NEBOSH

Diploma Part 1

Unit 1D3
Safety in the movement of people & materials

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Manual Handling

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 Manual handling
• ‘any transporting or supporting of a
load (including lifting, putting
down, pushing, pulling, carrying or
moving) by hand or bodily force’
• Responsible for 34% of reported
accidents causing injury and 6% of
accidents resulting in major injuries

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Manual Handling Operations
Regulations 1992
Regulation 4(1)a: Every employer
shall avoid the need for employees to
undertake manual handling
operations, so far as is reasonably
practicable, where there is a risk of
injury

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 Regulation 4(1)(b)(i):

Every employer shall make a suitable

and sufficient risk assessment of manual
handling operations where it is not
reasonably practicable to avoid them
having regard to the factors specified in
Schedule 1to the Regulations

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 Regulation 4(1)(b)(ii):

Every employer shall take

appropriate steps to reduce the risk of
injury to employees arising out of
their manual handling operations to
the lowest level reasonably
practicable

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 Regulation 4(1)(b)(iii):
Employers must take appropriate
steps to provide employees who are
carrying out manual handling
operations with general indications
and, where reasonably practicable to
do so, precise information on the
weight of each load and the heaviest
side of any load whose centre of
gravity is not centrally positioned

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 Regulation 5
Employees must make full and
proper use of any system of work
provided for them by their employer
in compliance with the relevant parts
of the Regulations
This adds to the general duties under
HASAWA (7 & 8)

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 Regulation 6

This provides for the issue of

exemption certificates by the
Secretary of State for Defence
for the armed forces in the
interests of national security

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 Regulation 7
Extends the requirements to offshore
installations in territorial waters

Regulation 8
Covers revocations including parts of
the Factories Act 1961 and the Offices,
Shops and Railway Premises Act 1963

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 Risk Assessment

• Suitable and sufficient

• Use competent persons
• Combine the knowledge and
experience of several individuals
with different skills

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 Types of person to involve
• Managers/safety professionals to
interpret the regulations
• Supervisors, engineers or other
specialists to examine the tasks
• Occupational health specialists
with knowledge of
physiology/capability
• Ergonomists
• Employees
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 Four Key factors

• The task
• The load
• The working environment
• The individual’s capability

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 The Task
• Movement in relation • Pushing/pulling
to the trunk • Sudden movement
• Posture • Prolonged effort
• Twisting or stooping • Rest/recovery periods
• Reaching • Unvaried work rate
• Lifting or lowering • Handling while seated
• Carrying • Team handling

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 The Load
• Weight
• Bulkiness
• Grasping difficulty
• Stability/balance
• External state e.g. hot, sharp

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 Environment
• Space
• State of floor
• Variations in level
• Extremes of temperature/humidity
• Wind
• Lighting conditions

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 Individual Capability
• Strength, height requirements
• Health problems e.g. hernia
• Maternity
• Illness
• Young persons
• Special information/training

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Personal Protective Equipment

• This should only be considered as a

last resort
• Includes gloves, foot protection etc.

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 Risk Reduction
• Ergonomic approach
• Kinetic lifting
• Mechanical assistance
• Consult all those involved
• Use industry-specific guidance
• Consider task, load, environment
and individual capability

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 Kinetic Lifting
• Assess the load
• Feet shoulder distance
apart
• One foot leading/one
behind
• Bend the knees
• Find suitable grip
• Tuck the chin in
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• Raise the load
maintaining the
median line (spine)
• Raise the head
• Keep the load close to
the centre of gravity
• Lift smoothly
• Avoid twisting
20
 Twisting
The ability to manipulate loads
decreases if the handler twists the
torso or spine
Lifting capacity reduces by:
• 10% for a 45o twist
• 20% for a 90o twist

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 Frequency of handling
Operation Frequency Capacity Reduction

1-2 times per minute 30%

5-8 times per minute 50%

12+ times per minute 80%

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 Types of injury

• Disc
• Loss of synovial fluid/cartilage
damage
• Ligament damage
• Cuts, bruises and fractures

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Mechanical Handling

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Types of equipment
• Conveyors
• Mobile mechanical equipment
e.g. forklift trucks
• Elevators
• Goods vehicles
• Cranes
• Lifts & hoists
• Covered by PUWER & LOLER
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Mobile mechanical handling
equipment
• Forklift trucks
• Reach trucks
• Order pickers
• Narrow isle trucks
• All require careful selection and
safe systems of work

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 Safety Guidelines
• Use trained, authorised personnel
• Immobilise when unattended
• Control keys
• Never exceed rated loads
• Never carry passengers unless the
equipment is designed for this
• Maintenance programmes

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 Safety Guidelines
• Train operators to do simple
maintenance tasks
• Record and report all defects
• Only use trained staff to carry out
maintenance
• Carry out statutory and other
inspections at prescribed intervals

