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COLLEGE OF ENGINEERING
2nd Term: Academic Year: 2023-2024

Topic: Manual and Mechanical Handling Hazard and Control

Work Equipment Hazard and Control
Reporter: Dumalhin, Eloysa, Hilario Rhex, Wigan, Dwight, Chumanni, Mary, Ayona, Carina, Gopeng, Janice

(I)Manual Handling
Manual handling is a term used to describe the various physical activities that involve lifting, holding, putting down,
pushing, pulling, carrying or moving an object or a load by one or more workers.
Manual handling activities can occur in almost all working environments such as factories, warehouses,
construction sites, farms, hospitals, offices, and other workplaces. Workers in different industries or sectors may be
exposed to varying degrees of manual handling risks.
Manual handling injuries occur due to lifting, carrying, pushing, or pulling heavy or awkward loads. These injuries
can be serious, including sprains, strains, fractures, and permanent disability. Here are different types of manual
handling injuries to avoid:
1. Strains And Sprain
Strains occur when muscles are overstretched or torn, while sprains occur when ligaments are stretched or torn.
Both can result in pain, swelling, and reduced mobility. Strains and sprains can occur during manual handling tasks
that involve lifting, carrying, pushing, or pulling heavy objects or loads.
Preventing strains and sprains during manual handling involves:
 Assessing the load to ensure it is within your physical capabilities,
 Using proper lifting techniques such as bending your knees,
 Keeping your back straight, and
 Using appropriate equipment such as lifting aids or trolleys.
 It is also essential to take breaks and stretch before and after handling loads to avoid overuse and fatigue
of muscles and joints.
2. Back Injuries
Back injuries are a common type of injury that can occur during manual handling tasks. Lifting heavy objects or
loads can put a lot of stress on your back muscles and spine, leading to strains or sprains.
To prevent back injuries during manual handling tasks, it is important to:
 Use proper lifting techniques such as bending your knees,
 Keeping your back straight, and
 Using your leg muscles to lift the load instead of your back muscles.
It is also important to avoid twisting or bending awkwardly while carrying a load and to take regular breaks to rest
your back muscles. Using appropriate lifting aids or trolleys can also help reduce the strain on your back.
3. Hand And Wrist Injuries
Hand and wrist injuries are a common type of injury that can occur during manual handling tasks. Repetitive
motions such as lifting, carrying, and grasping can strain your hand and wrist muscles, tendons, and ligaments,
leading to injuries such as carpal tunnel syndrome.
To prevent hand and wrist injuries during manual handling tasks, it is important to:
 Use proper lifting techniques, such as gripping the load firmly and evenly,
 Using your whole hand and not just your fingers, and
 Avoiding over-gripping or under-gripping the load.
Appropriate gloves or hand protection can also help reduce the risk of cuts or burns from sharp or hot objects. It is
also important to take regular breaks and stretch your hands and wrists to avoid overuse and fatigue of muscles
and tendons.

4. Neck Injuries
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COLLEGE OF ENGINEERING
2nd Term: Academic Year: 2023-2024

When carrying a load, it is important

to ensure it is evenly distributed and balanced on your shoulders or hands to avoid putting extra strain on your
neck muscles.

To prevent neck injuries during manual handling tasks, it is important to:

