Risk Assessment For Material Handling

MATERIAL HANDLING RISK ASSESSMENT
RA DESCRIPTION
Material Handling
PROJECT
NDIA Pasenger Terminal
LOCATION
CP 18 Work Areas
DATE: 23-02-12
RISK ASSESSMENT TEAM

NAME
DESIGNATION
Risk Assessment for material handling

Rev No.: Revision 0
SITE REPRESENTATION
SIGNATURE
Page 1 of 15
NAME
DESIGNATION
Date: 20/09/2012
SIGNATURE
DESIGNATION
R/A ORIGINATOR
INITIALS & SURNAME
APPROVED
N/A
Goutam Sarkar
CONTRACT MANAGER
SAFETY MANAGER
Rahman Majumder
OBI REPRESENTATIVE.
YES
NO
YES
NO
YES
NO
SEVERITY
CONSEQUENCE RATING
CATASTROPHIC
5
4
3
2
1
10
8
6
4
2
15
12
9
6
3
20
16
12
8
4
25
20
15
10
5
VERY
UNLIKELY
UNLIKELY
LIKELY
VERY LIKELY
ALMOST
CERTAIN
CRITICAL
SERIOUS
MEDIUM
MINIMAL
LIKELYHOOD
IF NOT
CONTROLLED
COMMENTS
SEVERITY OUTCOME
5
4
3
2
1
FATALITY
MAJOR INJURY / ILLNESS
SERIOUS INJURY / ILLNESS
MINOR INJURY / ILLNESS
NONE OR SMALL FA
RISK RANKING (RR) / PRIORITY FACTOR

POTENTIALLY MINOR / ACTION TO BE TAKEN WITHIN 7 DAYS
SCORE
1-2
POTENTIALLY SERIOUS / ACTION TO BE TAKEN WITHIN 48 HRS
SCORE
3 -6
POTENTIALLY MAJOR / ACTION TO BE TAKEN WITHIN 12 HRS
SCORE
7 - 10
POTENTIALLY CATASTROPHIC / ACTION NEEDED IMMEDIATELY
SCORE
11 - 25

Rev No.: Revision 0
Page 2 of 15
Date: 20/09/2012
RATING
L
M
H
H+
RISK ASSESSMENT
No
TASKS / ACTIVITY
1.
Off loading of glass

crates from flatbed
trailer for storing in
warehouse
HAZARD AND
RISK IDENTIFICATION
Hit by plant and equipment
Causing injury
Load failure
Causing injury and/or
property damage
Toppling of forklift/
telescopic handler
Poor visiblity of operator
Broken Crate
Worst
case
Rating
L S R
3 4 12
EH
S
HS
STARRT briefing
Reverse alarm
Banksman
Exclusion zone (authorised persons only)
Competent workforce
Adequate supervision
HS
STARRT
Inspection of lifting equipments
Lift plan
Competent rigger
Third party certified operators
Exclusion zone
Banksman
Adequately secured load
Suitable weather condition (wind)
Leveled and firm ground surface
Supervisor and operator must know the weight of the load
before unloading
Broken crates to be additionally supported before
unloading
10
15
PREVENTATIVE & CONTROL MEASURES
2.
Offloading glass
panels from broken
crates
Tilting and falling of glass

crate
Sliding glass panels
12
HS
3.
Transportation
(including loading
and offloading) of
Load failure
Sliding and falling of crates
12
HS

Rev No.: Revision 0
Page 3 of 15
STARRT
Adequate and competant supervision
Use pnumetic glass sucker to handle glasses
Stabilizing crates by additional supports
Secure glassess
Group handling
Eqipment daily check
Inspection of glass suckers by competant person
STARRT
Date: 20/09/2012
Controlled
Rating
L S R
No
TASKS / ACTIVITY
HAZARD AND
RISK IDENTIFICATION
Worst
case
Rating
L S R
EH
S
glass crates to site
4.
5.
Opening of glass
crates in warehouse
for segregation of
glass
Transportation of
segregated glass to
site and offloading
Fall of crates & fall

of glass
Fall of glass
15
12
HS
Transportation of
segregated glass to
work location
(manual)
Manual task
Uneven/
obstructed surface
Slip from hand
HS
7.
Storage of loose
glasses on site
Fall of glass
Glass hit by
moving plant and
equipment
HS

