Nebosh IGC2 Part 3

CHSS Ltd 2006 Page 1 of 38
wpc/SJ/ae/IGC2 Element 3 Manual and Mechanical Handling Sales Ref: sc/639/v3

Element 3

Manual and Mechanical
Handling Hazards and
Control


Contents
Page No
Introduction 5
Manual Handling Injuries 5
Anatomy of the Back 6
Control Strategy 7
Assessment of Manual Handling Risk 8
Level of Detail 11
Who Should Assess 11
Consulting Employees 12
Recording Assessments 12
Factors to Risk Assess 13
Risk Reduction 14
Information for Workers 16
Training 16
Duties of Employees 17
Review 18
Mechanical Handling 19
Introduction 19
Conveyors 20
Types of Conveyors 20
Cranes 23
Types of Crane 23
Mobile Cranes 24
Tower Cranes 25
Gantry Cranes 26
Overhead Gantry Cranes 27
Precautions 28
Hoists 31
Types of Hoist 31
Lifting Accessories 33
Types of Lifting Accessory 33
Lifting Equipment 34
Lifting Operations 35
References 36


Introduction

Manual handling injuries cause individual suffering and are costly to organisations in
terms of disruption and lost output. More than a quarter of the reported workplace
accidents each year are associated with manual handling. The vast majority of such
handling accidents result in over 3-day injuries, most commonly a sprain or strain,
often of the back. Many musculo-skeletal problems, such as muscle strains are the
result of the cumulative effects of manual handling.

Manual handling is the:

Transporting or supporting of loads by hand or bodily force.

This includes lifting, lowering, pulling, pushing and carrying of:

N inanimate objects, e.g. bags, parcels, boxes; and

N live objects, e.g. people, animals.

Manual Handling Injuries

Manual handling injuries can be classified as follows:

N External injuries: cuts, bruises, abrasions and crush injuries to fingers,
hands, forearms, ankles and feet.

N Internal injuries: muscle and ligament strains and tears, hernias, knee, ankle
and shoulder injuries.

N Cumulative back injuries: slipped disc (prolapsed inter vertebral disc).

Additional injuries relate to the contents of the load carried, e.g. corrosive chemicals,
and are discussed in other Elements.

Figure 1: Manual Handling Injuries (reported to UK Enforcing Authority, 1998)

Figure 1 shows that back injuries cause the most significant loss of working time so
particular attention should be paid to preventing back injuries.

Anatomy of the Back

The human spine is a flexible column comprising
24 bones called vertebrae. These bones are
divided into three areas: cervical, thoracic, and
lumbar.

This structure of bones provides support and
structure to the human body.

Between each pair of vertebrae is a tough fleshy
pad of tissue called an intervertebral disc. The
discs have a fibrous outer layer and a fluid
centre. The discs act as shock absorbers,
keeping the vertebrae apart and allowing the
spine to be flexible.

If the discs are continually compressed with the
weight of loads, especially whilst bending or
twisting, a prolapse can occur. The fluid centre
bulges through the fibrous outer and becomes
misshapen or damaged. This distortion will
cause the disc to press against the nerves, which
gives rise to back pain.
Back
47%
Other
16%
Hand
6%
Upper Limb
11%
Lower Limb
5%
Finger
15%
Figure 2: Anatomy of the Spine

Figure 3: Intervertebral Discs

Disc
Vertebra
A prolapse
can
occur here

Activities likely to put people at risk include:

N work involving handling excessive loads;

N prolonged lifting or supporting of loads in fixed positions;

N repetitive handling whilst bending, stooping or reaching, particularly for
lengthy periods of time; and

N twisting the trunk or neck during the task.

Control Strategy

There is now international acceptance of both the scale of the manual handling
problem and methods of prevention. Manual handling training alone has not been
successful in reducing the risk.

Guidance - a clear hierarchy of measures is established:

N avoid hazardous manual handling where there is a risk of occupational injury,
so far as is reasonably practicable, i.e. by eliminating the need to lift loads by
automation or mechanisation, e.g. placing products on pallets which can then
be lifted with fork-lift trucks;

N assess the risk of any hazardous manual handling tasks that cannot be
avoided, so far as is reasonably practicable;

N reduce the risk of injury, so far as is reasonably practicable, by
implementing control measures by designing the task to meet the needs of
the worker, e.g. eliminating the need to twist or stoop or reach, breaking the
load into smaller, weights, etc.; and

N review the assessment.

