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NEBOSH NEBOSH Certificate Certificate

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NEBOSH NEBOSH Certificate Certificate

Fork Lift Fork Lift TrucksTrucks

Counterbalance FLTCounterbalance FLT

Reach Truck

Typical StoresTypical Stores

Pedestrian TruckPedestrian Truck

Narrow Aisle Order PickerNarrow Aisle Order Picker

Telescopic Tele-porter Telescopic Tele-porter Lift TruckLift Truck Rough Terrain Rough Terrain

TruckTruck

Daily Express June 18Daily Express June 18thth 2001 2001

Fork Lift Truck AccidentsFork Lift Truck Accidents

• Overturning • Falling from loading bays etc• Loads falling • Vehicles striking people • Vehicles striking building / plant / equipment• Use by unauthorised persons• Changing batteries or fuel• Refuelling

LIFT TRUCK SAFETYLIFT TRUCK SAFETY

• What Hazards are associated with lift trucks ?– Weight (truck, load & combined)– Pedestrians & other vehicles– Traffic routes (doors, ramps & corners)– Speed– Exhaust gasses in confined spaces– Space availability for trucks / load requirements– Load stability– Truck fuel types – Fire & explosion– Lack of competence / misuse – Lack of competent supervision

LIFT TRUCK SAFETYLIFT TRUCK SAFETY

• Legal Requirements– HSW Act 1974– Management of health and safety at work

regulations– Provision and use of work equipment regs– Lifting operations and lifting equipment regs

• Guidance – ACOP (COP 26) rider operated lift truck - operator

training– Guidance HS(G)6 safe working with lift trucks– Guidance PM28 working platform

FLT, A.C.O.P.FLT, A.C.O.P.

Requires – Health requirements– Trainability assessment– Training programme– Regular re-training

FLT, A.C.O.P.FLT, A.C.O.P.

Three stages 1) Basic training– Skills / knowledge needed for safe operation

2) Specific job training– Knowledge of the work place and special

techniques3) Familiarisation training– On-the-job under close supervision

• Managers require training & information as a minimum :-– Basic training and knowledge– Risk assessments, and– Any written systems of work

Operator Health Requirements.Operator Health Requirements.

• Full movement of the trunk• Normal agility• Normal hearing• 12/6 vision

– If spectacles should be worn they must be worn at all times

• Epileptic seizure, heart problem, stroke– Doctor should certify a return to work

• Stable mentality

Lift Truck InstabilityLift Truck Instability

• Lift trucks become unstable both longitudinally and laterally due to a number of factors

• Longitudinal instability could be – Overloading– Moving with load at height– Harsh braking– Harsh use of controls– Incorrect use of mast tilt– Incorrect travel on ramps– Uneven ground– Undercutting

Lift Truck InstabilityLift Truck Instability

• Lateral instability could be – Turning at speed– Turning with load raised– Load’s shift in centre of gravity– Uneven ground– Travelling across inclines– Drain gully’s etc– Lifting with one fork– Damaged tyres– Pot holes and obstructions etc

Rated Capacity PlateRated Capacity Plate

• All lift trucks must display a rated capacity plate, which will show the actual weight at a certain distance from fork face that the truck can lift. e.g

Weight Load centre Mast height

2500 kgs 600 mm 4.5 metres

Rated Capacity PlateRated Capacity Plate

• The operator must never exceed the rated capacity• Operators must be given information about the rated

capacity• The capacity will change if

– Change Forks– Attachments are used

Lift Truck AttachmentsLift Truck Attachments

• When purchasing or fitting attachments you must check– The correct rated capacity plate is fitted– It was designed for the particular truck– Safe working loads are displayed – The operator is aware of the new capacity

Battery ChargingBattery Charging

• The charging process causes hydrogen gas, a procedure must be developed to prevent explosion and include – Select a well ventilated area– Prohibit smoking and naked flames

• The charging procedure should be – Isolate the mains– Connect the charger to the battery– Uncoil cable and switch on– Check charge level, if fully charged switch off– Disconnect charger from the truck, coil up the

leads to store• Use protective clothing whilst topping up

Hazards Associated with Electric Hazards Associated with Electric Fork Lift TrucksFork Lift Trucks

