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

Copyright RMS PublishingIGC First Edition - IGC2 Element 2 - v.1.0 - Slide 1860409

NEBOSH NEBOSH International International General CertificateGeneral Certificate


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Unit IGC2Unit IGC2Control of Control of International International workplace hazardsworkplace hazards


Element 2Element 2

Manual and Manual and mechanical handling - mechanical handling - hazards and controlhazards and control


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

Learning outcomes

Manual & mechanical handling hazards & control


2.1 Manual handling hazards and risks

2.2 Minimising manual handling risks

2.3 Safety in the use of lifting and moving equipment

Contents of element






Contents of element



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

Manual handling hazards and risksManual & mechanical handling hazards & control


• 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

Common types of manual handling hazards and injuries



Load

Individual Capability

Task

Environment

Remember………L I T E

The assessment of manual handling risksManual handling hazards and risksManual & mechanical handling hazards & control


The assessment of manual handling risksLevel of Risk:

FACTORS QUESTIONS High Med Low

Load Is it: Heavy? Bulky or Unwieldy? Difficult to grasp? Unstable, or with contents likely to shift? Sharp, hot or otherwise potentially damaging?

Individual Capability

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?

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.

Working Environment

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 L23Sample manual handling risk assessment form



The assessment of manual handling risks

Source: HSE Guidance L23

Reduction of handling capability as the hands move away from the central body area



The assessment of manual handling risks

• The load• Individual capability• The task• The working environment• Reviewing assessments






Contents of element



Means of minimising risks from manual handling

General approach

Load - Lighten, reduce in size, provide handles, eliminate sharp edges

Individual - Address individual factors, train, provide PPE and clothing

Task - Redesign tasks, reduce manual handling tasks, mechanise, team lift, rotation

Environment - Improve floor conditions, temperature, lighting, space

Minimising manual handling risksManual & mechanical handling hazards & control



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

Means of minimising risks from manual handlingMinimising manual handling risksManual & mechanical handling hazards & control


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

Training



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

Design, Automation / Mechanisation




Source: www.comcare.gov.au.

Frequently used objects should be stored in the ‘A’ zone



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




Means of minimising risks from manual handlingKinetic lifting - how not to do it!

Source: Ambiguous.



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




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





• 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

Mechanical Aids



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

1. Stop and think

2. Place the feet

3. Adopt a good posture

4. Get a firm grip

5. Don’t jerk

6. Move the feet

7. Keep close to the load

8. Put down, then adjust

Lifting techniques using kinetic handling principles





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




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




Lifting techniques using kinetic handling principlesPoor 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 principlesRepetitive 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 principlesAwkward 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



20 deaths and 5000 injuries• Injuries to driver 40%• Injuries to assistant 20%• Injuries to pedestrians 40%

• Fractures 80%• Injury to ankle & feet 60%

Fork lift trucks (FLT)

Fork lift truck hazards

Source: Corel Clipart

Safety in the use of lifting and moving equipmentManual & mechanical handling hazards & control






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




• 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

Fork lift trucks (FLT)Selection of equipment



• 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

Fork lift trucks (FLT)Industrial counterbalance lift truck



Fork lift trucks (FLT)Industrial counterbalance lift truck

Source: HSE Guidance HSG6.



• 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

Fork lift trucks (FLT)Industrial reach truck



Fork lift trucks (FLT)Industrial reach 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

Fork lift trucks (FLT)Rough-terrain counterbalance lift truck



Fork lift trucks (FLT)Rough-terrain counterbalance lift truck




• 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

Fork lift trucks (FLT)Telescopic materials handler



Fork lift trucks (FLT)Telescopic materials handler




• 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

Fork lift trucks (FLT)Side-loading lift truck



Fork lift trucks (FLT)Side-loading 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

Fork lift trucks (FLT)Pedestrian-controlled lift truck



Fork lift trucks (FLT)Pedestrian-controlled 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

Fork lift trucks (FLT)Large lift truck



Fork lift trucks (FLT)Large lift truck




Fork lift trucks (FLT)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



Fork lift trucks (FLT)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



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

Fork lift trucks (FLT)Training



Manually operated load moving equipment hazards

Sack truck

Source: Corel Clipart

The pallet truck



Lifts and hoists

• Overturn / collapse• Strike persons• Failure of ropes• Fall of load• Stranded at height

Source: HSG150, HSE Books.

Hazards



Movement of goods• Safety devices• Holdback gears• Overrun• Guards• Gates

Sophisticated controls• Controls in cage• Interlocks on doors• Shaft (in building)

fireproof

Lifts and hoistsSafe use and maintenance



Safe use of lifts and hoists depends on:• Adequate design• Competent operation• Sound construction• Inspection• Maintenance• Installation

Lifts and hoistsSafe use and maintenance



Hazards • Drawing in - clothing or limbs• Contact - moving parts (abrasion)• Entanglement - rolling, rotating parts• Striking - falling overhead items• Manual handling - loading or unloading• Noise - mechanical movement

ConveyorsSafety in the use of lifting and moving equipmentManual & mechanical handling hazards & control


The three basic types of conveyor are:• Belt• Roller• Screw

ConveyorsTypes of conveyor



Types of conveyor - belt

Conveyors

Source: J Ridley; Safety at Work; Fourth Edition - Courtesy HSE



Types of conveyor - free running rollers

Conveyors

Source: J Ridley; Safety at Work; Fourth Edition - Courtesy HSESource: J Ridley; Safety at Work; Fourth Edition - Courtesy HSE



© J Ridley – Safety at Work

Types of conveyor - belt driven rollers

Conveyors





Screw



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



Crane hazards• Overturning - weak support, operating

outside the capabilities• Overloading - exceeding the operating

capacity or operating radii• Collision - with other cranes, overhead

cables or structures• Failure of load bearing - structural components of

the part crane • Loss of load - from failure of lifting tackle

CranesSafety in the use of lifting and moving equipmentManual & mechanical handling hazards & control


Crane hazards

Factors which will affect all cranes:• Ground condition• Erecting dismantling• Load• Position of the crane• Adverse weather conditions

Cranes

Source: Core Clipart



• General requirements for cranes• Accessories• Operator training and practices

CranesSafe use and maintenance



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



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

• Planned by a competent person• Appropriate supervision• Work carried out in safe manner

Control of lifting operations



Requirements for lifting operationsStrong, stable and suitable equipment

• Strength• Stability• Suitability




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 person’s 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




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




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




Stability of cranes





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



Requirements for lifting operationsPositioned 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




• 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







Requirements for lifting operationsVisibly 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



• Load• Equipment and accessories• Route• Team involved• Method• Environment• Demarcation of lift area• Trial lift• Completion of lift and any dismantling required

Requirements for lifting operationsPlanned, supervised and carried out in safe manner by

competent workers



Requirements for lifting operations

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

Planned, supervised and carried out in safe manner by competent workers



Requirements for lifting operationsSpecial requirements for 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

The employer should ensure that lifting equipment for lifting persons:



Requirements for lifting operationsSpecial requirements for lifting equipment for lifting

persons

• 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 employer should ensure that if the risk described above cannot be prevented for reasons inherent in the site and height differences:



• 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

The need for periodic examination / testing of lifting equipment






Contents of element



Element 2Element 2

Manual and Manual and mechanical handling - mechanical handling - hazards and controlhazards and control


Unit IGC2Unit IGC2Control of Control of International International workplace hazardsworkplace hazards



Documents

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