Assessment of Manual Handling Risk

Where it is not reasonably practicable to avoid hazardous manual handling
operations at work, a detailed risk assessment should be undertaken.

An ergonomic approach is taken. Consider a range of relevant factors including the
following:

N Load;

N Individual capability;

N Task; and

N Environment.

(LITE)

An individuals state of health, fitness and strength can significantly affect a persons
ability to safely carry out certain manual handling tasks.

Physical capacity also varies with age, typically increasing until the early 20s and
gradually declining from the mid 40s. Pre-employment medical screening will
highlight any existing ill-health.

A detailed assessment of every manual handling operation could be lengthy, time
consuming, and in many cases a wasted effort, e.g. lifting a glass of cold water
involves no risk. Therefore a risk assessment guideline filter can be used to screen
out lifting operations with insignificant risk.

The guideline figures take into account:

N the weight to be lifted between foot to head level;

N whether the individual is male or female;

N whether the arms have to be extended to hold the load;

N how many lifting operations there are per hour;

N whether the individual is seated;

N how far the load is to be carried;

N whether twisting is involved; and

N whether the load is to be pushed or pulled.

Figure 4: Guideline Figures Which Trigger Manual Handling Assessment
The guideline filters are not weight limits. They may be exceeded where a more
detailed assessment shows it is safe to do so. However, normally the guideline
figures should not be exceeded by more than a factor of 2.

The guidelines are based on no more than 30 operations an hour with carrying
distance of 10 metres.

Each box in the diagram contains a guideline weight limit for lifting and lowering in
that zone. The diagram enables the assessor to take into account the vertical and
horizontal position of the hands as they move the load, the height and the reach of
the individual undertaking the task.

Twisting and Stooping

The combination of lifting and twisting, or lifting and stooping, are particularly
stressful on the back. Therefore, where a manual handling task involves twisting and
stooping, the guideline figures for lifting and lowering should be reduced as shown in
Table 1.


If person handling the load
twists / stoops through
Guideline figures given in Figure
4 should be reduced by
45
o

10%
60
o

15%
Twisting
90
o

20%

45

o

25%
60
o

35%
Stooping
90
o

50%

Table 1: Correction Factors for Stooping and Twisting

Pushing and Pulling

Guideline figures for pushing and pulling, whether the load is slid, rolled or supported
on wheels are as follows:

Pushing / pulling motion Equivalent
weight
Force
Starting or stopping a load 20 kg About 200 Newtons*
Keeping the load in motion 10 kg About 100 Newtons
The above figures assume pulling or pushing over a distance of no more than 20m
* Newton is a unit of force

Table 2: Guidelines for Pushing / Pulling

The pushing and pulling forces can be measured using a spring balance weighing
scale. This can be attached to the load (usually with a hook) and pulled.


Figure 5: Spring Balance

Level of Detail

It will be necessary to consider what tasks are undertaken to identify those which are
high risk, exceeding the guidelines filters and therefore need to be assessed first.

It is neither practicable nor necessary to conduct an individual assessment of every
single movement or operation.

Many tasks will be similar and frequently repeated. In these cases a generic risk
assessment is likely to be acceptable. In the case of delivery operations for example,
the guidance recommends listing the various types of tasks, loads and working
environment concerned, and then to propose a review of a selection of them.

The assessment should identify the problems likely to arise during the kind of
operations that can be foreseen and the measures necessary to deal with them.

On a day-to-day basis supervisors may have to make further specific judgements
when dealing with manual handling tasks. For example, in a warehouse dealing with
sacks of sand, a decision may have to be made about how to lift broken sacks to
prevent spillage and injury.

Who Should Assess?

The assessment should ideally be carried out by someone within the organisation
who has a thorough practical understanding of the manual handling taking place. In
complex or high risk cases, a team approach, possibly including a safety
professional, an industrial engineer, a supervisor and an occupational health nurse is
recommended.

Areas of knowledge required are:

N legal requirements;

N the nature of the handling operation;

N a basic understanding of human capabilities;

N identification of high risk activities; and

N practical steps to reduce risk.

