IGC2 - Element 2 Manual and Mechanical Handling (1st Ed) v.1.0

NEBOSH International General Certificate
Copyright RMS Publishing IGC First Edition - IGC2 Element 2 - v.1.0 - Slide 1 860409
Licence details
RMS Publishing Limited Victoria House, Lower High Street, Stourbridge DY8 1TA ACT Associates Limited. First Edition September 2007. All rights reserved. No part of this presentation may be stored in a retrieval system, reproduced, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without either the prior written permission of the Publishers. This presentation may not be lent, resold, hired out or otherwise disposed of by way of trade in any form other than that in which it is published, without the prior consent of the Publishers. This presentation may not be reproduced in any form without prior consent of the Publishers other than a single copy thumbnail handout for immediate use by the tutor. Whilst every effort is made to ensure the completeness and accuracy of the information contained herein, RMS/ACT can bear no liability for any omission or error.
Issued to: Strabag Single Licence Licence No: 860409

Unit IGC2 Control of International workplace hazards

Element 2
Manual and mechanical handling hazards and control

Manual & mechanical handling hazards & control
Learning outcomes
2.1 Describe the hazards and risk factors which should be considered when assessing risks from manual handling activities 2.2 Suggest ways of minimising manual handling risk 2.2 Identify the hazards and explain the precautions and procedures to ensure safety in the use of lifting and moving equipment with specific reference to fork-lift trucks, manually operated load moving equipment (sack trucks, pallet trucks), lifts, hoists, conveyors and cranes
Contents of element
2.1 2.2 2.3 Manual handling hazards and risks Minimising manual handling risks Safety in the use of lifting and moving equipment
Contents of element
Manual & mechanical handling hazards & control Manual handling hazards and risks
Common types of manual handling hazards and injuries

Stooping while lifting Holding the load away from the body Twisting movements Frequent or prolonged effort Heavy / bulky / unwieldy / unstable loads Sharp / hot / slippery surfaces of loads Space constraints Lack of capability of the individual
Common types of manual handling hazards and injuries

Rupture of intervertebral discs Muscle strain and sprain Torn or stretched tendons / ligaments Rupture of the abdominal wall (hernia) Cuts from sharp edges Bruises, fractures and cuts from dropped loads
Source: RMS Publishing
The assessment of manual handling risks

Load Individual Capability Task Environment RememberL I T E

Level of Risk: FACTORS Load QUESTIONS Is it: Heavy? Bulky or Unwieldy? Difficult to grasp? Unstable, or with contents likely to shift? Sharp, hot or otherwise potentially damaging? Does the job: Require unusual strength, height, etc.? Create a hazard to those who have a health problem? Require special knowledge or training for its safe performance? High Med Low
Individual Capability
Task
Does it involve: Holding load at distance from central body area? Unsatisfactory bodily movement or posture? Twisting the central body area. Stooping. Excessive movement of load? Excessive lifting or lowering distances. Excessive pushing or pulling distances. Risk of sudden movement of load. Frequent or prolonged physical effort. Insufficient rest or recovery periods.
Are there: Space constraints preventing good posture? Uneven, slippery or unstable floors? Variations in level of floors or work surfaces? Extremes of temperature, humidity or air movement? Poor lighting conditions?
Source: HSE Guidance L23
Working Environment
Sample manual handling risk assessment form Copyright RMS Publishing IGC First Edition - IGC2 Element 2 - v.1.0 - Slide 12 860409

Reduction of handling capability as the hands move away from the central body area
Source: HSE Guidance L23

The load Individual capability The task The working environment Reviewing assessments
Contents of element
Manual & mechanical handling hazards & control Minimising manual handling risks
Means of minimising risks from manual handling

General approach
Load Lighten, reduce in size, provide handles, eliminate sharp edges Address individual factors, train, provide PPE and clothing Redesign tasks, reduce manual handling tasks, mechanise, team lift, rotation Improve floor conditions, temperature, lighting, space
Individual
Task
Environment

