Element 3:- Manual and Mechanical Handling Hazards

Manual Handling Injuries

External:- Cuts, bruises, abrasions, crush injuries

Internal:- Strains, Tears, Hernias

Hierarchy to reduce handling injuries

Avoid handling
Assess
Implement controls

Manual Handling Risk Assessment

Load

Weight
Size
Shape
Rigidity
Difficult to grasp
Unstable
Sharp, hot, cold etc.

Individual

Sex
Stature
Individual capability
Training
Persons assessment of own capability

Task

Holding away from trunk

Twisting
Stooping
Reaching upwards
Large vertical movement
Long carrying distances
Strenuous pushing or pulling
Unpredictable movement of loads
 Repetitive handling
Insufficient rest or recovery
Work rate imposed by the process

Environment

Constraints on posture
Poor floors
Variations in levels
Hot/Cold/ humid conditions
Poor lighting

Correct Kinetic Handling Technique

Assess the load

Close to load as possible
Secure grip
Suitable feet position
Back straight
Bend the knees
Load close to the body
Smooth movement

Conveyors

Hazards
Trapping in drive mechanisms
Traps, Nips, Drawing in
Sharp edges
Items jamming conveyor
Falling objects
Riding or crossing conveyor
Impact with objects
Noise
Manual handling
Electrical hazards
Precautions
Guards, No loose clothing
Pop out rollers, nip guards
Edge protection, eliminate edges
Adequate design
Edge guards, barriers
Bridges, complete enclosure
Helmets, padding
Hearing protection
Mechanical handling
Suitable electrical equipment

Types of Cranes

Mobile
Tower
 Gantry
Overhead

Cranes may fail because of

Overturning
Overloading
Unsuitable support or inadequate bases for crane
Loss of load
Failure of load
Lack of maintenance
Failure of load bearing part

Safe use of Cranes

Suitable crane
Suitable ground conditions
Use of outriggers
Avoidance of obstructions
Care near overhead power lines
Designated and protected area
Suitable and tested lifting tackle
Correct slinging technique
Competent personnel
Load near ground if travelling
Good visibility
Good communications
Suitable storage for fuels etc

Hazards opposite of above plus

Use of crane in high winds

Employee safety during lifting

Trained personnel
Properly trained equipment
Equipment has had statutory inspections
Warning of lift taking place
No employee to walk under load
Ensure load is secure
SWL of crane and tackle not exceeded
 Lifted to correct height
Moved at appropriate speed
Adequate supervision
Lifting Accessories (Tackle)

Main Hazards

Overloading/used above safe working load

Incorrect use e.g. too wide an angle with chains
Insecure attachment of load
Damage to tackle
Incorrect slinging method
Failure to examine and inspect pre-use
Incompetent staff
 Test ( 3 )
Outline a good handling technique that could be adopted by a person
required to lift a load from the ground

We must emphasis for the following points

1. Address the size & weight of the load
2. Ensure that the travel is clear and well
3. then outlined a technique that included issues such as the correct
positioning of the feet
4. Keeping the back straight
5. Bending only the knees
6. Move a feet and avoid twisting at the waist
7. keep the load close to your body - heaviest side to the trunk
8. lifting smoothly while keeping the load close to the body

Give TWO examples of how a manual handling task might be avoided

However in many cases the use of sack trucks & smaller packages were
suggested
Whilst these might reduce the risk from manual handling they do not
entirely avoid it

store man is required to place boxes of metal components by hand on to

shelved racking
(i)List FOUR types of injury to which the employee may be at risk while
carrying out this task

1. Slipped disk, torn ligaments

2. Tendon sprain or hernia
Given that the question related to manual handling & stacking
potentially heavy boxes, there was, in addition, the possibility that the
boxes or their contents could fall causing
3. Cuts
 4. Abrasions & even fractures
_________________________________________________

(ii) Outline the factors in relation to the task & the load that will
affect the risk of injury

Task to be performed & this should have led to consider the rate of
work, in terms of
The number of boxes to be lifted & the frequency of lifting
Job rotation
the vertical & horizontal distances that the boxes are required to be
lifted or carried, particularly if they have to be lifted from the
ground &/or placed on high shelves
The need for excessive
Pulling the load
Or pushing of the load
Movement of load in package
twisting of the body
Should also have been considered
___________________________________________________________
Outline the factors that may affect the level of risk from manual handling
in relation to
(i) The load
(ii) The individual
The factors relating to the task carrying out the handling operation
The size & weight of the load
The possibility that the contents might move & the load become
unbalanced
The position of the centre of gravity
Difficulty in securing a firm grasp of the load
& the presence of sharp edges

Part (ii) the factors relating to the individual carrying out the handling
operation
These include
Body size & strength in relation to the task to be carried out (which
can be age or gender-related)
Physical handicaps or restrictions caused by illness, disability or
pregnancy
 Lack of training in manual handling
& inappropriate clothing or footwear or PPE as general

1) With respect to manual handling operations:

a) Identify ways in which the nature of the load may present

a risk of injury

the size & weight of the load;

The contents might move & the load become unbalanced;
the position of the centre of gravity;
difficulty in securing a firm grasp of the load;
& the presence of sharp edges.

b) State FOUR factors relation to the individual that may

increase the risk of injury

physical strength & stature

Sex of the employee
State of health of the employee
level of training in manual handling techniques.
The persons perceptions (or misperceptions) of the
requirements of the task or their own abilities.