Consulting Employees

Employees, health and safety representatives, and safety committees should be
encouraged to play a positive part in the assessment process. Consulting the
employees and using their own experience of the type of work performed will often
provide a valuable source of concerns, comments and suggestions.

Recording Assessments

The significant findings of the assessment should
be recorded (unless the manual handling
operations are straightforward, low risk, short
duration or could easily be repeated and
explained at any time). The record should be
kept for as long as it remains relevant.

The following template will help assessors to focus on these areas.

Factors to Risk Assess

Questions to consider Level of risk Possible remedial
action:

Yes Low Med High

Load - is it:
N Heavy?
N Bulky / unwieldy?
N Difficult to grasp?
N Unstable / unpredictable?
N Intrinsically harmful (e.g. sharp /
hot?)
Individual Capability - does the job:
N Require unusual capability?
N Hazard those with a health
problem?
N Hazard those who are pregnant?
N Require special information /
training?
Task does it involve:
N Holding loads away from trunk?
N Twisting?
N Stooping?
N Reaching upwards?
N Large vertical movement?
N Long carrying distances?
N Strenuous pushing or pulling?
N Unpredictable movement of loads?
N Repetitive handling?
N Insufficient rest or recovery?
N A work rate imposed by a process?
Environment - are there:
N Constraints on posture?
N Poor floors?
N Variations in levels?
N Hot / cold / humid conditions?
N Strong air movements?
N Poor lighting conditions?
Other factors:
N Is movement or posture hindered
by clothing? or
N Personal protective equipment?

Table 3: Simple Manual Handling Risk Assessment

Risk Reduction

If it is not possible to eliminate manual handling
tasks which involve a risk of injury, the risk
assessment should result in recommendations to
reduce the risk of injury.

Mechanical Assistance

Wherever possible manual handling should be
replaced or reduced by the use of mechanical
handling aids.

Load

To reduce the risk of the load:

N reduce the weight (this will increase the frequency of handling, but will reduce
the stress placed on the body by each lift);

N provide handles, etc. where the size, surface texture, or nature of a load
makes it difficult to grasp;

N ensure loads in packages cannot move unexpectedly whilst being handled;

N avoid sharp corners, jagged edges, rough surfaces, hot or extremely cold
surfaces; and

N provide information on the load, e.g. centre of gravity and weight.

Individual

The following should be considered:

N selection of employees for the task;

N self pacing; and

N PPE, e.g. gloves to protect against hot, cold or sharp surfaces.

Task

Where mechanical assistance cannot be provided there may be
scope for changes to the layout of the task to reduce the risk of
injury, e.g. by improving the flow of materials or products. An
ergonomic approach to reduce the risk of the task includes:

N avoid lifting heavy loads while seated;

Figure 6: Vacuum Lift

N safe system of work;

N job rotation;
N team handling;

N lift the load from waist height;

N store lighter or less frequently used items above or below waist height;

N change the layout to avoid bending, twisting, reaching and travel distances;

N ensure workbenches are of uniform height;

N avoid static postures; and

N provide voluntary rest breaks to change the activity.

Figure 7: Task Layout Change to Avoid Over Bending

Environment

To reduce the risk from environmental factors:

N provide adequate space and headroom;

N maintain good housekeeping standards to keep routes clear of spillages or
obstacles, etc.;

N provide adequate lighting;

N provide and use level routes or use gentle slopes, etc.;

N do not handle externally in poor, high wind, conditions; and
Before After


N ensure a comfortable working environment, e.g. heating, ventilation, lighting,
etc., to reduce the risks of muscle sprains and strains.

Information for Employees

Where tasks involve a risk of injury, employees should be provided with general
information about the risks, precautions, safe systems of work and precise
information on the:

N weight of each load; and

N heaviest side of any load whose centre of gravity is not positioned centrally.

Training

Training alone is not effective to control risk. However, training programmes should
include the following:

N how to recognise potentially hazardous loads;

N how to deal with unfamiliar loads;

N the proper use of handling aids;

N the proper use of personal protective equipment, e.g. gloves, safety footwear,
etc.;

N features of the working environment that contribute to safe manual handling;

N the importance of good housekeeping, e.g. keeping paths clear;

N the factors affecting individual capacity; and

N good handling techniques, e.g. kinetic handling.