Minimising the risk from manual handling Each manual handling operation should be examined and appropriate steps taken to minimise the risk of injury to the lowest level reasonably practicable in order to eliminate the potential of Musculoskeletal Disorder (MSD) degeneration Manual handling should be replaced or reduced by using mechanical handling aids

Mechanical assistance Levers Hoists Trolley, sack truck, truck roller or hoist Chutes Handling devices

Ergonomic approach (human physical and mental ability) Manual handling operations Task Load Working environment Individual capability View to fitting the operation to the individual rather than the other way round

Involving the workforce Effort should be made to seek contributions from workers Safety representatives or representatives of employee safety

Training
Training programme Recognise the hazard Assess unfamiliar loads Correct use of handling aids Choice of PPE Environmental factors Housekeeping Individual capability Correct handling techniques

Design, Automation / Mechanisation Workplace and workstation design Consider if the workplace: Suits the employee Has adequate space Work heights are matched or adjustable Has back support and leg room

Frequently used objects should be stored in the A zone
Source: www.comcare.gov.au.

Design, Automation / Mechanisation Workplace and workstation design Prevent excessive bending of the back Many jobs have combinations of risky movements Loading a machine from a bin on the floor combines: - Sidestepping - Twisting - Low lifting - Reaching

Kinetic lifting - how not to do it!
Source: Ambiguous.

Design, Automation / Mechanisation Remember: Pulling is more efficient than pushing where body weight is used Pulling up is stronger than pushing down when standing Pulling/pushing is more efficient if applied at or around waist level Pulling/pushing capacity is significantly reduced when the limbs are in extreme positions Controls requiring large forces should be operated by foot or by power aided hand controls

Design, Automation / Mechanisation Remember: Precision work: bench just above elbow height Light work: bench just below elbow height Heavy work: bench near hip height

Work bench heights

Work bench heights

Mechanical Aids Using a forklift to move a drum eliminates the manual handling required An electrically operated vacuum lifter eliminates the heavy lifting Ingredients can be put into a hopper then lifted by a hoist

Using a forklift to move a drum eliminates the manual handling required

An electrically operated vacuum lifter eliminates the heavy lifting The mechanical arm is guided by the employee

Ingredients can be put into a hopper then lifted by a hoist
Techniques for manually lifting loads

Lifting techniques using kinetic handling principles
1. Stop and think 2. Place the feet 3. Adopt a good posture 6. Move the feet 7. Keep close to the load
5. Dont jerk 4. Get a firm grip

Source: RMS Publishing Copyright RMS Publishing IGC First Edition - IGC2 Element 2 - v.1.0 - Slide 34 860409
8. Put down, then adjust

Lifting techniques using kinetic handling principles Putting it all into practice Poor posture Repetitive movements Awkward movements

Lifting techniques using kinetic handling principles Putting it all into practice Load between the feet Keep back straight Ensure palm, not fingers, take the weight Arms close to body Bend knees

Lifting techniques using kinetic handling principles Always remember: Assess the load Lift the load smoothly - do not jerk Avoid twisting and stretching

Lifting techniques using kinetic handling principles Poor posture Greatly increases likelihood of a manual handling injury Many construction tasks can cause poor posture e.g. laying a floor Ideal position for manual handling is waist height whilst standing

Lifting techniques using kinetic handling principles Repetitive movements Avoid need to lift heavy items by reducing loads and packaging into smaller weights Increases frequency Injuries occur over a period of time as a result of performing tasks repeatedly Regular breaks Job rotation Mechanical assistance

Lifting techniques using kinetic handling principles Awkward movements Avoid stretching Avoid bending at the waist Avoid twisting Avoid lifting whilst seated Avoid sudden movement Avoid jerky movements Can lead to cumulative strain
Contents of element
Manual & mechanical handling hazards & control Safety in the use of lifting and moving equipment
Fork lift trucks (FLT)

