MATERIAL HANDLING RISK ASSESSMENT

RA DESCRIPTION Material Handling

PROJECT NDIA Pasenger Terminal
LOCATION CP 18 Work Areas DATE: 23-02-12
RISK ASSESSMENT TEAM SITE REPRESENTATION
NAME DESIGNATION SIGNATURE NAME DESIGNATION SIGNATURE

Risk Assessment for material handling

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 DESIGNATION INITIALS & SURNAME APPROVED COMMENTS
R/A ORIGINATOR Goutam Sarkar N/A
CONTRACT MANAGER YES NO
SAFETY MANAGER Rahman Majumder YES NO
OBI REPRESENTATIVE. YES NO

SEVERITY CONSEQUENCE RATING SEVERITY OUTCOME

CATASTROPHIC 5 10 15 20 25 5 FATALITY
CRITICAL 4 8 12 16 20 4 MAJOR INJURY / ILLNESS
SERIOUS 3 6 9 12 15 3 SERIOUS INJURY / ILLNESS
MEDIUM 2 4 6 8 10 2 MINOR INJURY / ILLNESS
MINIMAL 1 2 3 4 5 1 NONE OR SMALL FA

1 2 3 4 5
LIKELYHOOD
IF NOT VERY ALMOST
CONTROLLED UNLIKELY LIKELY VERY LIKELY
UNLIKELY CERTAIN

RISK RANKING (RR) / PRIORITY FACTOR RATING

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

Risk Assessment for material handling

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 RISK ASSESSMENT
Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R
1. Off loading of glass Hit by plant and equipment 3 4 12 HS  STARRT briefing 2 4 8
crates from flatbed Causing injury  Reverse alarm
trailer for storing in  Banksman
warehouse  Exclusion zone (authorised persons only)
 Competent workforce
 Adequate supervision

Load failure 3 5 15 HS  STARRT 2 5 10

Causing injury and/or  Inspection of lifting equipments
property damage  Lift plan
Toppling of forklift/  Competent rigger
telescopic handler  Third party certified operators
Poor visiblity of operator  Exclusion zone
Broken Crate  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

2. Offloading glass Tilting and falling of glass 3 4 12 HS  STARRT

panels from broken crate  Adequate and competant supervision
crates Sliding glass panels  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
3. Transportation Load failure 3 4 12 HS  STARRT 2 4 8
(including loading Sliding and falling of crates  Inspection of lifting equipments
and offloading) of
Risk Assessment for material handling
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 Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R
glass crates to site  Lift plan
 Competent rigger
 Third party certified operators
 Exclusion zone
 Banksman
 Restraining of load
 Maintain load capacity of boom truck
 Adequate and competent supervision (if training required
it should be covered)

4. Opening of glass Fall of crates & fall 3 5 15 HS  STARRT briefing 2 5 10

crates in warehouse of glass  Placement of glass crates on firm and level ground
for segregation of  Incline glass crates at an angle (at least 5 degree)
glass opposite to the side being opened
 Structure to support against the inclination
 Trained and competent workers
 Adequate supervision
 Use of glass sucker
 Appropriate PPE
 Place on ‘A’ Frame for storage
5. Transportation of Fall of glass 3 4 12 HS  Load glass secured on A frame 2 4 8
segregated glass to  Third party cerfication required for A frame if being
site and offloading handled by crane
 Exclusion zone
 Competent Rigger / Banksman
 Lift plan
6. Transportation of Manual task 3 3 9 HS  STARRT 2 3 6
segregated glass to Uneven/  Assessmnet of load prior to work
work location obstructed surface  Assessment of movement surface prior to work
(manual) Slip from hand  Group / machanical shifting if required
 PPE
7. Storage of loose Fall of glass 3 3 9 HS  Locate store area away from work activity 2 2 4
glasses on site Glass hit by  Store segregated glass only on A frame
moving plant and  Secure storage area with barricade
equipment  Place warning signage
Risk Assessment for material handling
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 Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R
Glass hit by
pedestrians
8. Off loading of Hit by plant and 3 5 15 HS  STARRT 2 5 10
gypsum board equipment  Align container base with the ramp
bundle for storage Load failure  Competent forklift operator
in laydown  Banksman
 Reverse alarm & light
 Daily checklist completed ( equipment)
 Use lifting equipment and accessories appropriate for
weight been lifted
9. Transportation of Load failure 3 4 12 HS  STARRT briefing 2 4 8
gypsum boards to Hit by plant and  Reverse alarm
site by boom truck equipment  Banksman
and offloading by  Exclusion zone (authorised persons only)
forklift  Competent workforce
 Adequate supervision
 Restraining of load
 Maintain load capacity of boom truck
 Adequate and competent supervision (if training required
it should be covered)
 Inspection of lifting equipments
 Lift plan