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 Operating Areas
• Smooth level surfaces able to bear
the imposed loads
• Ramps for changes in floor level
• Gradients <10%
• Clearly mark bridge plates
• Keep aisles clear and check
overhead clearance

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 Operating Areas
• Designate secure parking areas
• Designate secure refuelling areas
• Prevent smoking in refuelling areas
• Provide notices warning pedestrians
etc.
• Protect pipes, racking etc.
• Lighting levels of 100 lux minimum

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 Overturning of Fork Trucks
• Travelling with a • Striking kerbs etc.
raised load • Driving down ramps
• Speeding (> 5mph) forwards
• Sudden braking • Poor ground conditions
• Turning at speed • Movement of live loads
• Turning on a slope • Unbalanced loads
• Crossing ramps at an
angle

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Other Fork Truck Problems
These can be caused by:
• Overloading
• Collision with structures
• Floor failure from overloading
• Loss of load
• Explosions and fire
• Carrying passengers
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 Traffic Routes
• Regulation 17 of the Workplace
(Health, Safety & Welfare)
Regulations 1992 requires the safe
circulation of pedestrians and
vehicles in the workplace to be
organised

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 Traffic Routes
• Separation of vehicles and
pedestrians
• Use of barriers
• Speed restrictions
• Clearly signed routes
• Signage to comply with that
on public highways
• Enforcement of rules
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Lifting machinery and equipment
• The use of lifting machinery and
equipment is covered by The
Lifting Operations and Lifting
Equipment Regulations 1998
(LOLER 1998)
• This should be considered in
conjunction with PUWER 1998

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 Hoists and Lifts
• A platform or cage whose
movement is restricted by a guide
or guides
• Good mechanical construction
• Sound materials
• Adequate strength
• Properly maintained

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 Hoists and Lifts
• Examination at least every 6 months by a
competent person
• HSE must be notified within 28 days of any
defects which make the equipment unsafe
• Protection against persons falling into hoist
and lift ways
• Protection against contact with moving parts

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 Hoists and Lifts

• All protection systems must include

interlocking devices
• SWLs must be clearly indicated
and should never be exceeded

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Hoists and Lifts for People
• Automatic device to stop cage
overturning
• No movement whilst the gates are
opening or closing
• Two separately connected ropes or
chains each capable of supporting
the weight of the cage/people

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 Cranes

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 Cranes
• Good construction
• Sound materials
• Adequate strength
• Free from obvious faults
• Properly maintained
• Inspected at least every 14 months

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 Cranes
Accidents are caused by:
• Collapse and/or loss of load
• Overturning
• Overloading
• Collisions with structures
• Collisions with power cables
• Incorrect assembly
• Operator error

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 Safe Operation of Cranes
• Use audible/visible load indicators
• Dead man type controls
• Use over travel switches
• Provide safe access/egress for the
operator & for maintenance/inspection
• Provide a safe operating position with
clear visibility

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 Safe Operation of Cranes
• Inspect slings, chains, shackles etc.
for damage & mark with SWLs
• Check overhead obstructions such
as power cables
• Provide operator training
• Regularly maintain and test
• Use PTW systems

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Conveyors

• Belt
• Roller
• Screw

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Risks from Conveyors

• Trapping
• Contact with moving parts
• Entanglement
• Striking by falling materials

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 Belt Conveyors
Guarding is required:
• At trapping points between drum and belt
• Where the belt changes direction
• At guide plates or feed points
• Along length
• Using trip wires
Provide safe access for inspection/maintenance
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 Roller Conveyors
• May be free running or driven
• Provide guards at power points
• Provide guards at in-running nips,
where belts are fitted etc.

Provide access walkways over the mechanism

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 Screw Conveyors

• Must be guarded to prevent access

at all times
• Lock off drive before maintaining
or repairing
• Used in grain silos, chemical plants
etc.

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 Monorail Conveyors
• Used for conveying parts to
production lines, moving garments
in warehouses etc.
• Main risk is trapping between the
rail and hanging item or
entanglement

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 Order Picking Machines
• Variations of fork lift trucks
• Can be remote controlled
• Keep pedestrians away from
remote controlled pickers

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Automated Warehouse Systems
• Full risk assessment required
• Automatic stop when an obstruction is
encountered
• Automatic overload devices
• Barriers to prevent contact with
pedestrians
• Lock off devices for maintenance
• Safe systems of work required
• CCTV for controllers
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PUWER 1998 - Part 111
• Deals with Mobile Work
Equipment (MWE)
• MWE put into use after 5th
December 1998 and all hired
equipment must comply
• MWE in use prior to 5th
December 1998 to comply by 5th
December 2002
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 Types of MWE
• Carrying out work whilst mobile
e.g. lift trucks
• Travelling between locations to carry
out work e.g. mobile cranes
• Self propelled, towed or remote
controlled equipment including
towed machines and trailers

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 Types of MWE
• Towed equipment powered by the
vehicle e.g. power mower
• Towed equipment with own power
source e.g. sprayer
• Towed equipment with no powered
parts e.g. a plough
• Remote controlled equipment