Battery charging• Hydrogen gas

– Ventilation, fire equipment, no smoking & signage• Sulphuric acid

– Protective clothing, spillage procedure, clean water, first - aid & topping up procedure

• Electricity– Insulated tools, safe charging procedures & isolation

Fork Lift Truck-Pre Shift Check ListFork Lift Truck-Pre Shift Check List( to be completed by the operator )( to be completed by the operator )

Truck Number________________ Week Commencing_______________________

Mon Tues Wed Thur Fri Sat Sun

Fuel / Oil / Water

Battery

Mast Forks

Load Chain

Guards cover

Wheels/Tyres

Seat

Hydraulics

Light/dials/horn

Gears

Brakes

Steering

Controls

Visual Check

Signature Supervisors sig’

Faults must be reported to the supervisorMon

Tues

WedThurFridSat

Sun

Purchasing or Hiring a Lift Truck.Purchasing or Hiring a Lift Truck.

• Managers must have checked – Type of truck is suitable – Unladen weight– The rated capacity– Load centre distance– Maximum height– Changes when using attachments

• Should also have a pre-operational check carried out which should cover – Tyres and batteries, brakes, horn, overhead

guard, hydraulic system, lights if fitted, capacity plate, leaks, lock or switch and key, all moving parts

General Controls Methods:-General Controls Methods:-

• Correct type of FLT for environment / load– Fuel type, racking / storage type, load capacity &

ground conditions, used indoor / outdoor• Training of operators / managers :-

– Both are competent in all types and systems used• Maintenance

– Service & breakdown as required– Maintain environment and traffic routes– Daily pre-operational checks by operators

Typical FLT QuestionsTypical FLT Questions

• List EIGHT rules to be followed to minimise the risk of Fork Lift Trucks overturning (8)

• List the ways in which a fork lift truck may become unstable whilst in operation (8)

• Outline the hazards and the corresponding precautions to be taken when charging batteries for fork lift trucks

(8)

SlingingSlinging

SLINGING SAFETYSLINGING SAFETY

• Legal requirements – Health & safety at work act – Management of health and safety at work regulations– Provision and use of work equipment regs – Lifting operations and lifting equipment regs

• Guidance – GS 39 guidance training of crane drivers and slingers

Lifting Operations Lifting Operations and Lifting and Lifting Equipment Equipment

Regulation 1998Regulation 1998

LOLERLOLER

LOLER LOLER

• Strength and stability – Adequate strength– Suitable for the task

• Lifting equipment for lifting persons – Prevent crushing, trapped, struck or people falling etc– Has devices to restrict / prevent carrier falling

LOLER LOLER

• Positioning and installation – Prevent load striking a person, drifting, falling freely,

being released unintentionally, and it is otherwise safe

– Prevent from falling down a shaft or hoist way, gates or other effective means to prevent access or egress

• Marking of lifting equipment – Marked to indicate their SWL, for each

configuration– Lifting people is clearly marked, or marked ‘not

designed for lifting persons’

LOLER LOLER

• Organisation of lifting operations – Ensure operations are properly planned, supervised,

conducted in safe manner• Planning lifting operations

– Plans carried out by • Slinger / FLT operator / crane operators etc

LOLER LOLER

• Thorough examination and inspection – After installation / before being put into service for

the first time– Before being put into service at a new site or

location to ensure it has been installed correctly / safe to operate

• Equipment exposed to deteriorating conditions examined – Equipment for persons, 6 months, other at least

every 12 months– Every time the exceptional circumstances occur

Planning Lifting OperationsPlanning Lifting Operations

• A simple plan for overhead travelling crane– Assess the weight of the load– Choose the right accessory for the lift– Check the route for travel– Prepare suitable place to set the load down– Fit the sling to the load– Make the lift (trial lift first)– Release slings, prevent trapping, – Inspect return to stores– Clear up

Main Controls For Safe SlingingMain Controls For Safe Slinging

• Risk assessments / method statements• Trained operators / competent managers• Information known of the

– Site conditions, loads• Awareness and control of

– Overhead, ground and boundary conditions / hazards– Barriers and any segregated areas