10. Transportation of Toppling of trolley 3 4 12 HS  STARRT 2 4 8

gyspum boards to Trolley run away  Assessment of the load and weight
work location by Hit permanent  Use of appropriate trolley
trolley structure  Assessment of load balance
Pinch points  Assessment of material shiftment route
Uneven surface  Adequate number of personal
Interfce with  Appropriate PPE
electrical cables
 Watchman

11. Off loading Hit by plant and 3 4 12 HS  STARRT briefing 2 4 8

Risk Assessment for material handling

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 Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R
ceiling/roof panels equipment  Reverse alarm
from Load failure  Banksman
container/flatbed  Exclusion zone (authorised persons only)
truck for storage in  Competent workforce
loaydown  Adequate supervision
 Restraining of load
 Maintain load capacity of boom truck
 Adequate and competent supervision (if training required
it should be covered)
 Inspection of lifting equipments
 Lift plan

12. Transportation of Load failure 3 4 12 HS  STARRT 2 4 8

ceiling/roof panels Sliding and falling of panels  Inspection of lifting equipments
to site  Lift plan
 Competent rigger
 Third party certified operators
 Exclusion zone
 Banksman
 Restraining of load
 Adequate and competent supervision (if training required
it should be covered)

13. Transportation of Manual task 3 3 9 HS  STARRT 2 3 6

ceiling/roof panels Uneven/  Assessmnet of load prior to work
to work location obstructed surface  Assessment of movement surface prior to work
(manually)  Group / machanical lifting if required
 PPE
14. Off loading of Hit by plant and 3 4 12 HS  STARRT 2 4 8
stones/tiles from equipment  Align container base with the ramp
container Load failure  Competent forklift operator
 Banksman
 Reverse alarm & light
 Exclusion zone
Risk Assessment for material handling
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 Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R
 Daily checklist completed ( equipment)
15. Transportation of Load failure 3 5 15 HS  STARRT briefing 2 5 10
stones/tiles to site Hit by plant and  Reverse alarm
by boom truck and equipment  Banksman
offloading by forklift  Exclusion zone (authorised persons only)
 Competent workforce
 Adequate supervision
 Restraining of load
 Maintain load capacity of boom truck
 Inspection of lifting equipments
 Lift plan

16. Transportation of Sliding of load 3 4 12 HS  STARRT 2 4 8

stones / tiles to Failure of hydrolic  Assessment of the load and weight
work locations by control  Use of appropriate jack pallet / trolley
jack pallets Uneven /  Assessment of load balance
obstructed shifting  Assessment of material shifting route
routes  Adequate number of personal
Run away from  Appropriate PPE
ramp
 Watchman
 Wooden angle stand for handling , transporation &
storage of tiles & stones
 Scheduled maintainance of equipment
17. Off loading of steel Fall from height ( 3 5 15 HS  STARRT 2 5 10
frames/GI channels from top of  Use of secondary fall protection
from open top container)  Use of secured platform (Podium ladder) for opening
container/ flatbed Hit by plant and container top
trailer equipment  Banksman
Load failure  Exclusion zone (authorised persons only)
 Competent workforce
 Adequate supervision
 Appropriate and certified lifting equipment
18. Transportation ( Load failure 3 4 12 HS  STARRT briefing 2 4 8
including loading Hit by plant and  Reverse alarm

Risk Assessment for material handling

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 Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R
and off loading by equipment  Banksman
forklift) of steel  Exclusion zone (authorised persons only)
frames/ GI  Competent workforce
channhels to site by  Adequate supervision
boom truck  Restraining of load
 Maintain load capacity of boom truck
 Inspection of lifting equipments
 Lift plan

19. Transportation of Toppling of trolley 3 4 12 HS  STARRT 2 4 8

steel frames/GI Trolley run away  Assessment of the load and weight
channhels to work Hit permanent  Use of appropriate trolley
location structure  Secured load by tying to the trolley
Pinch points  Assessment of load balance
Uneven surface  Assessment of material shifting route
Interfce with  Adequate number of personal
electrical cables
 Appropriate PPE
 Watchman