 Assess the load to ensure it is within your physical capabilities and
 Use proper lifting techniques, such as keeping your back straight and your shoulders relaxed.
5. Shoulder Injuries
Shoulder injuries are another common injury that can occur during manual handling tasks. Overhead lifting or
carrying heavy loads on the shoulders can strain your shoulder muscles, tendons, and ligaments, leading to rotator
cuff injuries and shoulder strains.
To prevent shoulder injuries during manual handling tasks, it is important to:
 Use proper lifting techniques, such as keeping your shoulders relaxed and
 Avoiding overhead lifting unless absolutely necessary.
6. Crush Injuries
Crush injuries are a potential hazard that can occur during manual handling tasks involving heavy machinery or
equipment. When handling heavy machinery or equipment, there is a risk of being crushed by the weight of the
load or moving parts.
To prevent crush injuries during manual handling tasks, it is important to:
 Ensure that the equipment is in good working condition and
 Use appropriate lifting aids or equipment, such as forklifts or cranes, to move heavy loads.
When working around moving machinery, it is important to:
 Be aware of the hazards and follow all safety procedures, such as using guard rails
 Use lockout/tagout procedures to prevent accidental activation of machinery.
 It is also essential to wear appropriate personal protective equipment, such as hard hats and safety shoes,
to protect yourself from falling objects or debris.
 Finally, it is essential to receive adequate training and to work within your physical capabilities to reduce
the risk of accidents and injuries.
7. Cuts And Lacerations
Cuts and lacerations are potential hazards during manual handling tasks involving sharp objects or materials.
Handling sharp objects or materials can result in cuts or lacerations to the skin.
To prevent cuts and lacerations during manual handling, it is important to:
 Use appropriate personal protective equipment, such as gloves and safety glasses, to protect yourself from
sharp objects or materials.
 Handle sharp objects or materials carefully and avoid rushing or taking shortcuts that can increase the risk
of injury.
8. Burns And Scalds
Burns and scalds are potential hazards when manually handling hot or caustic materials. Handling hot materials,
such as hot liquids or hot surfaces, can result in burns, while handling caustic materials, such as acids or alkalis, can
result in chemical burns.
9. Hernias
Hernias are a potential hazard that can occur during manual handling tasks. A hernia occurs when an internal part
of the body pushes through a weakness in the muscle or surrounding tissue wall, often in the abdomen or groin
area.
To prevent hernias during manual handling tasks, assessing the load and the individual’s physical capabilities is
important to:
 Ensure that the load is within its safe lifting capacity.
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COLLEGE OF ENGINEERING
2nd Term: Academic Year: 2023-2024

 Using appropriate lifting

aids or equipment, such as trolleys or hoists can also help reduce the strain on the abdominal muscles.
 Avoid over-straining and use proper lifting techniques such as bending the knees and keeping the back
straight.

10. Foot And Ankle Injuries

Foot and ankle injuries are other potential hazards during manual handling tasks. Carrying heavy loads can put a lot
of strain on your feet and ankles, leading to sprains and strains.
To prevent foot and ankle injuries during manual handling tasks, it is important to:
 Wear appropriate footwear, such as safety shoes or boots with slip-resistant soles to protect your feet and
improve traction.
 Use proper lifting techniques, such as keeping your back straight and your feet shoulder-width apart.
Appropriate lifting aids or trolleys can also help reduce the strain on your feet and ankles.
 Take regular breaks and stretch your feet and ankles to avoid overuse and fatigue of muscles and tendons.
11. Heavy Loads
Heavy loads can pose a significant hazard to workers required to lift or carry them. Lifting or carrying heavy objects
can cause a strain on the muscles, particularly in the back and legs, which can lead to serious injuries. Some
common tasks involving heavy loads include lifting boxes, carrying equipment, and loading or unloading trucks.
To prevent injuries related to heavy loads, it is important for employer to:
 Identify tasks involving heavy loads and develop strategies to minimize their weight and the lifting
frequency.
 Provide lifting aids, such as hand trucks, pallet jacks, or forklifts, to help workers move heavy loads safely.
12. Repetitive Motions
Repetitive motions can cause muscle fatigue and strain, leading to injury.
To prevent repetitive motion injuries, it is important for employer to:
 Identify tasks that involve repetitive motions and develop strategies to reduce their frequency or duration.
 Introduce job rotation or task-sharing schemes, providing rest breaks or job redesign to incorporate
activities allowing rest periods for the muscles involved.
13. Awkward Postures
Working in awkward postures, such as bending, twisting, or reaching overhead, can strain the back and other body
parts.
To prevent injuries related to awkward postures, it is important for employer to:
 Identify tasks involving them and develop strategies to minimize their frequency and duration.
 Conduct ergonomic assessments to identify and address potential workspace design and equipment
layout issues.
 Make adjustments to improve the posture and reduce the strain on the worker’s body.
14. Unstable Loads
Unstable loads can pose a significant hazard to workers required to carry or transport them. Unstable loads are not
evenly distributed, balanced, or secured, which can cause the worker to lose their balance and fall.
To prevent injuries related to unstable loads, it is important for employer to:
 Identify tasks involving them and develop strategies to minimize the risk of falls.
 Provide equipment, such as carts with stable bases, to help workers transport unstable loads safely.
15. Poor Grip
A poor grip can be hazardous because it requires workers to exert more force to maintain their grip on the load,
increasing the risk of injury. This can cause the worker to strain their muscles, particularly in the hands and arms, or
to be struck by the load or other objects.
To prevent injuries related to poor grip, it is important for employer to:
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COLLEGE OF ENGINEERING
2nd Term: Academic Year: 2023-2024