• Suitable equipment with correct SWL• Maintained and inspected equipment

LOLER LOLER

Reports and defects

• Person making examination shall – Notify employer defects, make written report, to

employer, leased or hired– Where the defect presents an imminent risk of serious

personal injury, send a copy to the relevant authority

LOLERLOLERKeeping of records • Employer keep EC declaration

– Every thorough examination report made is kept available

• Until he ceases to use the equipment• Accessories (incl; cranes & mobile elevated

work platforms)1-2 yrs• After installation / reconfiguration until he

ceases to use the equipment at the place it was installed or assembled

• In the case of regular in-service thorough examinations until the next report is made or 2 yrs

– Every record must be kept until the next record is made

Register of EquipmentRegister of Equipment

• Needed to ensure – Implementation of current legislation– Inspected, tested and maintained as required

• Helps to keep records– Where slings are within the organisation

• Enables monitoring – Use and maintenance of lifting equipment

• Provides information – To slinger about slings

• Age / defects for maintaining test• Inspection and use requirements

Types of SlingsTypes of Slings

3 Main types of sling materials • Chain slings

– Used for harsh conditions– Can become brittle…….anneal

• Steel wire rope– Flexible used in most industries

• Man-made fibres– 4 types nylon, terylene, polyester and polypropylene– Easy to use but have limitations depending on

material type• Slings can be damaged easily by

– Chemicals, harsh environments, sharp edges, hot or cold conditions, sunlight and poor storage

Seven Basic Slinging RulesSeven Basic Slinging Rules

1. Know weight of load, where it has to go

2. Select the correct sling – adequate strength – suitable for the load and– inspect before use

3. Fit the sling over the centre of gravity

4. Make a trial lift to check the set

5. Lower in clear area, keeping feet clear

6. Remove the slings carefully

7. Clear area, inspect sling and return to store

( report any damage )

Managers ResponsibilitiesManagers Responsibilities

• Ensure all slings and lifting equipment have – Individual markings and are entered in the register– The SWL clearly marked– Charts posted where required– Periodic examinations– Annealed as necessary– Repaired slings are re-proof tested and certificated– Competent people using correct techniques– Competent supervision

Typical Slinging QuestionsTypical Slinging Questions

• Outline the precautions that should be taken during lifting operations with a mobile crane (8)

• Outline the procedure for the safe lifting of a load by the crane, having ensured that the crane has been correctly selected and positioned for the job (8)

ConveyorsConveyors

Common ConveyorsCommon Conveyors

Belt

Roller

Chain

Screw

Slat

Cup

Hanging

Hazards With ConveyorsHazards With Conveyors• Traps or ‘in-running-nips’

– Between moving parts – Between moving and fixed parts– Created by the drive mechanism – Created at transfer points– Between belt and roller conveyor transfer point– Between screw and feed opening– Chain and chain wheel, moving belt and rollers– V-belts, pulleys, chain and sprockets

• Sharp edges• Falling objects• Noise• Dusts

Reversible Conveyor showing Trapping Reversible Conveyor showing Trapping PointsPoints

A reversible conveyor showing trapping points

In-Running Guard PlateIn-Running Guard Plate

Guarding of conveyor end using a horizontal guard plate

Dead PlatesDead Plates

Use of dead plate where two conveyors meet

Jump Out RollersJump Out Rollers

Junction of a roller conveyor and belt conveyor showing position of jump - out roller

Jump out roller

Conveyor Chain End GuardingConveyor Chain End Guarding

Guarding at the end of a chain conveyor by enclosure of the sprocket wheels and nip points

Fixed GuardsFixed GuardsProtective hood over the return point of the

conveyor

Transport Transport

And And

TransportationTransportation

Transport Accident RateTransport Accident Rate

• Every year about 70 people are killed in workplace transport related accidents

• 1,000 major injuries • 5,000 injuries that cause people to be off work for more

than three days

Causes of Transport AccidentsCauses of Transport AccidentsTransport Accidents can occur because of• Contact

– With structures, services, people• Overturning

– Incorrect loading, speeding, surface conditions• Collision : with other vehicles or pedestrians• Impact : falling onto or from vehicle• Entanglement

