agga work health safety audit checklists … by the agga work health safety sub committee june 2012...

Prepared by the AGGA Work Health Safety Sub Committee

June 2012

AGGA WORK HEALTH SAFETY

AUDIT CHECKLISTS & GUIDELINES

Australian Glass & Glazing Association Inc. Suite 8, Level 6, 3 Bowen Cres, Melbourne VIC 3004 T +61 3 8669 0170 F +61 3 9867 4557 www.agga.org.au

ABN 22 152 329 355

Disclaimer: The information provided in this document is current at the time of print, it is intended as a general guide only.

of 15

Contents

Introduction ..................................................................................................................................... 3

Glass Manual Tasks Guide ............................................................................................................. 4

Glass Lifting and Handling Equipment Checklist ........................................................................... 10

Attachments .................................................................................................................................. 15

NSW WorkCover Safety Alert: Working with sheet materials ..................................................... 15

WHS Self Audit Checklist .......................................................................................................... 15


ABN 22 152 329 355


of 15

Introduction

This document is designed to assist company directors and management in conducting a

self-audit of plant, equipment and operational procedures within their factory.

It has been produced as a guide only and no way detracts from other responsibilities that exist for relevant Work Health Safety (WHS) Acts and Regulations that are in force in different States and Territories. All situations must be assessed individually. These responsibilities include, but are not limited to:

Policies and procedures

Documentation and document control

Consultation

Roles and responsibilities

Risk and Hazard Management

Site specific


ABN 22 152 329 355


of 15

Glass Manual Tasks Guide

Introduction

Due to the risk of injury associated with manual tasks, this guide has been compiled to set

the base glass sizes employees are allowed to handle.

The base limits stipulated on the tables below are the maximums in the event of

there not being an alternative calculation method.

In any situation where you are unsure of your ability to safely lift a piece of glass it is a

requirement that you always seek assistance.

WARNING: This lifting guide is for the use of employees who have been trained in the

company’s glass manual tasks and practices. Untrained staff must not lift glass.

Legend

Single Person Lift Two Person Lift Assisted Lift

Mechanical or Multi Person Lift

Other glass product weights and requirements that are not specified in the following tables

Use the following calculation in the event of there being no label attached to determine the

approximate weight of a panel of glass ie, another glass company’s product.

Glass thickness x 2.5 / Length x Width = Glass Weight


ABN 22 152 329 355


of 15

3mm Glass 7.5kg/m2

Height mm Width mm

0 600 1220 1840 2440 Over 2440

500

1000

1220

1840

2440

2800

3300

4mm Glass 10kg/m2

Height mm Width mm

0 600 1070 1220 1840 2018 2440 2760 Over 2740

500

1070

1220

1840

2440

2760

2800

3300


ABN 22 152 329 355


of 15

5mm to 5.76 Glass 14.4kg/m2

Height mm Width mm

0 600 1220 1840 2018 2318 2440 Over

2440

500

1000

1246

1840

2440

2800

3300

6 to 6.7mm Glass 16.75kg/m2

Height mm Width mm

0 600 1220 1840 2440 Over 2440

500

1000

1220

1840

2440

2800

3300


ABN 22 152 329 355


of 15

8 to 8.38mm Glass 20.95/m2

Height mm Width mm

0 600 1220 1840 2440 Over 2440

500

1000

1220

1840

2440

2800

3300

10 to 10.38mm Glass 25.95kg/m2

Height mm Width mm

0 600 1220 1840 2440 Over 2440

500

1000

1220

1840

2440

2800

3300


ABN 22 152 329 355


of 15

11.76 Glass 29.4kg/m2

Height mm Width mm

0 600 1220 1840 2440 Over 2440

500

1000

1220

1840

2440

2800

3300

12mm Glass 30kg/m2

Height mm Width mm

0 600 1220 1840 2440 Over 2440

500

1000

1220

1840

2440

2800

3300


ABN 22 152 329 355


of 15

15mm Glass 37.5kg/m2

Height mm Width mm

0 600 1220 1840 2440 Over 2440

500

1000

1220

1840

2440

2800

3300

19mm Glass 47.5kg/m2

Height mm Width mm

0 600 1220 1840 2440 Over 2500

500

1000

1220

2440

2440

2800

3300


ABN 22 152 329 355


of 15

Glass Lifting and Handling Equipment Checklist

The following checklist will assist you in identifying what equipment requires regular inspection to ensure that they meet any relevant

standards. Images of some of the equipment items listed can be found on pages 13 & 14.