 Identify tasks that involve

handling objects with poor grip and develop strategies to minimize the risk of injury.
 Provide equipment, such as gloves with non-slip surfaces, to help workers maintain their grip on the load.

Conclusion
Manual handling hazards are common in many workplaces, and it is crucial to identify and control them to prevent
injuries and accidents. Workers should be trained in safe manual handling techniques and provided with
appropriate tools and equipment to reduce the risk of harm. Employers have a legal obligation to assess manual
handling tasks and put in place measures to minimize risks to their workers.

By taking steps to address manual handling hazards, employers can improve the health and safety of their
employees and create a safer working environment. Remember, prevention is always better than cure, so it is
essential to take proactive steps to avoid manual handling injuries in the workplace.

Mechanical Handling

Machinery generally refers to the machines that are used in industrial applications. These machines are usually
powered by electricity and perform various industrial tasks. Some examples of machinery include lathes machines,
milling machines, drill presses, and injection molding machines.

Mechanical Safety
The practice of protecting workers from exposure to potential mechanical hazards. In the United States, OSHA‘s
Mechanical Safety Standard (29 CFR 1910.219) requires employers to protect workers from exposure to moving
machinery and equipment parts.
Mechanical safety is important because it protects workers from injuries when exposed to moving machinery and
equipment parts. Injuries that can occur include cuts, bruises, and fractures. Employers can prevent these injuries
by protecting workers from exposure to these hazards.
When assessing the risks associated with machinery, it is important to consider all potential hazards, both those
that are always present and those that can appear unexpectedly. All phases of the machine life cycle need to be
considered, including transport, assembly, and installation; commissioning; use; maintenance; dismantling,
disabling, and scrapping. By considering all possible hazards, it is possible to develop a comprehensive risk
management plan that will help to keep workers safe and minimize the possibility of accidents.

Why Is Machinery Safety Important?

Faulty machinery can lead to severe injury and/or death. This is why it’s critically important that all machines be
properly maintained, inspected, and used correctly. Machinery safety is important for several reasons, some of
which include:
 Moving machinery can cause injuries in many ways:
 People can be struck and injured by moving parts of machinery or ejected material. Parts of the body can
also be drawn in or trapped between rollers, belts, and pulley drives.
 Sharp edges can cause cuts and severe injuries, sharp-pointed parts can cause stabbing or puncture of the
skin, and rough surface parts can cause friction or abrasion.
 People can be crushed between parts moving together or towards a fixed part of the machine, wall, or
another object, and two parts moving past one another can cause shearing.
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COLLEGE OF ENGINEERING
2nd Term: Academic Year: 2023-2024

 Parts of the machine,

materials, and emissions (such as steam or water) can be hot or cold enough to cause burns or scalds, and
electricity can cause electrical shock and burns.
 Injuries can also occur due to machinery becoming unreliable and developing faults or when machines are
misused through inexperience or lack of training.

Mechanical Machinery Hazards & Control Measures

There are many potential hazards associated with machinery. Some of these hazards are always present, while
others can appear unexpectedly. It is important to be aware of all potential hazards in order to develop a
comprehensive risk management plan.

The following are some common hazards associated with machinery:

1. Crushing Hazards
On construction sites, crushing hazards are often caused by excavators and other heavy machinery. If an employee
is struck by a piece of machinery, it can result in serious injuries or even death.

To prevent these hazards, employers need to provide employees with proper training and safety procedures.

2. Shear Hazards
Shear hazards are caused by moving parts that can cut or slice through
skin and flesh. Shear hazards can occur when workers use hand-operated
tools, such as knives, or when operating machinery with moving parts,
such as saws. Employees should always use the proper safety equipment
and procedures when working with hand-operated tools or machinery to
prevent shear hazards.