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Regulation 25 - Employees carried on
MWE
Every employer shall ensure that no
employee is carried on MWE unless:
1. it is suitable for carrying persons; and
2. it incorporates features for reducing
to ALARP risks to their safety,
including risks from wheels or tracks

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 Regulation 25
Prevention of risks to drivers,
operators and passengers from:
• Falling from the equipment
• Unexpected movement
• Objects falling on the equipment
• Problems with surfaces
• Wheels and tracks

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 Regulation 25
Does not cover:
• Risks from other moving parts
e.g. power take off drives (See
Regulation 11)
• Risks associated with mounting or
dismounting from the equipment
which is covered by HASAWA

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 Regulation 25
• Seating to be provided where necessary
• Cabs, operators stations & work
platforms to prevent falling
• Falling object protective structures
(FOPS) e.g. safety cab
• Restraining systems e.g. seat belts
• Speed adjustment
• Guards & barriers to prevent contact
with wheels or tracks

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Regulation 26 - Rolling over of MWE
Every employer shall ensure that where
there is a risk to an employee riding on an
MWE from it’s rolling over, it is
minimised by:
• stabilising the MWE
• providing a structure to allow falling on
side only (excluding FLTs - see 27)
• providing a structure to give clearance if
falling further (excluding FLTs - see 27)
• a device giving comparable protection
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 Regulation 26 (continued)

• Where there is a risk of anyone

being carried by an MWE being
crushed by it’s rolling over, the
employer shall ensure that it has a
suitable restraining system

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 Regulation 26 (continued)
This regulation does not apply
where:
• it would increase the overall risk to
safety
• it would not be reasonably
practicable to operate the MWE
• in relation to MWE in use before
5th December 1998 it would not be
reasonably practicable
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Roll over protective structures (ROPS)

• Normally fitted on MWE which is

at risk of 180o or more roll over
• Engineering analysis required for
older vehicles before retro-fitting
• If a tractor is fitted with a ROPS
rather than a cab, a restraining
system will be needed

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Roll over protective structures (ROPS)

• Even with compliance with the

Agricultural (Tractor Cabs) Regs.
1974, a seat restraint may still be
required if there is danger of injury
from contact with the inside of the
structure during roll over

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Regulation 27 - Overturning of fork-lift
trucks
Every employer shall ensure that a
fork-lift truck which carries an
employee is adapted or equipped to
reduce to as low as is reasonably
practicable the risk to safety from
overturning

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Regulation 27 - Overturning of fork-lift
trucks (continued)

• FLTs with vertical masts

• FLTs fitted with ROPS e.g. rough
terrain variable reach trucks fitted
with fork lift attachments
• All other FLTs are covered by
Regulation 26

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Regulation 27 - Overturning of fork-lift
trucks (continued)
• Vertical masts will prevent
overturning by more than 90o if it
has sufficient strength
• A variable reach FLT can overturn
by 180o of more and needs a ROPS
• If the operator can be crushed if
thrown out during the overturning a
seat restraint will be required

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Regulation 27 - Overturning of fork-lift
trucks (continued)
• Restraining systems are required
for all FLTs with ROPS
• Most accidents occur with counter
balanced, centre control high lift
trucks with seated operators and
these normally required restraining
systems

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Regulation 28 - Self-propelled WE
Every employer shall ensure that,
where self-propelled work equipment
may, while in motion, involve risk to
the safety of persons:
• it has facilities to prevent starting
by an unauthorised person
• has facilities to minimise collisions
between vehicles on the same set
of rails
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• it has a device for braking and
stopping. The braking system
should be capable of holding it
fully loaded on the steepest slope.
• where safety constraints require,
emergency facilities operated by
readily accessible controls or
automatic systems are available for
braking and stopping in the event
of the failure of the main facilities
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• If the driver’s direct field of vision
is inadequate, devices should be
provided for improving vision such
as mirrors, CCTV, Fresnel lenses,
Radar
• Where escape from self-propelled
WE in the event of a fire could not
be achieved easily, fire fighting
appliances should be carried
e.g. a tower crane
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 Regulation 29 - Remote
controlled self propelled WE

• Must stop automatically once it

leaves it’s control range
• Where there is a risk of crushing or
impact it incorporates features to
guard against such risk unless other
appropriate devices are able to do so

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 Regulation 30 - Drive Shafts
30(1): Where the seizure of a drive shaft
between MWE and its accessories or
anything towed is likely to involve a
risk to safety, every employer shall:
• ensure that the MWE has a means of
preventing such seizure; or
• where such seizure cannot be avoided, take
every possible measure to avoid an adverse
effect on the safety of the employee
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30(2): Every employer shall ensure
that the WE has a system for
safeguarding the shaft:
• where MWE has a shaft for
transmission of energy between it
and other ME; and
• the shaft could become soiled or
damaged by contact with the
ground when uncoupled

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