Safe Handling, Lifting and Moving of Loadssafe Handling, Lifting and Moving of Loads
Safe Handling, Lifting and Moving of Loadssafe Handling, Lifting and Moving of Loads
Safe Handling, Lifting and Moving of Loadssafe Handling, Lifting and Moving of Loads
INTRODUCTION
Injury to muscles or the skeleton (principally the back) is common in all workplaces. It accounts,
nationally, for a very significant proportion of total sickness absence from work. Staff at all NERC
sites have suffered from such injuries, which tend to be slow to heal, affect both work and leisure
activities and tend to recur.
You must record all injuries and near misses in the local Accident Book.
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CONTENTS:
Operational procedure
Roles and responsibilities
System flow diagram
What might go wrong? probable sources of system and individual failure
Management, monitoring and auditing
Appendices:
Appendix I: Summary of Manual Handling Operations Regulations (1992)
Appendix II: General guidance on lifting
Appendix III: HSE guidance on maximum safe loads
Appendix IV: Risk assessment for manual handling
Appendix V: Training
Appendix VI: Promotional material
Appendix VII: Sources of further information
NOTE: Handling loads mechanically e.g. by using cranes, fork lift trucks etc is covered by
separate regulations and must be assessed independently. The few NERC sites which carry out
large scale loading and unloading operations must write specific policies and procedures for this
highly specialised work.
If you hire lifting and moving equipment you must comply with the requirements of the hirer. NERC
staff will normally need training to operate hired equipment. You must assess the risks of hired
equipment in the normal way. If you use large equipment or move heavy loads, the safety of
bystanders becomes an issue. You may need to close the areas where this equipment is to be
used to staff who are not involved in operating it. The head of site, or a senior line manager, must
consider safety issues before hiring such equipment.
Contractors who need to use heavy lifting equipment should discuss responsibilities and limitation of
access to work sites with local NERC management before work starts. Dealing with contractors on
NERC sites is covered in NERC Health & Safety Procedure Number 13: Managing contractors.
Acknowledgements: Material was received from Les Wright, Valerie Kennedy, Paul Howe, and
Simon Thurston/Ivan Ezzi some of which has been incorporated into this Procedure. The author
gratefully acknowledges the source of the material and the valued participation of these NERC
Safety Advisers.
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OPERATIONAL PROCEDURE
Manual handling operations fall into two clear categories: regular tasks and occasional lifting.
Managers should assess and control regular tasks. Occasional lifting can only practically be
assessed by individual staff at the time. In both cases, expert advice and assistance may be
sought via the site and Centre/Survey Safety Advisers.
The need to handle materials should be assessed at the site level. Management have an
obligation under the Manual Handling Operations Regulations (1992) to minimise manual
handling of materials wherever possible. Where are deliveries received, used or stored? Is a
better route or organisation possible? Is heavy equipment stored as near as possible to where it
is used? Is movement of materials a risk to bystanders? Document questions asked and
possible solutions. Cost and plan for longer-term improvements; remember, compensation
payments may be substantially higher than immediate cash cost.
Identify regular tasks. Clear description of the tasks is essential to making accurate
assessment of the hazards and risks. An honest description of how the task is done now may
prevent a future injury. For each task, identify and document:
Staff involved and training record in manual handling
Loads to be moved (maximum loads to be assessed for example, if several items are
crated for transport to the field, the crate should be assessed even if the items are carried
individually on arrival at the field site)
Weights of loads
Height and distance of load movement
Complexity of lift (straight or twisting movement, size of item)
Availability of lifting or moving aids (trucks, trolleys, ramps etc.)
Regularity of the task
Risk to bystanders
Difficulty of the terrain (carrying loads in, for example, mud flats, mountainous areas or thick
woodland may be very strenuous; you may need to assess the fitness of individual staff
through appropriate medical examinations. The Management of Health & Safety at Work
Regulations (1999) call for assessment of the need for health surveillance.)
Carry out a risk assessment for each task. The rationale and principles of risk assessment
are detailed in NERC Health & Safety Procedure Number 12. In terms of manual handling, risk is
the likelihood of personal injury arising from movement of specific loads by specific staff
members; it is classified as high, medium or low.