20. Transportation of Sharpe corners 3 3 9 HS  STARRT 2 3 6

ducts to site / work Manual lifting  Assessment of load and weight
location  Appropriate PPE including anti abrasive gloves
 Use of group lifting

21. Off loading of Hit by plant and 3 4 12 HS  STARRT 2 4 8

conduit pipes from
container/flatbed
trailer
equipment  Use of secondary fall protection
Load failure  Use of secured ladder (podium)
 Banksman
 Exclusion zone (authorised persons only)
 Competent workforce
 Adequate supervision
 Appropriate and certified lifting equipments

Risk Assessment for material handling

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 Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R
22. Transaportation and Load failure 3 4 12 HS  STARRT briefing 2 4 8
offloading of conduit Hit by plant and  Reverse alarm
pipes to site equipment  Banksman
 Exclusion zone (authorised persons only)
 Competent workforce
 Adequate supervision
 Maintain load capacity of boom truck
 Inspection of lifting equipments
 Lift plan

23. Transportation of Sharpe edge 3 3 9 HS  STARRT 2 3 6

conduit pipes to Manual lifting  Assessment of load and weight
work location  Appropriate PPE including anti abrasive gloves
(manually)  Use of group lifting

24. Off loading cables Load failure 3 4 12 HS  STARRT briefing 2 4 8

from flatbed trailer Hit by plant and  Banksman / Rigger
by crane equipment  Exclusion zone (authorised persons only)
 Competent workforce
 Adequate supervision
 Maintain load capacity
 Inspection of lifting equipments
 Lift plan

25. Transportation of Load failure 3 4 12 HS  STARRT briefing 2 4 8

cables to site and
offloading by Boom
truck
Hit by plant and  Reverse alarm
equipment  Banksman
 Competent workforce
 Adequate supervision
 Maintain load capacity of boom truck
 Inspection of lifting equipments
 Lift plan

26. Transportation of Uncontroled load 3 3 9 HS  STARRT 2 3 6

cables to work Hit pedestrian or  Isolation of the area by barricading
Risk Assessment for material handling
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 Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R
location by rolling of structures  Watchman
cable drum Pinch point  Controlled group lifting
Manual task  Trained and competent manpower
 PPE

27. Off loading panel Load failure 3 4 12 HS  STARRT briefing 2 4 8

boards Hit by plant and  Reverse alarm
equipment  Banksman
 Competent workforce
 Adequate supervision
 Maintain load capacity of boom truck
 Inspection of lifting equipments
 Lift plan

28. Transportation of Sliding of load 3 4 12 HS  STARRT 2 4 8

panel boards to Failure of hydraulic  Assessment of the load and weight
work location by control  Use of appropriate jack pallet / trolley
jack pallet Uneven /  Assessment of load balance
obstructed shifting  Assessment of material shifting route
routes  Adequate number of personnel
Run away from  Appropriate PPE
ramp
 Watchman
 Scheduled maintainance of equipment
29. Off loading fire Load failure 3 4 12 EHS  STARRT briefing 2 4 8
proofing materials Hit by plant and  Reverse alarm
by forklift equipment  Banksman
/telehandler  Competent workforce
 Adequate supervision
 Maintain load capacity
 Exclusion zone
 MSDS
 Spill kit available
 Inspection of lifting equipment

Risk Assessment for material handling

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 Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R
30. Transportation of Load failure 3 3 9 HS  STARRT briefing 2 3 6
fire proofing Hit by plant and  Banksman
materials to site by equipment  Competent workforce
truck  Adequate supervision
 Inspection of lifting equipment

31. Transportation of Sliding of load 3 4 12 EHS  STARRT 2 4 8

fire proofing Failure of hydrolic  Assessment of the load and weight
materials to work control  Use of appropriate jack pallet / trolley
location Uneven /  Assessment of load balance
obstructed shifting  Assessment of material shifting route
routes  MSDS
Run away from  Spill kit available
ramp
 Adequate number of personal
 Appropriate PPE
 Watchman