Fork lift truck hazards 20 deaths and 5000 injuries Injuries to driver 40% Injuries to assistant 20% Injuries to pedestrians 40%
Fractures Injury to ankle & feet
80% 60%
Source: Corel Clipart

Hazards Overturning Driving too fast Sudden braking Driving on slopes Driving with load elevated

Hazards Collisions With buildings With pedestrians With other vehicles

Hazards Loss of load Insecure load Poor floor surface Passengers should not be carried

Hazards Overloading Exceeding maximum capacity

Hazards Failure Load bearing part (e.g. chain)

Safe use and maintenance Selection of equipment Industrial counterbalance lift truck Industrial reach truck Rough-terrain counterbalance lift truck Telescopic materials handler Side-loading lift truck Pedestrian-controlled lift truck Large lift truck

Selection of equipment Many types of truck for a range of activities Specialist trucks e.g. reach trucks, overhead telescopic, rough terrain trucks Accidents occur due to incorrect selection or use

Industrial counterbalance lift truck This has a counterweight to balance the load on the fork arms The fork arms and load project out from the front of the machine Loads can be raised or lowered vertically and the mast maybe tilted forwards or backwards up to 150 A wide range of attachments is available

Industrial counterbalance lift truck
Source: HSE Guidance HSG6.

Industrial reach truck This is so called because the mast is moved forwards or reached out to pick up the load For travelling, the load is reached back and carried within the wheelbase This allows greater manoeuvrability in areas where space is restricted

Industrial reach truck

Rough-terrain counterbalance lift truck Similar in design to the industrial counterbalanced lift truck but is equipped with larger wheels and pneumatic tyres, giving it greater ground clearance It has greater ability to operate on uneven and soft ground

Rough-terrain counterbalance lift truck
Source: HSE Guidance HSG6. Copyright RMS Publishing IGC First Edition - IGC2 Element 2 - v.1.0 - Slide 56 860409

Telescopic materials handler This is fitted with a boom that is pivoted at the rear of the machine The boom is raised and lowered by hydraulic rams The boom can be extended or retracted to give extra reach or height

Telescopic materials handler

Side-loading lift truck The operator is positioned at the front and to one side of the lift truck The load is carried on the deck, the mast being traversed out sideways to pick up or set down the load This type of lift truck is used for stacking and moving long loads

Side-loading lift truck

Pedestrian-controlled lift truck This has a limited lift height, usually not greater than two metres It may be electrically or manually powered for lifting and for traction The operator walks with the machine and controls it with a handle

Pedestrian-controlled lift truck

Large lift truck When choosing the correct truck for the job the following factors should be taken into account Power source Tyres Size and capacity Height of the mast Audible and/or visual warning systems fitted Protection provided for the operator dependent on rough terrain Training given to operators

Large lift truck

Mechanical handling equipment operators No person should be permitted to drive a forklift truck or mobile plant unless they have been: - Selected - Trained - Authorised to do so or - Have had properly organised formal training

Selection of personnel The safe use of forklift trucks calls for a reasonable degree of both physical and mental fitness and of intelligence The selection procedure should be devised to identify workers who have shown themselves reliable and mature during their early years at work

Training Stage 1: Basic skills and knowledge Stage 2: Knowledge of the operating principles and controls Use of the forklift truck in gangways, slopes etc. Work to be undertaken e.g. loading and unloading Stage 3: Further instruction in the place of work Testing Refresher training
Manually operated load moving equipment hazards

Sack truck The pallet truck
Source: Corel Clipart Copyright RMS Publishing IGC First Edition - IGC2 Element 2 - v.1.0 - Slide 68 860409
Lifts and hoists

Hazards Overturn / collapse Strike persons Failure of ropes Fall of load Stranded at height
Source: HSG150, HSE Books.
Lifts and hoists

Safe use and maintenance Movement of goods Sophisticated controls Safety devices Controls in cage Holdback gears Interlocks on doors Overrun Shaft (in building) fireproof Guards Gates
Lifts and hoists