For each load, in each task, assess and document:
The safe load which can be moved by each staff member under the conditions of the task
(use the guidance values in Appendix III and the questionnaire on the risk assessment form
in Appendix IV to determine this value)
Training, experience, gender, body weight and size and general fitness of individuals
Moving aids available
Risk by comparing safe load against load to be moved (with and without aids) (use the risk
assessment form in Appendix IV)
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SITE
HEAD
Assess flow of
materials at site level
SENIOR
LINE
MANAGER
Can manual
handling
be eliminated ?
Revision
After agreed period
On change of staff
On significant change in
task
When monitoring indicates
system change needed (eg
following injuries or near
misses)
ALL LEVELS OF
LINE
MANAGEMENT
AND STAFF
INVOLVED IN THE
TASKS
YES
NO
Risk
assessment
of tasks
Safe
Systems of
Work
Authorisation
SENIOR LINE
MANAGER
Record of
agreement
and date for
revision
Agreement
ALL STAFF
INVOLVED
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Management:
The Piper-Alpha syndrome: The system is perfect in theory but everyone is operating it simply
to conform with the law. There is no safety culture because there is no ownership of or
commitment to the safety systems.
Remedy continuing management commitment, leadership by example, involvement of
staff in the assessment and operation of safety systems.
Mixed messages: they come from management at all levels. Managers are often unaware of the
conflict. If staff are told: Safety is paramount, Deadlines have to be met and Costs must be
kept down, which do they respond to in practice? If the senior manager is saying Safety first but
the immediate supervisor is saying We havent time to do that, who will staff listen to? Safety
must not be allowed to get in the way of science expressed at any management level, and not
countered, can undo months of effort to instill a safety culture.
Remedy making managers aware of their inconsistencies, rapid and clear countering of
negative messages, leadership by example.
Passing the buck: Safety is the job of the Safety Adviser nothing to do with me. The message
to staff is that safety is of peripheral interest and to be delegated if at all possible.
Remedy remind managers that they carry both legal responsibility and liability. By
ducking responsibility they increase liability - for both the individual manager and the
organisation. Compensation payments come out of the science budget of the
Centre/Survey/Laboratory. HSE will prosecute the most senior manager against whom they
can prove negligence.
Pressure from supervisors: Most likely to affect more junior staff and, particularly, students and
casual workers.
Remedy senior management support for susceptible staff. Make it clear to supervisors
that such pressure is unacceptable. A culture of acting on information given by whistleblowers.
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Management:
The management of safe handling, lifting and moving of loads requires:
Clear lines of responsibility
The setting of priorities and goals
Commitment to provide facilities and equipment required for safety
Provision of accredited training where a need is identified
Documentary evidence that tasks involving manual handling have been identified and
assessed for risk of personal injury
Written Safe Systems of Work for all tasks involving significant risk
Signed agreements between management and staff to work to Safe Systems of Work
Records of the agreements and agreed dates of revision
Agreed monitoring and auditing systems
Provision for staff feedback and whistleblowing
Monitoring:
The monitoring of safe handling, lifting and moving of loads requires:
Documentation of the management system
Written records of the process of production of Safe Systems of Work
Documentation of management follow-up after introduction of such systems
The recording of incidents, injuries, illness, fatigue and near misses associated with the
handling of loads
Documentation of actions taken as a result of follow-up and accident reporting
Assessment of safety attitudes amongst staff
Documentation of training undertaken
Maintenance of equipment and moving aids
Auditing:
The auditing of safe handling, lifting and moving of loads requires:
Checking that the above documentation is in place
Certifying that training is adequate and accredited
Assessing management and staff attitudes by interview
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drag, never drag what you can roll, never roll what you can leave'.
You must produce a risk assessment and Safe System of Work for regular handling jobs. For oneoff or occasional jobs, it is still worth while checking the guidance on load size (Appendix III) and
considering the consequences before moving the load. Back injury is very common, can cause
long-term pain and incapacity and is easy to avoid.
Common sense rules:
Always wear suitable loose fitting clothing and safety footwear. Make use of personal protective
equipment where appropriate e.g. gloves, safety hats etc
Always make use of appropriate handling aids e.g. barrows, trolleys, sack barrows, pallet trolley
etc to minimise carrying distances.
Where possible avoid carrying loads up stairs
If you have to move loads around the corridors then get somebody else to open fire doors for
you.
Avoid storing heavy loads on the floor the safest height to lift and put down loads from is at
waist level.
Do not use kick stools and step ladders for with manual handling operations both are
inherently unstable. Use suitable staging, platforms and walkways to handle loads above head
height.