1. Block Glass Lifting Grabs Image Type Qty Inspection

Frequency Date of Last Inspection

Next Inspection Due Date

2.1 Basket

2.2 Saddle

2.3 Side Loading

2.4 Plate

2. Vacuum Lifting Equipment Image Type Power Supply

Fitted (see below)

Qty Inspection Frequency

Date of Last Inspection


3.1 Bar Lifter

3.2 Tilt Only

3.3 Rotate Only

3.4 Tilting & Rotating Type

Other:

Power Supplies A - 12v DC Power Pack mounted on Lifting Frame B - 415v AC Compound Pump (mounted on Crane Crab overhead) C - Compressed Air Venturi operation D – Other (please specify)


ABN 22 152 329 355


of 15

3. Mobile Ergonomic Handlers Image Make Model Qty Inspection



5.1 Arlington RDE500 GFB900 AA380

5.2 Intellitech GL351 GL500 Other

5.3 Winlet 350 575 Other

5.4 Other:

4. Crane Liftable Stillages & A-Frames Image Type Rated WLL Qty Inspection



6.1

6.2

6.3

6.4

5. Lifting Slings Image Type Size Qty Inspection



7.1 Chains

7.2 Terylene

7.3 Spreader bar


ABN 22 152 329 355


of 15

6. Floor Mounted Static Racks, A-Frames & Storage Systems Image Type Qty Inspection



8.1 Modular A-Frames

8.2 Free Fall racks

8.3 Concertina Compactor racks

8.4 Container (Glass Import) A-Frames

8.5 Drawer Type Manual Systems

8.6 Double Decker (Key Hole) Type Systems

8.7 Pole Racks for Double & Triple Stacking Cases & End-caps

8.8 Peg & Plank and Toast Racks

8.10 (1) Case Supports

8.10 (2) Case Stabilizers

8.11 Slot & Harp Type Racks

8.12 Offcut Racks

7. Rolling Stock Image Type Size Qty Inspection



9.1 Trollies

9.1 Barrows

9.2 Dollies

9.2 Gun Carriages

8. Glass Transporters Image Truck Make,

Model, Year of Manufacture, GVM

Body Dimensions

L x W x H

Qty Wheelbase & rear overhang

from rear axle to back bumper

Outside of rear tyre

dimension

Max. glass size

capability

Max. load weight carried

Type & Number of Glass

Restraints

Date of Last Inspection


10.1

10.2

10.3

10.4


ABN 22 152 329 355


of 15

Glass Lifting and Handling Equipment Images


ABN 22 152 329 355


of 15

Attachments

NSW WorkCover Safety Alert: Working with sheet materials

WHS Self Audit Checklist

Working with sheet materials

February 2012

The purpose of this alert is to provide information about hazards and the potential for serious injury when storing or handling sheet materials that are stacked on their edges.

BackgroundA worker received fatal injuries while unpacking glass sheets from a timber crate. Workers had removed the top and front of the crate, and were in the process of lifting the sheets from the crate onto a transport truck. After unloading approximately half of the crate, the remaining sheets became unstable and toppled, crushing the worker against the truck.

Contributing factorsInvestigations are continuing; however, a number of factors may have contributed to the incident.

• The crate that toppled was stored upright on the factory floor, not placed on an A-frame prior to opening.

• The factory had A-frames; however the design only held one crate on each side. The usual storage method at the site was to successively lean additional crates against the crate in the A-frame and then chock the bottoms with timber. In this manner, up to six additional crates would be leaning against a crate in an A-frame.

• The crate that toppled was not stored in this manner, but was leant against the ends of one such arrangement. An attempt to keep the crate on a lean while unloading sheets was made using timber chocks.

• There was limited space in the factory, and the layout at the time hindered movement around the crate and the truck.

Action requiredThe incident involved glass handling; however, the following is also applicable to other sheet materials that are stored upright on an edge. Hazards associated with the handling and storage of sheets may arise from:

• the work practices and systems of work in use, including manual handling

• the plant and equipment used to transport, handle and store the sheets or crates

• the layout and condition of the place of work.