3. Cutting/Severing Hazards
There are many types of cutting hazards, but the three most common are
contact with a moving sharp-edged part, contact with a rotating part, and
contact with a moving part.
 The first type of cutting hazard is contact with a moving sharp-
edged part. This can happen when using a machine with a blade,
such as a bandsaw. If the blade is not properly guarded, your
clothing or skin can come into contact with the blade and be cut.
 The second type of cutting hazard is contact with a rotating part.
This can happen when you are using a drill press or lathe. If the
chuck or bit is not properly secured, your clothing or skin can
come into contact with the rotating part and be cut.
 The third type of cutting hazard is contact with a moving part. This can happen when you are using a
power saw or drill. If the blade or bit is not properly secured, your clothing or skin can come into contact
with the moving part and be cut.
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COLLEGE OF ENGINEERING
2nd Term: Academic Year: 2023-2024

To avoid these hazards, always

ensure that the blades on your machines are properly guarded and that the chucks and bits on your drill presses
and lathes are properly secured. If you use a power saw or drill, ensure the blade or bit is not worn or damaged.

4. Drawing In Or Trapping Hazards

This hazard can occur when clothing or body parts become caught in
moving parts of a machine. The result can be severe injuries or even
death. Always wear protective clothing, such as gloves and long
sleeves, to prevent this hazard when working with machinery

5. Stabbing Or Puncture Hazards

Stabbing or puncture hazards can occur when using a machine with a pointy or
sharp edge, such as a drill press. If the bit is not properly secured, your clothing or
skin can come into contact with the pointy or sharp edge and be punctured. Always
ensure the bit on your drill press is properly secured to prevent this hazard. Also,
wear proper protective clothing, such as gloves, when using machinery.

7. Friction Or Abrasion Hazards

Friction and abrasion hazards are often found in mechanical machinery.

When contact is made with a fast-moving surface that may be smooth
(e.g., touching a spin dryer) or rough (e.g., touching a belt sander),
there is a potential for serious injury.
There are several ways to protect yourself from these hazards:
 Wear appropriate Personal Protective Equipment (PPE), such as gloves, safety glasses, and ear protection.
 Be aware of your surroundings and stay clear of moving parts.
 Follow the manufacturer’s instructions for operating the machinery safely.

8. Impact Hazards
The most common type of impact hazard is when the body is struck by a
powered part of a machine. This is similar to crushing, but there is no
fixed structure to trap the person. The speed and weight of the object do
the damage.

Non-Mechanical Machinery Hazards & Control Measures

1. Electricity
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COLLEGE OF ENGINEERING
2nd Term: Academic Year: 2023-2024

When working with non-mechanical

machinery, it is important to be aware of the potential electrical hazard.

2. Noise

Noise is a non-machinery hazard that can occur when using certain machinery. This can happen when the machine
is not properly muffled or there is a break in the sound-proofing material.

3. Vibration

Vibration is a hazard that can occur when using non-mechanical machinery. This can happen when the machine is
not properly balanced or there is a vibration-dampening material break.

Conclusion

Mechanical or Non-mechanical machinery can be hazardous if not used or maintained properly. To prevent these
hazards, it is important to be aware of the dangers and to take steps to avoid them.

Work Equipment Hazard and Control

Types of Heavy Equipment

 Loader
 Grader
 Excavator
 Concrete Mixer
 Crane & Boom Trucks/ Dump Truck
 Forklift
 Wheel loader
 Bobcat/Compact Loader
 Air Compressor
 Plate/Jaw/Roller Compactor
 Feller Buncher

Hazards of Heavy Equipment

Operating heavy equipment involves working with powerful machinery, which presents several potential hazards.
By understanding these hazards, we can take proactive measures to minimize the associated risks.

1. Moving Parts and Crush Hazards

Heavy equipment often consists of large moving parts such as rotating blades, tracks, and conveyor belts, which
can pose a significant crush hazard. Operators and workers must be cautious and maintain a safe distance from
these moving parts to avoid accidents.