– In dangerous parts of the machinery or controls• Explosion

– Changing batteries, inflating tires, accident fires • Operator / driver error

– Inadequate training, tired, hurried, reckless, misperception

Planning Traffic FlowPlanning Traffic Flow

Access to automated areas should be strictly controlled• Segregate

– People and Vehicles• Storage areas

– Clearly marked out• Gangways

– Clearly marked– Wide enough – Clear of obstructions

• External doorways– Barriers

Controlling Vehicle Manoeuvring Controlling Vehicle Manoeuvring AreasAreas

• What measures could we use to control the hazards ?– Lighting– One way system– Reverse warnings on vehicles– CCTV coverage for area and driver– Competent supervision– Prohibition areas– Training, information– Size of area– Maintained safe area ie. slippery, holes etc– Drive through system, etc

TRANSPORTATION OF TRANSPORTATION OF SUBSTANCESSUBSTANCES

SYNDICATE

What are the main factors which may need to be considered, when organising the transportation and delivery of dangerous substances

• The main areas that need to addressed are – Substance– Transport– Route Considerations– Driver

The SubstanceThe Substance

– Amount– Physical form i.e powder, liquid etc– Chemical classification– Adverse effects– Compatibility with other chemicals– Method of handling i.e loading / unloading– Containerisation method

• The carriage of dangerous goods regulations could apply

TransportationTransportation

• Type of vehicle required– Flatbed, articulated, van etc

• Mechanical state of vehicle– Inspections, thorough examinations

• Site considerations– Manoeuvrability – Signage– Separation of traffic routes

• Vehicles / pedestrians– etc

Route ConsiderationsRoute Considerations

• Route to be taken– Motorways, A or B roads– Consultation with other bodies e.g police for escort

• Signage & statutory markings– Flammables, explosives, hazchem, plating

• Spillage controls– Driver competence and training

• Weather conditions

DriverDriver

• Health• Qualified and experienced

– Training– Competence

• Assistance – Needed / available

• Information regarding :-– Substance, effects, handling etc– In the cab, only the substance info on the vehicle– Procedures and emergency procedures

Typical Transport QuestionsTypical Transport Questions

• Outline the main precautions to be taken to ensure the safe transport of hazardous substances by road (8)

• Outline measures to be taken to prevent accidents when pedestrians are required to work in vehicle manoeuvring areas (8)

Manual Manual HandlingHandling

Manual HandlingManual Handling

• Manual handling is– The lifting, lowering, carrying, the pulling or pushing of

a load by hand or by bodily force

• A load could include – People or animals

Potential InjuriesPotential Injuries• Muscles torn, or strained• Ligaments split or stretched• Joints sprained• Cartilage worn, split or flaked• Bones broken• Discs slipped or prolapsed• Nerves trapped or damaged• Feet bruised, crushed, amputated• Eyes detached retinas• Skin cuts• Many injuries :-

– Are over 3 day absence from work– Injured person never returns to work

Manual Handling RegulationsManual Handling Regulations

• These regulations define a clear approach – Avoid manual handling– Assess– Reduce the risk

• Each employer shall – Where it is not reasonably practicable to avoid manual

handling operations which involve a risk of being injured

– Make a suitable and sufficient assessment of all such manual handling operations

• Re-assess if – No longer valid…or– There have been significant changes

Infrequent Weight Guidelines’Infrequent Weight Guidelines’

• Reduce by 10% = if Twisting beyond 45 and/or 20% beyond 90

•Reduce by 30% = if repeated 5 - 8 times per min,

Or 80% = for more than 12 times per minute

Manual Handling Reg’sManual Handling Reg’s

• Duty of the employee – Must make full use of any

• System of work provided by the employer• Special methods required as a result of the risk

assessments • Methods taught in induction training

– Take reasonable care for ourselves and others– Co-operate with the employer

ManagementManagement Regulations Regulations

• Duty of employees – Requires employees to follow any training

or safe system of work– Must use

• Equipment, machinery, dangerous

substances, transport, equipment, safety devices, etc, as required by the company / training

– Must Inform the employer of any failure in H&S procedures

Assessment CriteriaAssessment Criteria

Task

Individual

Load

Environment

Syndicate

List “Six” hazards in each of the groups

Task HazardsTask Hazards

• Stooping over• Twisting the waist• Bending sideways• Changing grip• Only one hand • Reaching above the shoulder• Reaching below the knee• Long lifting or lowering

distances• Accelerating or Stopping• Sudden movement

• Task duration• Frequency• Sitting • Travel Distances• Hand positions• Time constraints• Distance from the body• Carry up or down stairs• Energy required to push or pull