When storing sheet materials, consider the following • Store the sheets or crates on a lean on an A-frame or other purpose-designed racking that can support the material

in a stable manner (a lean of 3-6° from the vertical is commonly recommended, and 5-6° is recommended for transportable racks, pallets and stillages).

• Once stored, use appropriate restraints to retain sheets or crates in position and prevent later movement due to wind, impact or other actions.

• Do not overload frames or racking.

• Ensure supporting surfaces are level and strong enough to sustain the load of the frame, racking, crate or sheets.

• If using chocks under crates, they should extend the full depth of the crate. Be aware that chocks can result in concentrated loads on both the crate and the supporting surface.

SAFETY ALERT

• Ensure storage areas have adequate clearance to allow access for workers and lifting equipment. Storage areas should not be used to unload individual sheets unless the layout, access, equipment used and safe work procedures allow it.

• Ensure workers are adequately trained in systems of work for the storage of sheet materials.

When unpacking sheet materials from crates, consider the following • Before unpacking crates, position them on a lean (3-6° is recommended). This could be done using an A-frame or

other appropriately designed structure.

• If the crate is providing support to sheets on a lean, be aware that removing tops, sides or ends of the crate can weaken it.

• Be aware of possible movement inside crates and containers as a result of transport.

• Be aware of recoil when releasing straps used to strap crates or bundle sheets of material together.

• Some materials may stick together when bundled due to friction or suction between the sheets. However, if straps are loosened/removed or the seal is broken individual sheets may still slip.

• Use appropriate lifting equipment when handling sheets. Do not exceed the working load limit of any lifting device.

• Remain clear of hazard (fall) zones when lifting and handling sheets.

• Ensure that workers are adequately trained and supervised for the tasks they are performing.

• Ensure that working areas are well lit and have adequate space for the tasks being undertaken.

• Use appropriate personal protective equipment (PPE) (eg gloves).

Further informationThe Work Health and Safety Act 2011 (WHS Act) requires persons in control of a business or undertaking at a workplace to ensure, so far as is reasonably practicable, that workers and other persons at a workplace are not exposed to risks arising from the business or undertaking and that all staff are adequately trained and supervised.

Clauses 34 to 36 of the Work Health and Safety Regulation 2011 (WHS Regulation) places specific obligations on duty holders to identify reasonably foreseeable hazards that are associated with work being undertaken, and then to manage those risks accordingly.

• Safety alert – Storage and handling of glass sheets (catalogue no. WC05346)

• Safety alert – Storage and handling of sheet materials deir.qld.gov.au/workplace/resources/pdfs/alert-storage-handling-sheetmaterials.pdf

• Poster – Handling glass safely (catalogue no. WC06032)

• Glazing and glass federation code of practice – Glass handling, storage and transport ggf.org.uk/publication/ggf_code_of_practice_for_glass_handling_and_storage

• New South Wales Glass and Glazing Association – nswgga.org.au/

• workcover.nsw.gov.au or phone 13 10 50

Catalogue No. WC03707 WorkCover Publications Hotline 1300 799 003 WorkCover NSW, 92-100 Donnison Street, Gosford, NSW 2250 Locked Bag 2906, Lisarow, NSW 2252 | WorkCover Assistance Service 13 10 50 Website workcover.nsw.gov.au

ISBN 978 1 74341 044 8 © Copyright WorkCover NSW 0212

Disclaimer

This publication may contain work health and safety and workers compensation information. It may include some of your obligations under the various legislations that WorkCover NSW administers. To ensure you comply with your legal obligations you must refer to the appropriate legislation.

Information on the latest laws can be checked by visiting the NSW legislation website (www.legislation.nsw.gov.au).

This publication does not represent a comprehensive statement of the law as it applies to particular problems or to individuals or as a substitute for legal advice. You should seek independent legal advice if you need assistance on the application of the law to your situation.

© WorkCover NSW

This Alert contains safety information following inquiries made by WorkCover NSW about an incident or unsafe practice. The information contained in this Alert does not necessarily include the outcome of WorkCover’s action with respect to an incident. WorkCover does not warrant the information in this Alert is complete or up-to-date and does not accept any liability to any person for the information in this report or as to its use.

Company / Site: Date of Inspection: Next Inspection Date: Inspection Team:

INSPECTION ITEMYes No

N/A

Comment / Controls

Non-ConformanceAction

Indicate person responsible & dateTips

WHS POLICIES & PROCEDURES

WHS Policy Statement displayed?