NEVER intentionally create large loads when a number of small loads is a safer alternative.
Making sure everything is kept together may be a convenient method of housekeeping but is
unacceptable if it creates an unsafe manual handling operation.
When packing boxes, crates etc to form a load for transport, always provide an indication of the
weight and centre of gravity on the outside. However, when handling loads use common sense
if you suspect that such information may be misleading i.e. the information applied to the
original load but the box has been repacked always test the load.
There are basic principles in lifting:
Foot placement - start with the load between the feet. The leading foot should be in line
with the side of the load, pointing in the direction of movement, with the toes level with
the front edge of the load. If the load is too big for you to do this, you should not be lifting
it.
Knees bent / Back straight - get down to the level of the load by bending the knees and
hips. Tuck the chin in, and keep the back straight. Lean forward a bit to get over the load,
but do not incline the trunk more than is absolutely necessary. Avoid putting one knee on
the floor and deep knee bends.
CONTINUED ..
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Note that the figures assume lifting with a straight back; bending over, for example to lift from a
freezer, substantially reduces the safe weight for lifting. Take the lowest figure from any of the
coloured boxes through which the hands pass in the course of the lift. The figures also assume
adequate space for the lifter to achieve a stable body position and that the load is readily grasped
with both hands. You may need to reduce this figure for factors covered later in this guidance.
CONTINUED .
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Carrying
Similar to lifting; guidelines assume carrying close to the body for no further than 10 metres.
Reduce the figure if the load is carried further. Where the load can be carried on the shoulders
without having first to be lifted (eg. sacks from a lorry) a more detailed assessment may show that
the guideline figure can be exceeded.
CONTINUED .
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Extensive
Moderate
Minimal
Delete as
applicable
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
Does it involve:
Change of grip?
Twisting of the trunk?
Stooping?
Jerking or sudden movement?
Frequent or sudden movement?
Prolonged effort?
Reaching away from the trunk?
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
PART C: MOVEMENT
Frequency of movement (number of times per minute)? Please specify:
Does handling involve carrying?
If yes what is the carrying distance in metres?
Does the handling involve:
Pushing?
Welding?
Is the workplace dictated by process or other controlling factor?
Are rest allowances a feature of the work pattern?
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
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Delete as
applicable
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
High
Medium
Low
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Actions required:
Who informed:
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Appendix IV Table 1. Deciding the level of risk will inevitably call for judgement. This table can be used as guidance
in making these decisions when completing the risk assessment form.
Level of risk.
Questions to consider.
The tasks - do they involve.
holding loads away from trunk?
twisting?
stooping?
reaching upwards?
large vertical movement?
long carrying distance?
strenuous pushing or pulling?
bulky/unwieldy?
difficult to grasp?
unstable/unpredictable?
intrinsically harmful(e.g.
sharp/hot?)
variations in levels?
hot/cold/humid conditions?
strong air movements?
poor lighting conditions?
Individual capability - does the job:
require unusual capabilities?
LOW
MED
HIGH
Up to figure in guidelines.
Awkward to handle.
Grip is difficult to maintain.
Rarely.
Exposure to harmful
characteristic generally
avoidable.
Occasionally
Exposure not easily avoidable.
Moderate interference.
Significant interference.
Possibly.
Likely.
Certainly.
Considered necessary.
Rarely.
Occasionally
Certainly.
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APPENDIX V: TRAINING
The levels of training required by the Management of Health & Safety at Work Regulations
(1999) and the Manual Handling Operations Regulations (1992), should be in proportion to
the risks involved in a particular task. You should consider whether the trainee will be developing
a Safe System of Work or working to a previously developed system. The person who gives the
training must have a relevant, recognised and current qualification.
The course content should comply with NERC Health and Safety Procedure No. aaaa which
defines the core content of Health & Safety training requirements.
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The full text of the Manual Handling Operations Regulations (1992) can be obtained at
http:/tionestop.techindex.co.uk. Your local Safety Adviser has a password to access this site;
material can be downloaded to wordprocessors.
A pdf-file version of the HSE leaflet Getting to grips with Manual Handling is available at
http:/www.hse.gov.uk/pubns/manlinde.htm. The leaflet can be printed out free from this source.
The leaflet also references a wide range of extra sources of information from HSE; all of these
can also be downloaded from the Technical Indexes webpage above.
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