Kinetic Handling

Kinetic handling is a good technique for lifting and moving loads.
Although good manual handling technique is no substitute for other
risk-reduction steps it forms a valuable addition to other risk reduction
methods.

To be successful, good handling technique requires training and
practice. The content of training in good handling technique should be
tailored to particular tasks or situations.

Kinetic Handling Technique

1. assess the load;

2. ensure that the travel route is clear
and well lit;

3. get as close to the load as possible;

4. get a secure grip (wear gloves if
necessary);

5. position feet apart, one foot flat to the floor at the side of
the load, the other foot behind, with heel raised;

6. keep the back straight - maintain the natural spinal curve
by lifting the head;

7. bend the knees - lift using the thigh muscles;

8. keep the load close to the body heaviest side to the trunk,
avoid jerking, make a smooth movement;

9. move the feet - avoid twisting at the
waist; and

10. put down, then adjust slide to
desired position.

Duties of Employees

Employees should:

N follow safe systems of work provided;

N use mechanical aids provided properly; and

N follow manual handling training provided.

Review

Manual handling assessments should be made in the following circumstances:

N an accident or chronic ill-health, e.g. back strain, occurs;

N where there is reason to suspect it is no longer valid;

N where there has been a significant change in the manual handling task to
which it relates; and

N periodically.

Any changes required by the review should be implemented.

Mechanical Handling

Introduction

Lifting equipment is used extensively in organisations, from supermarkets to quarries.
Fatalities and damage to buildings, etc. occur when lifting equipment fails due to
incorrect erection, damage, lack of maintenance and poor planning. Lifting
equipment includes:

1. conveyors;

2. cranes; and

3. hoists.

Conveyors
Types of Conveyor

Conveyors are found in many workplaces from supermarket checkouts, airports and
postal rooms to car assembly plants, quarries and construction sites.

There are three basic types of conveyor extensively used in organisations: belt,
screw and roller.

Figure 8: Types of Conveyors

Belt conveyor Roller Conveyor Screw Conveyor

Belt Conveyor Roller Conveyor Screw Conveyor

Hazards and Precautions

Conveyors are used to transport a wide range of materials and therefore hazards are
associated with the machinery itself, non-machinery hazards and positional hazards.

Hazards Precautions
Mechanical hazards
Trapping in drive
mechanisms.
Fixed guards at motor driven rollers and tail pulley, avoiding
loose clothing.
Figure 9: Tail Pulley Guard

Traps, nips or drawing
in between moving
and fixed parts.

Pop out rollers, trip devices, nip guards particularly of the
chains, drive chains and transfer points.
Figure 10: Pop Out Roller

Figure 11: Transfer Point Guard
Figure 12: Nip Guards Between Rollers

Max.
clearance
5mm
(both
sides)

Hazards Precautions
Sharp edges friction
burns, cuts, abrasions
Edge belt protection, restricted access, elimination of sharp
edges
Positional hazards
Items jamming in
conveyors.
Adequate design to allow for flow of material, guarding to
prevent jams.
Crushing and impact
from falling objects.
Edge guards, barriers around the conveyor to prevent
access.
Personnel riding or
crossing conveyors.
Bridges over the conveyor, complete enclosure if possible.
Impact against
overhead systems.
Bump caps, restricted access, warning signs / tape,
cushioning or padding.
Non-mechanical hazards
Noise from conveyor
mechanisms.
Enclosing the conveyor mechanisms, hearing protection.
Manual handling of
materials onto
conveyors.
Mechanical aids, ensuring conveyor is at waist height.
Electrical hazards
from power supply.
Earth bonding, earth leakage breakers, inspection and
maintenance of the electrical system.
General precautions applying to all the above are:
Maintenance: strict maintenance procedures should be in place to isolate and lock
off conveyors when any sort of maintenance is carried out.
Emergency stop devices: should be fitted at either end and at intervals along the
length of long conveyors.

Table 4: Conveyor Hazards and Precautions

Cranes
Types of Crane

Cranes are used widely to move heavy equipment and materials within and outside
workplaces and construction sites. There are four main types of crane in regular use:

1. mobile cranes;

2. tower cranes;

3. gantry cranes; and

4. overhead cranes.

