Mechanical & Manual Handling Hazards and Control General Certificate NGC2 Element 2
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Mechanical & Manual Handling
Hazards and Control
General Certificate NGC2 Element 2
References
• Page 147
• Manual Handling Operations Regulations
1992
• Lifting Operations and Lifting Equipment
Regulations 1998 (LOLER)
• The Provision and use of Work Equipment
1998
Manual Handling Operations
Regulations 1992
What is meant by
MANUAL HANDLING?
Manual handling is any transporting or
supporting of a load, including:
Lifting
Putting Down
Pushing
Pulling
Carrying or Moving of a load
What is meant by
MANUAL HANDLING
THIS DOES NOT INCLUDE THE
MANIPULATION OF TOOLS, CONTROL
LEVERS
& VALVES
Manual Handling?
Accidents
This information is based on
reported over three day injuries only
More than a quarter of the accidents
reported to enforcing authorities are
associated with Manual Handling
21%
15%13%
5%
35%
8%3%
Trips
Struck by
Other
Machines
Handling
Fall
Chemicals
Manual handling - injuries at work UK
Manual handling injuries at work -
UK
65%6%
7%
8%
9%5%
Sprains & strains
Fractures
Lacerations
Contusions
Superficial
Others
Manual handling injuries at work -
UK
45%
16%
9%
8% 6% 3%
13%
Back
Fingers & thumbs
Arm
Lower Limb
Torso
Hand
Other
Manual handling at work
Key facts
• Single biggest cause of lost time injuries
• Majority of injuries are sprains and strains (65%)
• Back injuries account for 45%
These are the most likely lifting errors that cause nearly all
manual handling or back related injuries.
High risk activities that can cause
back pain
• Traditional methods of lifting
• Repetitive or restricted movements
• Moving awkward or heavy loads
• Working in an awkward posture
• Frequent bending
• Forceful, repetitive or rapid lifts
These are the most common errors people make when
lifting things:
High risk activities that can cause
back pain
• Holding loads away from body
• Twisting
• Stooping
• Reaching upwards
• Excessive up and down movements
Main causes of back pain
• Cumulative builds up over a period of time e.g. poor posture or obesity
• Traumatic- caused by sudden violent stress e.g. one man lift for a whacker
• Degenerative vibration & shocks to the spine e.g. lorries/grab lorries
1. Cervical (neck)
The smallest vertebra that supports the smallest amount of weight. It also
cradles the skull and provides movement and rotation
2. Thoracic (Chest)
This group supports the ribs but doesn’t provide a great deal of rotation
3. Lumbar (lower back)
This supports a large amount of weight and provides good movement for
the upper body. It is also the source of the majority of spine related
injuries.
4. Sacrum (tail bone)
This consists of five vertebra that fit into the pelvic girdle.
The shape of the spine consists of four defined
curves; it is not straight and rigid
The Spine
The intervertebral discs are made up of a strong ‘fibrous’ layer called
annulus and a soft, jelly like inner layer called nucleus.
Intervertebral disc
How to lift?
• No matter how you are taught you are going
to do it your way!
• Its too difficult to do it the proper way!
• I have done it this way for years!
•WRONG!!!!!
Video
Four basic requirements for
manual handling• Avoidance
– Can it be mechanised?
• Assessment
– Identify hazards and apply control measures
• Risk Reduction
– Can the weight be reduced
• Training
– Kinetic lifting technique
Manual handling
How to do it – 1
• Assess the load
• Foot position
• Centre of gravity (of load)
• Unlock knees/hips
• Hand position/palmar grip
Manual handling
How to do it – 2
• Straight back
• Head up
• Thighs do the work
• Load close to the body
• Load not too high
Manual handling – risk assessment
What to consider?
• Task
• Individual
• Load
• Environment
The Task
Manual handling – Risk assessment
• Frequency of lift
• Stooping or Twisting
• Bending sideways
• Reaching above shoulder
• or below knee
• Changing grip
• Effort required
• Carrying up/down stairs/steps
• Distance traveled
The Individual
Manual handling – Risk assessment
• Under 18 over 50
• Gender
• Heart problems
• Respiratory problems
• Weak/damaged back
• Hernias
• Fitness
• Training and skills
• Experience
The Load
Manual handling – Risk assessment
• Size
• Shape
• Weight
• Centre of Gravity
• Loose Material
• Sharp Edges or Corners
• Hot/Cold
• Type of Contents
The Environment
Manual handling – Risk assessment
• Adequate space
• Is good posture possible
• Obstacles
• Hot/cold/wet/dry
• Lighting/visibility
• Noise, vibration
• House keeping
• Weather Conditions
Manual handling - Individual risk
assessment
Selecting methods of reducing risk
• Can you avoid manual handling?
• Can you use a mechanical aid? Sack trucks, trolleys etc
• Can you split the task to make it more manageable?