Rev No.: Revision 0
Lift plan
Competent rigger
Exclusion zone
Banksman
Restraining of load
Maintain load capacity of boom truck
Adequate and competent supervision (if training required
it should be covered)
STARRT briefing
Placement of glass crates on firm and level ground
Incline glass crates at an angle (at least 5 degree)
opposite to the side being opened
Structure to support against the inclination
Trained and competent workers
Use of glass sucker
Appropriate PPE
Place on A Frame for storage
Load glass secured on A frame
Third party cerfication required for A frame if being
handled by crane
Exclusion zone
Competent Rigger / Banksman
Lift plan
STARRT
Assessmnet of load prior to work
Assessment of movement surface prior to work
Group / machanical shifting if required
PPE
Locate store area away from work activity
Store segregated glass only on A frame
Secure storage area with barricade
Place warning signage
HS
6.
Page 4 of 15
Date: 20/09/2012
Controlled
Rating
L S R
10
No
TASKS / ACTIVITY
8.
Off loading of
gypsum board
bundle for storage
in laydown
9.
Transportation of
gypsum boards to
site by boom truck
and offloading by
forklift
HAZARD AND
RISK IDENTIFICATION
Glass hit by
pedestrians
Hit by plant and
equipment
Load failure
Load failure
Hit by plant and
equipment
Worst
case
Rating
L S R
EH
S
15
HS
12
HS
Controlled
Rating
L S R
10
STARRT
Align container base with the ramp
Competent forklift operator
Banksman
Reverse alarm & light
Daily checklist completed ( equipment)
Use lifting equipment and accessories appropriate for
weight been lifted
STARRT briefing
Reverse alarm
Banksman
Competent workforce
Restraining of load
Lift plan
10. Transportation of
gyspum boards to
work location by
trolley
Toppling of trolley
Trolley run away
Hit permanent
structure
Pinch points
Uneven surface
Interfce with
electrical cables
12
HS
STARRT
Assessment of the load and weight
Use of appropriate trolley
Assessment of load balance
Assessment of material shiftment route
Adequate number of personal
Appropriate PPE
Watchman
11. Off loading
Hit by plant and
12
HS
STARRT briefing

Rev No.: Revision 0
Page 5 of 15
Date: 20/09/2012
No
TASKS / ACTIVITY
HAZARD AND
RISK IDENTIFICATION
ceiling/roof panels
from
container/flatbed
truck for storage in
loaydown
Worst
case
Rating
L S R
EH
S
equipment
Load failure
ceiling/roof panels
to site
Load failure
Sliding and falling of panels
Reverse alarm
Banksman
Competent workforce
Restraining of load
Lift plan
12
HS
STARRT
Lift plan
Competent rigger
Exclusion zone
Banksman
Restraining of load
STARRT
Assessmnet of load prior to work
Assessment of movement surface prior to work
Group / machanical lifting if required
PPE
STARRT
Align container base with the ramp
Competent forklift operator
Banksman
Reverse alarm & light
Exclusion zone
ceiling/roof panels
to work location
(manually)
Manual task
Uneven/
obstructed surface
HS
14. Off loading of

stones/tiles from
container
Hit by plant and

equipment
Load failure
12
HS

Rev No.: Revision 0
Controlled
Rating
L S R
Page 6 of 15
Date: 20/09/2012
No
TASKS / ACTIVITY
HAZARD AND
RISK IDENTIFICATION
Worst
case
Rating
L S R
EH
S
Daily checklist completed ( equipment)
Controlled
Rating
L S R
stones/tiles to site
by boom truck and
offloading by forklift
Load failure
Hit by plant and
equipment
15
HS
STARRT briefing
Reverse alarm
Banksman
Competent workforce
Restraining of load
Lift plan
10
stones / tiles to
work locations by
jack pallets
Sliding of load
Failure of hydrolic
control
Uneven /
obstructed shifting
routes
Run away from
ramp
12
HS
17. Off loading of steel

frames/GI channels
from open top
container/ flatbed
trailer
Fall from height (

from top of
container)
Hit by plant and
equipment
Load failure
15
HS
10
18. Transportation (
including loading
Load failure
Hit by plant and
STARRT
Use of appropriate jack pallet / trolley
Assessment of material shifting route
Appropriate PPE
Watchman
Wooden angle stand for handling , transporation &
storage of tiles & stones
Scheduled maintainance of equipment
STARRT
Use of secondary fall protection
Use of secured platform (Podium ladder) for opening
container top
Banksman
Competent workforce
Appropriate and certified lifting equipment
STARRT briefing
Reverse alarm