Hazards

Cranes may fail for a number of reasons, e.g. collapse, overturn, breakage of lifting
wire:

N unsuitable support or inadequate base for crane;

N lack of maintenance; and

N overloading.

Hazards associated with the operation of cranes include:

N contact, e.g. overhead electricity cables, other buildings, etc.;

N incorrect positioning of crane, e.g. on soft ground, too far away from load;

N improper methods of use of crane, e.g. use in high winds;

N incorrect signals by the signaller (banksman);

N personnel working at or near the track of an overhead travelling crane;

N limitations of height or reach on site;

N ground bearing capacities, position of basements, underground services,
weather conditions, etc.;

N use and storage of fuel storage facilities; and

N contact with persons below the lifting area.

In addition, the design of different types of crane may create specific hazards.

1. Mobile Cranes

Mobile cranes are fitted with wheels for road use or crawler tracks, e.g. large
construction sites. They are very mobile and suitable for small lifts. They are useful
around construction sites and for occasional use. Mobile road (or rubber wheeled)
cranes are the most common type of crane used.

Figure 13: Example Mobile Cranes

These cranes normally have outriggers fitted. They extend from the chassis of the
crane and are used to support the weight of both the crane and the load. The
outriggers can increase the capacity of the crane, but they also increase its size. The
outriggers should be on firm foundations such as solid timber packing, steel plates or
specially cast concrete pads.

Hazards

The main causes of failure associated with this type of crane are:

N overturning, e.g. working on uneven and sloping ground, working without the
outriggers deployed, soft ground leading to outriggers sinking;

N overloading, e.g. driving with a suspended load, going down a slope with the
load raised and exceeding the load radius;

N striking objects and people, e.g. hitting overhead including power lines,
impact with buildings and other structures; and

N fall of load.
Telescopic Jib Lattice Jib

Figure 16: Example Tower Crane
Figure 14: Overturned Mobile Cranes

Figure 15: Mobile Crane Load Radii

Level ground: correct
load radius
Uphill position: decrease
in the load radius
Downhill position:
increase in the load radius
! !

2. Tower Cranes

Tower cranes consist of a tall, slender
lattice mast with a jib unit at the top.
They are used for long duration
work, e.g. construction sites, where
large areas of access are required to
be covered. They are normally fixed
to one location but can be mounted
on rails.

Hazards

Hazards associated with the use of
tower cranes include:

N overturning, e.g. due to incorrect construction, swinging or unstable loads,
operating outside the safe working radius;

N overloading, e.g. collapse or bending of jib due to overloading or wear; high
wind conditions;

N striking objects and people, e.g. impaired operator vision of the load; and

N fall of persons and load.

3. Gantry Cranes

Gantry cranes consist of a framework of two vertical supports connected with a
horizontal beam or lattice along which a trolley moves. To allow a gantry crane to
move backwards and forwards the bases of the uprights have wheels fitted which run
on railway tracks. The crane can cover the full length of the gantry rails and the
width between. They provide great flexibility within the area. Some are fitted with
rubber wheels which can steer and drive the gantry. These are used extensively for
handling freight containers.

Figure 17: Example Gantry Cranes

Hazards

Hazards associated with gantry cranes include:

N overturning;

N overloading;

N striking objects and people, e.g. contact with crane wheels overhead,
movement of loads in the vicinity of other workers; and

N fall of persons and load.

Figure 18: Overturned Gantry Crane

4. Overhead Gantry Cranes

Overhead cranes are used within buildings. Horizontal rails are attached to the
structural steel framework of the building or on columns outside at a high level. They
are common in engineering works and plants where repeated lifting is required and
access for conventional cranes is difficult (e.g. in power stations, to lift out turbines
for maintenance). Over head gantry cranes take power from fixed electrical busbars
along the horizontal support rails.