 Scheduled maintainance of equipment

32. Loading of terrazzo Load failure 3 3 9 HS  STARRT briefing 2 3 6
sand bags on to Hit by plant and  Banksman
boom truck and equipment  Competent workforce
offloading of site  Adequate supervision
 Inspection of lifting equipment

33. Transportation of Load failure 3 5 15 HS  STARRT briefing 2 5 10

terrazzo sand bags
to work location by
crane
Hit by plant and  Banksman / Rigger
equipment  Competent workforce
 Adequate supervision
 Inspection of lifting equipment
 Lift plan
 Completion of daily equipment checklist
 Exclusion zone

Risk Assessment for material handling

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 Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R

34. Transportation of Load failure / 3 5 15 EHS  STARRT briefing 2 5 10

terrazzo chemical displacement  Inspection of pallets integrity
drums to site by Hit by plant and  Securing load with straps
truck and offloading equipment  Banksman
by forklift  Competent workforce
 Adequate supervision
 Inspection of lifting equipment
 MSDS
 Spill kit

35. Transportation of Sliding of load 3 4 12 EHS  STARRT 2 4 8

terrazzo chemical Failure of hydraulic  Assessment of the load and weight
drums to onsite control  Use of appropriate jack pallet / trolley
storage area/ work Uneven /  Assessment of load balance
location by jack obstructed shifting  Assessment of material shiftment route
pallet routes  Adequate number of personal
Run away from  Appropriate PPE
ramp
 Watchman
 Wooden angle stand for handling , transporation &
storage of tiles & stones
 MSDS & spill kit

 Scheduled maintainance of equipment

36. Offloading of water Load failure 3 4 12 HS  STARRT briefing 2 4 8
proofing sheets Hit by plant and  Reverse alarm
equipment  Banksman
 Exclusion zone (authorised persons only)
 Competent workforce
 Adequate supervision
 Maintain load capacity
 Inspection of lifting equipments

Risk Assessment for material handling

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 Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R
37. Transportation of Toppling of trolley 3 3 9 HS  STARRT 2 3 6
water proofing Trolley run away  Assessment of the load and weight
sheets to work Hit permanent  Use of appropriate trolley
location structure  Secured load by tying to the trolley
Uneven surface  Assessment of load balance
Interfce with  Assessment of material shifting route
electrical cables  Adequate number of personal
 Appropriate PPE
 Watchman

38. Offloading conveyor Load failure 3 5 15 HS  STARRT briefing 2 5 10

parts Hit by plant and  Reverse alarm
equipment  Banksman
 Exclusion zone (authorised persons only)
 Competent workforce
 Adequate supervision
 Maintain load capacity
 Inspection of lifting equipments

39. Transporting Load failure 3 5 15 HS  STARRT briefing 2 5 10

conveyor parts to
site by flatbed trailer
and offloading by
crane
Hit by plant and  Banksman/ Rigger
equipment  Exclusion zone (authorised persons only)
 Competent workforce
 Adequate supervision
 Maintain load capacity
 Inspection of lifting equipments
 Lift plan

40. Transportation of Load failure 3 4 12 HS  STARRT briefing 2 4 8

conveyor parts to Hit by plant and  Reverse alarm
work location by equipment  Banksman
forklift / pallet trolley  Exclusion zone (authorised persons only)

Risk Assessment for material handling

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 Worst EH Controlled
No TASKS / ACTIVITY HAZARD AND case S PREVENTATIVE & CONTROL MEASURES Rating
RISK IDENTIFICATION Rating L S R
L S R
 Competent workforce
 Adequate supervision
 Maintain load capacity
 Appropriate PPE
 Inspection of lifting equipments

41. Off loading PCA Load failure 3 5 15 HS  STARRT briefing 2 5 10

units Hit by plant and  Banksman
equipment  Exclusion zone (authorised persons only)
 Competent workforce
 Adequate supervision
 Maintain load capacity
 Inspection of lifting equipments
 Lift plan

42. Shifting PCA units Toppling of trolley 3 4 12 HS  STARRT

to work location Trolley run away  Assessment of the load and weight
Hit permanent  Use of appropriate trolley
structure  Secured load by tying to the trolley
Uneven surface  Assessment of load balance
 Assessment of material shifting route
 Adequate number of personal
 Appropriate PPE
 Watchman

43.

Risk Assessment for material handling

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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 CO. NO SIGNATURE NAME CO. NO SIGNATURE

Risk Assessment for material handling

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