Rev No.: Revision 0
12
HS
Page 7 of 15
Date: 20/09/2012
No
TASKS / ACTIVITY
HAZARD AND
RISK IDENTIFICATION
and off loading by

forklift) of steel
frames/ GI
channhels to site by
boom truck
equipment
Worst
case
Rating
L S R
EH
S
Banksman
Competent workforce
Restraining of load
Lift plan
Controlled
Rating
L S R
steel frames/GI
channhels to work
location
Toppling of trolley
Trolley run away
Hit permanent
structure
Pinch points
Uneven surface
Interfce with
electrical cables
12
HS
STARRT
Secured load by tying to the trolley
Appropriate PPE
Watchman
ducts to site / work
location
Sharpe corners
Manual lifting
HS
STARRT
Assessment of load and weight
Appropriate PPE including anti abrasive gloves
Use of group lifting
21. Off loading of

conduit pipes from
container/flatbed
trailer
Hit by plant and

equipment
Load failure
12
HS
STARRT
Use of secondary fall protection
Use of secured ladder (podium)
Banksman
Competent workforce
Appropriate and certified lifting equipments

Rev No.: Revision 0
Page 8 of 15
Date: 20/09/2012
No
TASKS / ACTIVITY
HAZARD AND
RISK IDENTIFICATION
Worst
case
Rating
L S R
3 4 12
EH
S
HS
STARRT briefing
Reverse alarm
Banksman
Competent workforce
Lift plan
Controlled
Rating
L S R
22. Transaportation and

offloading of conduit
pipes to site
Load failure
Hit by plant and
equipment
conduit pipes to
work location
(manually)
Sharpe edge
Manual lifting
HS
STARRT
Assessment of load and weight
Appropriate PPE including anti abrasive gloves
Use of group lifting
24. Off loading cables

from flatbed trailer
by crane
Load failure
Hit by plant and
equipment
12
HS
STARRT briefing
Banksman / Rigger
Competent workforce
Maintain load capacity
Lift plan
cables to site and
offloading by Boom
truck
Load failure
Hit by plant and
equipment
12
HS
STARRT briefing
Reverse alarm
Banksman
Competent workforce
Lift plan
cables to work
Uncontroled load
Hit pedestrian or
HS
STARRT
Isolation of the area by barricading

Rev No.: Revision 0
Page 9 of 15
Date: 20/09/2012
No
TASKS / ACTIVITY
HAZARD AND
RISK IDENTIFICATION
location by rolling of
cable drum
Worst
case
Rating
L S R
EH
S
structures
Pinch point
Manual task
Watchman
Controlled group lifting
Trained and competent manpower
PPE
Controlled
Rating
L S R
27. Off loading panel

boards
Load failure
Hit by plant and
equipment
12
HS
STARRT briefing
Reverse alarm
Banksman
Competent workforce
Lift plan
panel boards to
work location by
jack pallet
Sliding of load
Failure of hydraulic
control
Uneven /
obstructed shifting
routes
Run away from
ramp
12
HS
Load failure
Hit by plant and
equipment
12
EHS
STARRT
Adequate number of personnel
Appropriate PPE
Watchman
STARRT briefing
Reverse alarm
Banksman
Competent workforce
Exclusion zone
MSDS
Spill kit available
Inspection of lifting equipment
29. Off loading fire

proofing materials
by forklift
/telehandler

Rev No.: Revision 0
Page 10 of 15
Date: 20/09/2012
No
TASKS / ACTIVITY
HAZARD AND
RISK IDENTIFICATION
Worst
case
Rating
L S R
3 3
9
Controlled
Rating
L S R
HS
STARRT briefing
Banksman
Competent workforce
12
EHS
STARRT
MSDS
Spill kit available
Appropriate PPE
Watchman
HS

STARRT briefing
Banksman
Competent workforce
15
HS
STARRT briefing
Banksman / Rigger
Competent workforce
Lift plan
Completion of daily equipment checklist
Exclusion zone
10
fire proofing
materials to site by
truck
Load failure
Hit by plant and
equipment
fire proofing
materials to work
location
Sliding of load
Failure of hydrolic
control
Uneven /
obstructed shifting
routes
Run away from
ramp
32. Loading of terrazzo

sand bags on to
boom truck and
offloading of site
Load failure
Hit by plant and
equipment
terrazzo sand bags
to work location by
crane
Load failure
Hit by plant and
equipment

Rev No.: Revision 0
EH
S
Page 11 of 15
Date: 20/09/2012
No
TASKS / ACTIVITY
HAZARD AND
RISK IDENTIFICATION
Worst
case
Rating
L S R
EH
S
Controlled
Rating
L S R
terrazzo chemical
drums to site by
truck and offloading
by forklift
Load failure /
displacement
Hit by plant and
equipment
15
EHS
STARRT briefing
Inspection of pallets integrity
Securing load with straps
Banksman
Competent workforce
MSDS
Spill kit
10
terrazzo chemical
drums to onsite
storage area/ work
location by jack
pallet
Sliding of load
Failure of hydraulic
control
Uneven /
obstructed shifting
routes
Run away from
ramp
12
EHS
STARRT
Assessment of material shiftment route
Appropriate PPE
Watchman
Wooden angle stand for handling , transporation &
storage of tiles & stones
MSDS & spill kit