Figure 19: Example Overhead Gantry Crane

Hazards

Hazards associated with these types of crane include:

N overloading;

N striking objects and people, e.g. restricted vision of load and travel,
movement of loads in the vicinity of other workers

N electric shock to maintenance staff from exposed electrified rails (busbars);

N unauthorised use by untrained personnel;

N lack of maintenance; and

N fall of load / persons

Precautions

Precautions for all four types of crane include:

Suitability of the Crane

Consideration will need to be given to the following factors when deciding which
crane is most suitable for the planned lift:

N weight of the load and the safe working load (SWL) of the crane;

N the distance the load is away from the crane;

N any wind loading that may occur;

N size, shape and stability of the load;

N distance to be moved;

N stability or strength of the surface upon which it is
going to be erected;

N condition of a crane, e.g. wear;

N condition of ground, e.g. on a slope, obstacles in
path, etc.; and

N whether it is a one-off or repeated lift.

Procedure for Safe Lifting

Prior to carrying out a lift it is necessary to assess the risks including materials,
equipment, environment and people, and develop and implement a safe lifting plan:

N use competent operators and ensure adequate training to; plan the lift, drive,
signal (banksman) and sling;

N ensure good communication, visibility, and the use of standard hand signals
or radii;

N inform personnel about lift and keep area clear of other persons;

N all personnel working with or near lifting equipment should wear safety
helmets;

N ensure the correct lifting accessories is used with the safe working load;

N ensure the lifting accessories are free from defect;

N ensure the weather conditions do not pose a risk, e.g. high winds, ice;

N secure the load, inspect slings for damage;

N ensure path is free of obstacles;

N ensure the load is lifted vertically;

N perform each part of the operation (lifting / slewing / moving and lowering) at
a rate that maintains proper control;

N during the lift ensure the load is: secure, balanced and controlled. Attach tag
lines where necessary;

N avoid overhead power lines; and

N ensure a safe position for landing, release the tension and then release the
lifting tackle.

Other Considerations for Safe Lifting:

N pre-use inspections;

N all lifting equipment should undergo thorough examination and test at regular
intervals;

N servicing, maintenance, testing, thorough examinations, etc. should be
arranged as required before the crane is used on site;

N ensure that overhead travelling cranes do not approach within 6m of persons
working at or near the wheel track;

N seek permission to conduct lifts over adjacent properties;

N use purpose-made, tested stands to inspect the base of heavy loads;

N if any lift, hoist, crane or excavator collapses or overturns on site or any load
bearing part fails, it should be thoroughly investigated and, if local legislation
requires, reported to the Enforcing Authorities as a dangerous occurrence;
and

N cranes should be marked with their safe working load (SWL).

Hoists

Types of Hoist

Hoists vary from simple chain hoists used to lift equipment, to vertical construction
hoists, with cages capable of carrying people and equipment, to hoists designed to
lift people, e.g. in hospital.

Figure 20: Example Hoists

Hazards

General hazards include:

N failure of the lifting chains / ropes;

N being struck by moving parts of the hoist; and

N being hit by materials falling from the platform / cage.

Hazards specific to vertical goods hoists include:

N falling down the hoist way from a landing level, e.g. a
scaffold platform or from a hoist cage;

N falling down the hoist way with the cage due to failure of
the lifting rope / chains or operator error; and

N being struck by landing levels or parts of the enclosure
while trying to ride on a goods only hoist.
Goods Hoist Chain Hoist

Precautions

General precautions include:

N controls that can be operated from only one position, e.g. ground level;

N train workers to use the hoist;

N clear visibility of landings or clear signals from other workers during loading or
unloading operations;

N secure the wheels of wheelbarrows with chocks (blocks placed in front of
wheels) to prevent them moving during the lift;

N not overfilling wheelbarrows, etc. with materials;

N not carrying loose materials such as bricks on an open platform hoist;

N not allowing passengers to ride on a goods hoist;

N clearly indicating the safe working load and not exceeding it; and

N ensuring the hoist is inspected and thoroughly examined.

Precautions specific to vertical goods hoists with cages include:

N secure the perimeter fence at ground level with gates; and

N secure the enclosures with gates at other landing / scaffold platform levels.

Lifting Accessories
Types of Lifting Accessory

Work equipment for attaching loads to machinery for lifting are often called lifting
accessories or tackle. It includes any equipment used to connect a load to lifting
equipment such as:

N lifting beams;

N pulley blocks;

N chain slings;

N wire rope slings;

N textile slings;

N hooks;

N rings;

N shackles; and

N eye bolts.