Outline the factors that should be considered in an

assessment of manual handling activities

Load :- Size, Shape, Sharp edges, Hot/cold

Individual:- Age, Sex, physical capability

 Task:- Stooping, Stretching, Pulling, Pushing

Environment:- Temperature, lighting, Floors

Outline the factors that may affect the level of risk from
manual handling in relation to:

(i) The task

Holding away from body

Twisting
Stooping
Reaching upwards
Long carrying distance

(ii) The load

a) Weight
b) Size and shape
c) Difficult to grasp
d) Unstable/unpredictable
e) Sharp edges
f) Hot/cold

a) List TWO types of injury that may be caused by

the incorrect manual handling of loads
Slipped disc, torn ligaments, tendon sprain or
hernia. Cuts, abrasions & fractures if boxes fall
b)Outline a good handling technique that could be adopted
by a person required to lift a load from the ground

Consider the size & weight of the load,

Correct positioning of the feet
Take firm grip
keeping the back straight,
bending only the knees
Use strength of thigh muscles
Lifting smoothly keeping the load close to the body.

Outline the factors that could contribute towards the

development of work-related upper limb disorders
(WRULDs) amongst employees at a supermarket checkout.
space constraints,
poor equipment (such as chairs that are not adjustable),
bulky or heavy items, poor design or reliability of
scanning equipment,
high levels of repetition, working at a fast pace, over-
reaching (often from a seated position),
insufficient rest breaks,
environmental conditions such as temperature & humidity,
& lack of appropriate training.

Outline a procedure for the safe lifting of a load by a

crane, having ensured that the crane has been correctly
selected & positioned for the job.

the correct selection of the sling & its inspection for

damage before use;
the employment of competent persons to attach the sling to
the load in order to ensure a correct balance;
 Provide unrestricted view for the crane driver or, where
this is not possible, the use of competent banksmen to
maintain effectives communication with the driver;
checking that the area where the lift is to take place is kept
clear of employees;
& ensuring that the load is raised at the correct speed,
lowered slowly to its landing position & controlled during
its passage, possible by the use of tag lines.
A store man is required to place boxes of metal
components by hand on to shelved racking.

(a) List FOUR types of injury to which the employee

may be at risk while carrying out this task.

Slipped disc, torn ligaments, tendon sprain or hernia.

Cuts, abrasions & fractures if boxes fall

(b) Outline the factors in relation to the task & the

load that will affect the risk of injury.

Factors relation to task include

the number of boxes to be lifted & the frequency of

lifting,
The vertical & horizontal distances that the boxes are
required to be lifted or carried, particularly if they have
to be lifted from the ground &/or placed on high
shelves.
The need for excessive pulling or pushing of the load &
twisting of the body should also have been considered.

Factors relating to the load include:

the weight & size of the boxes,

the weight distribution,
 the provision of handles or other means to ensure an
adequate grip,
the presence of sharp edges,
& the security of the loads within the boxes to prevent
unexpected movement.

(c)
Outline a good manual handling technique that could be
adopted by the employee when required to lift one of the
boxes from ground level

Consider the size & weight of the load,

& the location to which it is to be moved,
& then outlined a technique that included issues such as
the correct positioning of the feet,
keeping the back straight,
bending only the knees,
& lifting smoothly while keeping the load close to the
body.

Outline the issues to consider when undertaking a manual

handling assessment of a task that involves lifting buckets of
water out of a sink.

frequency of the activity,

vertical & horizontal distances to be lifted/transported,
distance of load from the body,
awkward body movements & so on.
the type/size of bucket & water temperature;
wet floors, space constraints & ambient temperature.
physical capabilities & limitations of the individual
Outline FOUR hazards & the corresponding precautions
to be taken when using conveyor systems for moving
materials within a workplace.

traps & drawing-in (with nip guards & trip devices as

possible precautions);
entanglement (fixed guards, avoidance of loose
clothing);
impact against overhead systems (bump caps, restricted
access, warning signs, cushioning);
items falling off (edge guards or barriers);
contact hazards (belt edge protection, restricted access,
elimination of sharp edges);
manual handling hazards (appropriate height of
conveyor, the use of mechanical aids);
& noise (various attenuation methods, hearing
protection).

An office employee is required to replace 20 litre (20kg)

water bottles located on top of water coolers.

(i) Identify FOUR factors specific to the

employee that might increase the risk of injury
when carrying out this task.
 physical strength & stature
Sex of the employee
state of health of the employee
level of training in manual handling techniques.
the persons perceptions (or misperceptions) of the
requirements of the task or their own abilities.

(ii) Outline a good handling technique that could be

used when lifting a full bottle from the floor.

making an initial assessment of the load

the need to take a firm grip of the bottle
lifted smoothly
keeping the back straight
using the leg muscles
ensuring that the trunk is not twisted

Outline the precautions to be taken to prevent accidents

to employees working at ground level in a workshop
where heavy loads are lifted & transported by means of
an overhead gantry crane

The use, training & competence of key personnel (operator,

signaller, slinger)
maintenance & statutory inspection of the crane & lifting
tackle.
warnings of a lift taking place (audible &/or visible),
ensuring that the load is secure,
does not exceed the safe working load,
lifted to the correct height & moved at an appropriate
speed,
 & ensuring that al those working in the area have been
properly trained & are adequately supervised.