Safe use and maintenance Safe use of lifts and hoists depends on: Adequate design Competent operation Sound construction Inspection Maintenance Installation
Conveyors
Hazards Drawing in Contact Entanglement Striking Manual handling Noise
clothing or limbs moving parts (abrasion) rolling, rotating parts falling overhead items loading or unloading mechanical movement
Conveyors
Types of conveyor The three basic types of conveyor are: Belt Roller Screw
Conveyors
Types of conveyor - belt
Source: J Ridley; Safety at Work; Fourth Edition - Courtesy HSE
Conveyors
Types of conveyor - free running rollers
Conveyors
Types of conveyor - belt driven rollers
J Ridley Safety at Work
Conveyors
Screw
Conveyors
Safe use and maintenance Fixed guards on drums Enclosure of conveyed items by side guards Trip wires, if necessary and sides un-guarded Emergency stop buttons Safe access at intervals Avoid loose clothing Restrict access Wearing bump caps Regular maintenance by competent person
Cranes
Crane hazards Overturning Overloading Collision weak support, operating outside the capabilities exceeding the operating capacity or operating radii with other cranes, overhead cables or structures structural components of the crane from failure of lifting tackle
Failure of load bearing part Loss of load -
Cranes
Crane hazards Factors which will affect all cranes: Ground condition Erecting dismantling Load Position of the crane Adverse weather conditions
Source: Core Clipart
Cranes
Safe use and maintenance General requirements for cranes Accessories Operator training and practices
Cranes
Rules for safe operation of a crane Always!! Ensure operators and slingers are trained and competent Select the right appliance and tackle for the job Ensure the appliance is stable when lifting (outriggers) Use the correct slinging methods Protect sling from sharp edges Ensure the sling is attached to the hook Ensure the load is moving at the right height and speed Use standard signals
Cranes
Rules for safe operation of a crane Never!! Drag a load or allow sudden shock loading Use equipment if damaged Exceed the safe working load Lift with sling angles greater than 120 Lift a load over workers
Requirements for lifting operations

Control of lifting operations Planned by a competent person Appropriate supervision Work carried out in safe manner

Strong, stable and suitable equipment Strength Stability Suitability

Strong, stable and suitable equipment Strength: Lifting equipment is of adequate strength and stability for each load Every part of a load and anything attached to it and used in lifting it is of adequate strength If the load to be lifted is a person, equipment with a generous capacity above the persons weight may be selected in order to provide a higher factor of safety In a lifting operation the equipment only has an overall lifting capacity equivalent to the item with the lowest strength

Strong, stable and suitable equipment Stability A number of factors can affect the stability of lifting equipment: - wind conditions - slopes/cambers - ground conditions Lifting equipment must be positioned and installed so that it does not tip over when in use Mobile lifting equipment should be sited on firm ground

Strong, stable and suitable equipment Stability Care should be taken that the equipment is not positioned over: - cellars - drains or underground cavities - or near excavations In the uphill position, the greatest danger occurs when the load is set down In the downhill position, the load moves out of the radius and may cause the equipment to tip forwards

Strong, stable and suitable equipment Stability of cranes

Strong, stable and suitable equipment Suitability Correct type for the task Safe working load limit in excess of the load being lifted Correct type and combination of lifting accessories attached Lifting equipment used within industry varies and includes: - mobile cranes - static tower cranes - overhead travelling cranes Selecting lifting equipment to carry out a lifting activity should be done at the planning stage

Positioned and installed correctly Lifting equipment must be positioned or installed so that the risk of the equipment striking a person is as low as is reasonably practicable Detailed consideration must be given to the location of any heavy piece of lifting equipment Surveys must be carried out to determine the nature of the ground and what underground hazards are present If the ground proves to be soft, then this can be covered in timber, digger mats or hard core