Hazards

The main hazards associated with lifting accessories are:

N overloading / used above the safe working load;

N incorrect use, e.g. too wide an angle between legs of
sling or use of wrong eye bolt at an angle;

N defects:

- textile slings damaged, cut, abraded or stretched;
- chains deformed, cracked or stretched links; and
- broken wires or kinks;

N insecure attachment of load;

N damage to sling, ropes, etc., e.g. caused by lack of
packing to sharp corners of load;

N incorrect slinging method; and

N failure to examine and inspect pre-use.

Precautions

The following precautions apply to lifting accessories:

N all lifting accessories should be certificated before use;

N all accessories for lifting should be thoroughly examined by a competent
person at specified intervals and visually inspected before use or at intervals
laid down in an examination scheme (during use);

N dynamo type eye bolts (those with a narrow waist which are suitable only for
vertical forces) should not be used with multiple leg type slings (non-vertical
forces);

N repairs to lifting tackle should not be carried out on site. A test certificate
should be obtained for any repaired item of lifting tackle;

N slings and other lifting accessories should not be used for operations for
which they were not intended, e.g. towing, and should not be altered or
adapted by unsafe methods, i.e. knots, bolts through links, etc.;

N sufficient materials for packaging between sling and load should be provided;

N training should be provided in safe slinging methods, signals, etc. for
operatives carrying out this work;

N the safe working load (SWL) should be clearly marked on the accessory;

N overrun devices should be fitted to tracks, rope pulleys, etc.; and

N all lifting accessories should be secured and left in a safe condition at the end
of each working period.

Lifting Equipment

Employers should ensure that all lifting equipment is:

N sufficiently strong, stable and suitable for the proposed use. Similarly, the
anchorage, load and anything attached (e.g. timber pallets, lifting points)
should be suitable;

N thoroughly examined by a competent person:

- after installation and before being put into service for the first time;
- after assembly and before being put into service at a new site or in a
new location;
- at least every 12 months (6 months when used for lifting persons, and
lifting accessories); or
- in accordance with an examination scheme; and
- each time that exceptional circumstances, which are liable to jeopardise
the safety of the lifting equipment, have occurred;

N inspected by a competent person at suitable intervals between thorough
examinations;

N marked accordingly where it is used for lifting people and is safe for such a
purpose, e.g. all necessary precautions have been taken to eliminate or
reduce any risk; and

N visibly marked, with any appropriate information to be taken into account for
its safe use, e.g. safe working loads. Accessories, e.g. slings, clamps, etc.
should be similarly marked.

Following a thorough examination or inspection of any lifting equipment, a report is
submitted by the competent person to the employer to take the appropriate action.

Lifting Operations

Employers should ensure that before any lifting operations are considered, the
following precautions are undertaken:

N lifting operations are planned, supervised and carried out in a safe manner
by people who are competent;

N lifting equipment is positioned or installed to prevent the risk of injury, e.g.
from the equipment or the load falling or striking people;

N loads are not carried or suspended over areas occupied by persons. Where
this is not practicable a safe system of work should be established to
minimise the risks to persons who may need to be below the load;

N where it is necessary to leave loads suspended, access to the danger zone is
prevented, ensuring that the load has been secured properly;

N if the operator of lifting equipment cannot observe the full path of the load,
either directly or by means of auxiliary devices, the employer should ensure
that a responsible person has appropriate means of communication to guide
the operator.

The person planning the lifting operation should have adequate practical and
theoretical knowledge and experience of planning lifting operations. The plan should
address the risks identified by a risk assessment and identify the resources required,
the procedures, and the responsibilities so that the operation is carried out safely.

References
ISO 2003 ISO 12100-1: Safety of machinery, basic
concepts, general principles for design, basic
terminology and methodology.

ISO 2003 ISO 12100-2: Safety of machinery, basic
concepts, general principles for design, technical
principals.

HSE 1998 L23: Manual Handling (Guidance).

HSE 1998 L113: Safe Use of Work Equipment (ACoP).

Notes

Notes

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CHSS Ltd 2006 Page 1 of 38

wpc/SJ/ae/IGC2 Element 3 Manual and Mechanical Handling Sales Ref: sc/639/v3

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