Senior manager statement advising "Duty of Care" to all

employees displayed in key areas such as lunch room, office and

notice board in factory.

Policies & procedures documented?

Employees consulted on WHS issues?

Always engage staff including shop floor and office in consultation

either individually or via team leaders/supervisors.

Are incidents & accidents fully investigated and results

actioned?

Always seek root cause by asking why.

Are return to work related injury or illness employees

assigned to alternative duties if required?

Have an alternative duties list available for discussion.

Work instructions displayed at work stations

Insert instructions into plastic sleeves that protect and are easily

replaced.

Are work instructions reviewed & amended when

necessary?

Is there a register for all known hazards?

Hazards are easier to control when documented and available for

discussion.

Are risk assessments conducted & hazards controlled?

Use template available from WorkSafe in your State.

Are roles & responsibilities defined for individuals?

Meet with individuals and discuss specific job duties.

Are Managers treating safety as a high priority by being

involved in all safety initiatives?

Discuss WHS at all meetings.

Do Managers drive the safety culture whilst leading by

example?

Managers should always follow correct work instructions including

wearing appropriate PPE.

WHS SELF AUDIT CHECKLIST

Page 1 of 7



N/A

Comment / Controls




PERSONNEL PROTECTIVE EQUIPMENT

Is all PPE maintained in good condition?

Maintain PPE in good order & replace when necessary.

Is appropriate PPE worn as required?

High risk areas such as saws must have adequate signage.

TRAINING

Are all employees inducted?

Have a good induction book/checklist.

Are all employees properly trained including in the use of

any equipment they are using?

Keep a training register and put authorised staff names next to

equipment where possible.

FIRST AID

Is there an adequate number of first aid kits for the

number of employees?

Refer to WorkSafe in your State for the correct number.

Are first aid kits clearly signposted?

Have First Aiders wear different hi-vis tops.

Are trained first aid personnel listed / recorded /

displayed?

Are emergency contact phone numbers displayed?

Display emergency phone numbers in reception.

GENERAL HOUSEKEEPING

Are walkthrough inspections conducted daily weekly or

monthly?

Use a template with factory items listed and inspections carried out

by various individuals.

Are bins cleared regularly?

Never overfill bins as it is unsafe and requires extra work cleaning

up.

Is combustible material placed or stored correctly?

Are work areas clear of obstacles?

Always ensure employees inspect area before commencing any

task.

Page 2 of 7



N/A

Comment / Controls




GENERAL HOUSEKEEPING cont.

Are walkways & passageways minimum of 900mm

wide?

Walkways clearly marked with 50mm yellow lines.

Are walkways clearly marked with 50mm yellow lines?

Are there any leads or connections across walkways?

Is there adequate lighting?

Inspect regularly.

Are toilets & amenities cleaned regularly?

Are all ladders kept in good condition?

Have a ladder register in place.

Are entry & egress walkways kept clear?

Use signage. No leads or connections across walkways.

HAZARDOUS SUBSTANCES

Is regulation PPE issued?

Follow MSDS instructions.

Is the MSDS Register up to date for chemicals used?

MSDS supplied on purchases from supplier.

Are containers correctly labelled?

Do not store in non-suitable containers such as drink bottles.

Are flammables stored correctly?

Suitable storage containers are available from safety suppliers.

Is the correct signage displayed?

Follow MSDS instructions.

Are unused chemicals disposed of correctly?

Page 3 of 7



N/A

Comment / Controls




FIRE SAFETY EMERGENCY

Is fire equipment installed correctly & serviced regularly?

Use reputable supplier.

Is the correct signage displayed?

Outsource reliable service provider to manage equipment.

Is there an emergency evacuation plan in place?

Test plan twice yearly.

Are fire exit doors clearly marked and clear of

obstructions?

Mark floor near fire exits.

LIFTING EQUIPMENT

Does the following plant & equipment comply with

Australian Standards?

Purchase copy of standard for factory plant.

AS 4100 Steel Structures

AS 4084 Steel Storage & Racking

AS 4991 Lifting Devices

AS 3775 Chains & Slings

AS 1418 Cranes & Hoists

Is there a scheduled maintenance program in place &

records kept?

Keep records of all repairs and frequency required.

Are compliance tags & instructions attached to

equipment

Check any new purchases for tags.

Have operators undergone competency training?