Positioned and installed correctly The surrounding environment must also be taken into consideration and factors may include: - Highways - Railways - Electricity cables - Areas of public interest Lifting equipment should be positioned and installed such that loads are not carried or suspended over areas occupied by workers

Positioned and installed correctly
Source: RMS Publishing Copyright RMS Publishing IGC First Edition - IGC2 Element 2 - v.1.0 - Slide 93 860409

Visibly marked Safe working load (SWL) must be clearly marked on: - Lifting machinery - Equipment - Accessories Accessories must be marked with supplementary information Equipment designed for lifting workers must be clearly marked and equipment which is not designed for lifting persons must have appropriate markings to the effect that it is not to be used for lifting workers

Planned, supervised and carried out in safe manner by competent workers Load Equipment and accessories Route Team involved Method Environment Demarcation of lift area Trial lift Completion of lift and any dismantling required

Planned, supervised and carried out in safe manner by competent workers
People involved with lifting operations Competent person Appointed to plan the operation Load handler Attaches and detaches the load Authorised person Ensure the load is safely attached Operator Appointed to operate the equipment Responsible person Communicates position of load (banksman) Assistants Appointed to relay communications

Special requirements for lifting equipment for lifting persons The employer should ensure that lifting equipment for lifting persons:
To prevent a person using it being crushed, trapped or struck or falling from the carrier To prevent so far as is reasonably practicable a person using it Has suitable devices to prevent the risk of a carrier falling Is such that a person trapped in any carrier is not thereby exposed to danger and can be freed

Special requirements for lifting equipment for lifting persons The employer should ensure that if the risk described above cannot be prevented for reasons inherent in the site and height differences: The carrier has an enhanced safety coefficient suspension rope or chain The rope or chain is inspected by a competent person every working day
The need for periodic examination / testing of lifting equipment

To ensure that damaged or dangerously worn equipment does not remain in service, all items of lifting equipment must periodically be examined by a competent person Lifting equipment exposed to conditions causing deterioration that is liable to result in dangerous situations is to be thoroughly examined regularly The term competent is generally taken to mean someone who is qualified and experienced in carrying out such examinations
Contents of element
Element 2
Manual and mechanical handling hazards and control

Unit IGC2 Control of International workplace hazards



IGC2 - Element 2 Manual and Mechanical Handling (1st Ed) v.1.0

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NEBOSH International General Certificate

Issued to: Strabag Single Licence Licence No: 860409

NEBOSH International General Certificate

Unit IGC2 Control of International workplace hazards

Manual and mechanical handling hazards and control

Manual & mechanical handling hazards & control

Manual & mechanical handling hazards & control

Manual & mechanical handling hazards & control

Common types of manual handling hazards and injuries

Common types of manual handling hazards and injuries

Source: RMS Publishing

The assessment of manual handling risks

The assessment of manual handling risks

The assessment of manual handling risks

Source: HSE Guidance L23

The assessment of manual handling risks

Manual & mechanical handling hazards & control

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Means of minimising risks from manual handling

Techniques for manually lifting loads

5. Dont jerk 4. Get a firm grip

8. Put down, then adjust

Techniques for manually lifting loads

Techniques for manually lifting loads

Techniques for manually lifting loads

Techniques for manually lifting loads

Techniques for manually lifting loads

Techniques for manually lifting loads

Manual & mechanical handling hazards & control

Fork lift trucks (FLT)

Fractures Injury to ankle & feet

Fork lift trucks (FLT)

Source: RMS Publishing

Fork lift trucks (FLT)

Fork lift trucks (FLT)

Fork lift trucks (FLT)

Fork lift trucks (FLT)

Fork lift trucks (FLT)

Fork lift trucks (FLT)

Fork lift trucks (FLT)

Fork lift trucks (FLT)

Fork lift trucks (FLT)

Source: HSE Guidance HSG6.

Fork lift trucks (FLT)

Fork lift trucks (FLT)

Source: HSE Guidance HSG6.

Fork lift trucks (FLT)