Individual HazardsIndividual Hazards

Under 18’s and Over 50’s

Male or female

Heart or respiratory problems

Weak or damaged back

Hernias or movement limitations

Clothing or equipment hazards

Lack of fitness

Untrained ( kinetics )

Load HazardsLoad Hazards

Weight

Average weight

Difficult to grip (no handles slippery etc)

Bulky and unwieldy

Obscured vision

Sharp edges

Hot or cold

C of gravity offset

C of gravity likely to shift

Stability

Environmental HazardsEnvironmental Hazards

• Adequate space• Is good posture possible• Reaching around or over

objects• Hot, cold or humid• Wet or dry• Adequate lighting• Poor vision ( dust )• Smelly ( odorous )

• Noisy• Stable or vibrating surface• Dirty, dusty • Steps or slopes• Uneven surfaces• Spillage's• Route hazards• Tripping or snagging hazards

Methods of Reducing The RiskMethods of Reducing The Risk

• Load – Reduce weight and size– Improve grip / handles– Ensure stability and grip – Mark weight / heaviest side

• Task – Layout / method– Body position– Team effort– Recovery time

Methods of Reducing The RiskMethods of Reducing The Risk

• Working environment – Improve space constraints, improve housekeeping– Keep floors and steps level, no holes / obstructions– Maintain temperature, humidity and lighting

• Individual capability – Personal consideration / assessment– Give information, instruction and training– Promote involvement

Control Methods Overview Control Methods Overview

• Eliminate, Mechanise or Automate – Bionic arm, conveyors, robots, suction C/B arms– Air bearings, water, roller tracks, skates / barrows,

slings / cranes, F L trucks, pallet trucks, auto guided, trucks

• Reduce – Twist, bend, reach, time constraints, weight, size,

interface with vehicles, distances• Ensure

– Handles, grip, shape, stability, good housekeeping, recovery time, adequate / appropriate PPE

• Train – Induction (kinetic), job specific

• Supervision

Mechanical Handling DevicesMechanical Handling Devices

Kinetic HandlingKinetic Handling

• “A good method of handling“ which minimises the risk of injury, lost time, lost production, and ruined lives

• 6 Key points to kinetic lifting – Foot position– Lift with the Legs– Straight back– Palm grip– Elbows In– Chin In

• Promotes good kinetic movement – Load, body task, work in unison– Use a test lift

• Should be included in Induction training programme

Practical Training ContentsPractical Training Contents

• Kinetic lifting– Test lift, weight assessment, handles etc,– Define task, check route– 6 key points of kinetic handling

• Team lifting– Leader, define the task– Clear commands, e.g. prepare to – Check the route,

• Pushing and or pulling– Line from pushing foot– Balance, between shoulder and knuckle– Using over centre body weight

• Special techniques – Pulling down, thrusting upwards, pressing down

Training ProgrammesTraining Programmes

• Guidance suggests programme should contain a clear understanding of– How potentially hazardous handling operations can be

recognised– How to deal with unfamiliar handling operations– The correct use of handling aids– Features of the working environment that contributes

to Safety– Importance of good housekeeping– Factors affecting individual capability– Good handling techniques

Typical Manual Handling Typical Manual Handling QuestionsQuestions

• a) List two types of injury that could result from poor manual handling techniques (2)

• b) Outline the general strategy that an employer is required to take to reduce the risk of injury from manual handling operations in the workplace (6)

• a) Define the term ‘manual handling’ (2)• b) List three categories of injury that could be caused by

the incorrect manual handling of loads (3)• c) Outline practical measures designed to reduce the risk

of injury from manual handling activities at work (15)

Manual Handling QuestionsManual Handling Questions

a) List TWO types of injury that may be caused by the incorrect manual handling of loads(2)

b) Outline a good handling technique that could be adopted by a person required to lift a load from the ground(6)

a) List the main factors to be considered in the making of an assessment under the Manual Handling Operations Regulations 1992 (4)

b) Outline practical risk reduction measures in relation to manual handling (16)

Course CloseCourse Close