Training is available - contact your supplier. Maintain up to date

training records.

Page 4 of 7



N/A

Comment / Controls




GLASS STORAGE FRAMES & RACKS

Are frames & racks constructed to suit the glass weight &

size?

Use only frames from a reputable supplier and request specs.

Regularly inspect welds.

Do storage frames or racks have 3-5 degree angle?


Regularly inspect welds.

Is there a minimum clearance of 600mm between racks

& cases?

Clearly marked with 50mm yellow lines.

Is there a minimum clearance of 800mm from block or

case ends to any exterior/interior walls?

Clearly marked with 50mm yellow lines.

Is glass stored with weight even on both sides of rack?

Check equal number of packs as excess weight on one side can

place undue stress on frame.

Do floor surfaces have sufficient strength to support the

weight and are free from cracks or undulations?

Obtain specs from landlord.

All off-cuts or surplus glass to be stored correctly

Only store glass inside racks fully supported. Large offcuts should

be stored in horizontal type racks. Wear hard hats when placing or

removing offcuts that are overhead.

Are glass cases properly restrained when being

unloaded?

Refer to NSW WorkCover Safety Alert: Working with sheet

materials.

TRANSPORTING GLASS

Are glass delivery truck racks constructed to suit the task

5 deg angle?


Glass trolley wheels to have the correct load ratio


Is the trolley SWL capacity tag visible & load not

exceeded?

Calculate weight & do not over fill trolley.

Is glass appropriately secured on equipment when

transporting?

Use restraining bars, straps etc.

Page 5 of 7



N/A

Comment / Controls




TRANSPORTING GLASS cont.

Are rubbers & timbers fixed to equipment to protect

glass?

Avoid glass to metal contact.

Does your company engage in a Scheduled

Maintenance Program (SMP) with regard to trucks &

equipment?

Service trucks regularly.

Is glass overhanging trolleys clearly marked

Use tape or hi-vis markers on glass corners.

MACHINERY

Does machinery & plant comply with Australian

Standards (including AS4024 Safety of Machinery 2006)

for design, manufacturing and testing?

Use reputable supplier and request specs.

Are Risk Assessments done for each plant item

Use template available from WorkSafe in your State.

Does your company engage in a Scheduled

Maintenance Program (SMP) with regard to plant &

equipment?

Keep records of all repairs and frequency required.

Have employees undergone competency training with

regard to plant & equipment?

Keep a training register and put authorised staff names next to

equipment where possible.

Are machine guards in place and working according to

type of equipment?

Meet with individuals and discuss specific job duties.

Are daily pre-start checks done on machines?

Consult with operators as a group to determine possible risks.

Are emergency stops working and signposted?

Check all new equipment purchases.

Are lockout tag procedures used to identify and isolate

plant?

Purchase lockout tags from safety equipment supplier.

ELECTRICAL EQUIPMENT

Is tagging & testing carried out & up to date?

Consult your electrical contractor.

Are plugs, sockets and switches in satisfactory

condition?


Page 6 of 7



N/A

Comment / Controls




ELECTRICAL EQUIPMENT cont.

Are leads in a satisfactory condition not frayed, damaged

or presenting a tripping hazard?


Are you using correct power boards?

Do not use double adaptors.

Is all electrical work carried out by a qualified licenced

person?

Check suppliers qualifications.

MANUAL HANDLING TRAINING

Are employees trained in manual handling techniques?

Manual handling training is available through AGGA. Stretching

before work helps start the day.

Are employees wearing the correct PPE?

Is the work area inspected for obstacles & hazards

before commencing the task?

Always ensure employees inspect area before commencing any

task.

Do employees determine the weight & size of a panel

before commencing a task?

Refer to AGGA Glass Manual Tasks Guide.

Is the correct lifting technique used for the size & weight

of the glass being handled?

Refer to AGGA Glass Manual Tasks Guide.

Is glass always inspected for faults?

Visible inspection is a must.

Are glass sheets aired before free-falling?

Use a sucker to air sheet to prevent numerous sheets coming

together.

Is the correct lifting equipment used for the glass

weight/sizes?

Check compliance plates of equipment before use.

Is glass always placed into cullet bins?

Do not break glass on bins as it will shatter and could cause injury.

Page 7 of 7

agga work health safety audit checklists … by the agga work health safety sub committee june 2012...

Documents