STARRT briefing
Reverse alarm
Banksman
Competent workforce
36. Offloading of water

proofing sheets

Rev No.: Revision 0
Load failure
Hit by plant and
equipment
12
HS
Page 12 of 15
Date: 20/09/2012
No
TASKS / ACTIVITY
HAZARD AND
RISK IDENTIFICATION
Worst
case
Rating
L S R
3 3
9
EH
S
HS
STARRT
Appropriate PPE
Watchman
Controlled
Rating
L S R
water proofing
sheets to work
location
Toppling of trolley
Trolley run away
Hit permanent
structure
Uneven surface
Interfce with
electrical cables
38. Offloading conveyor

parts
Load failure
Hit by plant and
equipment
15
HS
STARRT briefing
Reverse alarm
Banksman
Competent workforce
10
39. Transporting
conveyor parts to
site by flatbed trailer
and offloading by
crane
Load failure
Hit by plant and
equipment
15
HS
STARRT briefing
Banksman/ Rigger
Competent workforce
Lift plan
10
conveyor parts to
work location by
forklift / pallet trolley
Load failure
Hit by plant and
equipment
12
HS
STARRT briefing
Reverse alarm
Banksman

Rev No.: Revision 0
Page 13 of 15
Date: 20/09/2012
No
TASKS / ACTIVITY
HAZARD AND
RISK IDENTIFICATION
Worst
case
Rating
L S R
EH
S
Competent workforce
Appropriate PPE
41. Off loading PCA

units
Load failure
Hit by plant and
equipment
15
HS
STARRT briefing
Banksman
Competent workforce
Lift plan
42. Shifting PCA units

to work location
Toppling of trolley
Trolley run away
Hit permanent
structure
Uneven surface
12
HS
STARRT
Appropriate PPE
Watchman
43.

Rev No.: Revision 0
Page 14 of 15
Date: 20/09/2012
Controlled
Rating
L S R
10
RISK ASSESSMENT COMMUNICATIONS FORM.

I, THE UNDERSIGNED HEREBY ACKNOWLEDGE THAT THIS RISK ASSESSMENT HAS BEEN DISCUSSED WITH ME AND THAT I UNDERSTAND THE
CONTENTS AND THE RISKS INVOLVED IN THE TASK TO BE PERFORMED. I HAVE ALSO BEEN INSTRUCTED ON THE SAFE METHODS TO
PERFORM THIS TASK.
NAME

Rev No.: Revision 0
CO. NO
SIGNATURE
NAME
Page 15 of 15
CO. NO
Date: 20/09/2012
SIGNATURE

Risk Assessment For Material Handling

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Risk Assessment For Material Handling

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MATERIAL HANDLING RISK ASSESSMENT

NDIA Pasenger Terminal

RISK ASSESSMENT TEAM

Risk Assessment for material handling

INITIALS & SURNAME

RISK RANKING (RR) / PRIORITY FACTOR

Risk Assessment for material handling

Off loading of glass

PREVENTATIVE & CONTROL MEASURES

Tilting and falling of glass

Risk Assessment for material handling

PREVENTATIVE & CONTROL MEASURES

glass crates to site

Fall of crates & fall

Risk Assessment for material handling

PREVENTATIVE & CONTROL MEASURES

11. Off loading

Hit by plant and

Risk Assessment for material handling

PREVENTATIVE & CONTROL MEASURES

14. Off loading of

Hit by plant and

Risk Assessment for material handling

PREVENTATIVE & CONTROL MEASURES

Daily checklist completed ( equipment)

17. Off loading of steel

Fall from height (

Risk Assessment for material handling

and off loading by

PREVENTATIVE & CONTROL MEASURES

21. Off loading of

Hit by plant and

Risk Assessment for material handling

PREVENTATIVE & CONTROL MEASURES

22. Transaportation and

24. Off loading cables

Risk Assessment for material handling

PREVENTATIVE & CONTROL MEASURES

27. Off loading panel

29. Off loading fire

Risk Assessment for material handling

PREVENTATIVE & CONTROL MEASURES

Scheduled maintainance of equipment

32. Loading of terrazzo

Risk Assessment for material handling

PREVENTATIVE & CONTROL MEASURES

Scheduled maintainance of equipment

36. Offloading of water

Risk Assessment for material handling

PREVENTATIVE & CONTROL MEASURES

38. Offloading conveyor

Risk Assessment for material handling

PREVENTATIVE & CONTROL MEASURES

41. Off loading PCA

42. Shifting PCA units

Risk Assessment for material handling

RISK ASSESSMENT COMMUNICATIONS FORM.

Risk Assessment for material handling

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