• Can someone help you?
Manual Handling Operations
Regulations 1992 Regulation 4 (Duties of Employers) is broken down
into 5 other Sections
4(1)(a) Avoidance of Manual Handling
4(1)(b)(i) Assessment of Risk
4(1)(b)(ii) Reducing the Risk of Injury
4(1)(b)(iii) The load - providing additional information
4(2) Reviewing the Assessment
Manual Handling Operations
Regulations 1992
Amended in 2002 to take account of individual
capabilities etc
HSE ASSESSMENT FILTER
Generally, for infrequent
lifting/lowering
actions, tasks moving
loads inside the weight
parameters do not
require formal
assessment – but use
with care !
Mechanical
Handling
Four elements
• Mechanical handling equipment
• The load
• The workplace
• The employee
Four elements
• Mechanical handling equipment
– Must be capable of lifting/moving the
load
– Must be fault free
– Well maintained
– Inspected regularly
– Hazards include: collisions between
people & equipment, trapping of body in
moving parts
Mechanical Handling Devices
An example of Manual
Handling Automation
Bob
Bill
?
Four elements
• The load
– Must be made ready to be moved
– Hazards include: nature of load i.e.
flammable or hazardous to health,
security and stability i.e. collapsing
pallets
Four elements
• The Workplace
– Designed so that worker is separated
from moving loads
– Hazards include: – falling items from craned load
Four elements
• The employee
– Must be properly trained and
competent
– Must be supervised
Mechanical handling Equipment
Conveyors• Belt, roller and screw
• Hazards include: nip, entanglement, loads
falling off, impact against overhead
systems, collisions between people &
equipment, trapping of body in moving
parts, manual handling, noise & vibration
Mechanical handling
Elevators• E.g. Brick elevator
• Hazards include: nip, entanglement, loads
falling off, impact against overhead
systems, collisions between people &
equipment, trapping of body in moving
parts, manual handling, noise & vibration
Mechanical handling
Fork lift or
powered industrial trucks• Hazards include: overturning, overloading,
collisions, silent operation, uneven floors, overhead obstructions, loss of load, poor maintenance, use of work platform, speed, poor vision, pedestrians, dangerous stacking, carrying passengers, fire, lack of driver training
Mechanical handling
Fork lift trucks• Hazards include:
noise, exhaust,
vibrations, manual
handling, ergonomics
Hazard elimination - FLT
• Testing – Certificate required, info on maximum loads (SWL) - LOLER
• Maintenance – Inspected regularly, records kept, condition of tyres, brakes, audible alarms, lights, properly adjusted seat,
• Operator – Training for driver and slingers
• Lighting
• Driver training
Hazard elimination - FLT
• Operating area
– look at overhead cable, pits, drains, striking
other FLT’s
– Blind corner elimination (mirrors)
– Passing places
– Proper storage routes kept clear
– Exclusion of pedestrians
– Suitable warning signs & signals
Fork Lift Truck
• Create an
operator’s
checklist for a
workplace FLT
What can go wrong - cranes
• Overturning
• Overloading
• Poor slinging of load
• Insecure or unbalanced load
• Collision with another structure or overhead power line
• Failure of support
• Operator error
• Loss of or exceeding (SWL) load
• Sudden loading or shock loading
• No banks man
• Lack of proper maintenance
Hazard elimination - cranes
• Testing – Certificate required, info on
maximum loads
• Maintenance – Inspected regularly, records
kept
• Operating area – look at overhead cable,
pits, drains, striking other cranes
• Operator – Training for driver and slingers
Hazard elimination - cranes
• Safety Measures;
– Load & radius indicators
– Controls – dead man type
– Over travel switches to prevent cable going into drum
– Access
– Operating position – good visibility
– Passengers – none
– Lifting tackle – safety checks for load on chains, slings,
wires, ropes, shackles and bolts
Hazard elimination - cranes
• Safety Measures;
– Do not leave load suspended whilst not in use
– Ensure that loads are never carried over people
– Lift load vertically never use to drag
– Travel with load as close to the ground as
possible
– Switch off power to crane when left unattended
– Always use out-riggers where fitted
LIFTING OPERATIONS & LIFTING
EQUIPMENT REGS 1992 (LOLER)
Lifting equipment should be :
• Strong, stable and marked for SWL
• Positioned/installed to minimise risks
• Used for work which is properly planned,
organised and done by competent people
• Subjected to ongoing thorough examination
and inspection by competent persons
LIFTING OPERATIONS & LIFTING
EQUIPMENT REGS 1992 (LOLER)
A Written Scheme of Examination should be
prepared by a competent person specifying the
frequency and types of testing and inspection by
an independent engineer,
Or
All lifting equipment (and accessories) should be
thoroughly inspected and tested every 12 months
(and every six months for those that are designed
to carry people).
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