authorised persons only)

Risk Assessment for material handling


Rev No.: Revision 0

Page 13 of 15

Date: 20/09/2012

No

TASKS / ACTIVITY

HAZARD AND
RISK IDENTIFICATION

Worst
case
Rating
L S R

EH
S

PREVENTATIVE & CONTROL MEASURES

Competent workforce
Adequate supervision
Maintain load capacity
Appropriate PPE
Inspection of lifting equipments

41. Off loading PCA


units

Load failure
Hit by plant and
equipment

15

HS

STARRT briefing
Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
Maintain load capacity
Inspection of lifting equipments
Lift plan

42. Shifting PCA units


to work location

Toppling of trolley
Trolley run away
Hit permanent
structure
Uneven surface

12

HS

STARRT
Assessment of the load and weight
Use of appropriate trolley
Secured load by tying to the trolley
Assessment of load balance
Assessment of material shifting route
Adequate number of personal
Appropriate PPE
Watchman

43.

Risk Assessment for material handling


Rev No.: Revision 0

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Date: 20/09/2012

Controlled
Rating
L S R

10

RISK ASSESSMENT COMMUNICATIONS FORM.


I, THE UNDERSIGNED HEREBY ACKNOWLEDGE THAT THIS RISK ASSESSMENT HAS BEEN DISCUSSED WITH ME AND THAT I UNDERSTAND THE
CONTENTS AND THE RISKS INVOLVED IN THE TASK TO BE PERFORMED. I HAVE ALSO BEEN INSTRUCTED ON THE SAFE METHODS TO
PERFORM THIS TASK.
NAME

Risk Assessment for material handling


Rev No.: Revision 0

CO. NO

SIGNATURE

NAME

Page 15 of 15

CO. NO

Date: 20/09/2012

SIGNATURE