2. Falling Objects and Striking Hazards

Improperly secured loads or unstable materials being lifted by heavy equipment can result in falling objects that
pose a striking hazard. Operators and workers should wear appropriate personal protective equipment (PPE) and
maintain a safe distance from the equipment during lifting and loading operations.
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COLLEGE OF ENGINEERING
2nd Term: Academic Year: 2023-2024

3. Electrocution Hazards

Heavy equipment relies on electrical systems to function properly. Operators should be aware of the risks
associated with working near power lines, underground cables, or electrical installations. Insulated tools and
proper training can help mitigate the risk of electrocution.

4. Noise and Vibration Hazards

Working with heavy equipment often involves prolonged exposure to high levels of noise and vibrations, which can
lead to hearing loss, musculoskeletal disorders, and fatigue. Wearing hearing protection and taking regular breaks
can mitigate these hazards.

5. Fire and Explosion Hazards

Heavy equipment that operates with flammable fuels, hydraulic fluids, or lubricants poses a risk of fire or explosion.
Routine inspections, proper storage of flammable substances, and adherence to safety protocols help prevent
these incidents.

6. Pinch Hazards

Heavy equipment may have mechanisms or parts that can pinch body parts if operators or workers come into
contact with them. Awareness and adherence to safety protocols can prevent such accidents.

7. Visibility Hazards

Limited visibility from the operator’s cabin can lead to accidents. The use of mirrors and additional safety devices,
along with proper positioning and signaling, improves visibility and reduces the risk of collisions.

8. Lack of Training and Inadequate Maintenance

Insufficient operator training and inadequate maintenance of heavy equipment contribute to safety hazards.
Comprehensive training programs and regular inspections and maintenance routines are essential to ensure safe
equipment operation.

9. Control Measures for Heavy Equipment Safety

To mitigate the hazards associated with heavy equipment, several control measures should be implemented. These
measures aim to protect equipment operators and those working in close proximity. Here are effective control
measures for heavy equipment safety:

10. Operator Training and 3rd party Certification

Comprehensive training programs should be provided to operators to ensure they possess the necessary skills and
knowledge to operate the equipment safely. Certification programs validate an operator’s competency, and
ongoing training keeps them updated on safety practices.

11. Equipment Inspection and Maintenance

Regular inspections and maintenance routines help identify and address potential issues with heavy equipment.
Operators should conduct pre-shift inspections to check for any signs of wear, damage.

12. Personal Protective Equipment (PPE)

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COLLEGE OF ENGINEERING
2nd Term: Academic Year: 2023-2024

Operators and workers must wear

appropriate PPE when working with heavy equipment. This includes items such as hard hats, high-visibility vests,
safety glasses, gloves, and steel-toed boots. PPE serves as a barrier between the operator and potential hazards,
reducing the risk of injuries.

13. Clear Communication and Signaling

Effective communication is crucial when working with heavy equipment. Operators should have clear signals and
communication protocols established with ground personnel to ensure safe maneuvering and operations. Visual
and audible warnings enhance safety on the worksite.

14. Blind Spot Prevention

Equipment cabins should be designed to minimize blind spots. Adequate mirrors and additional safety devices
improve visibility and reduce the risk of accidents caused by limited visibility.

15. Fire Extinguishers

Heavy equipment should be equipped with fire extinguishers to respond promptly to fire incidents. The number of
fire extinguishers required may vary based on client requirements and local regulations.

16. Proper Attire and Mirrors

Operators should refrain from wearing loose clothing that may get entangled with the equipment’s control levers.
Additionally, the use of rearview and side-view mirrors helps improve visibility and awareness of the equipment’s
surroundings.

17. Seat Belt Usage

Operators should always wear seat belts while operating heavy equipment. Seat belts help protect operators in the
event of sudden stops, collisions, or equipment overturning.

18. Refueling Safety

When refueling heavy equipment at the site, it is crucial to switch off the engine and ensure no hot work is being
conducted within a specific radius. Bonding and grounding should be done before refueling to prevent static
electricity buildup. A separate permit should be obtained for equipment refueling.

19. Hot Work Permit

In live plants like refineries, a hot work permit should be obtained before performing any hot work activities near
or on heavy equipment. This permit ensures that necessary precautions are taken to prevent fire or explosion
hazards.

20. Safe Loading and Unloading

When loading and unloading materials or objects, operators should follow safe procedures to prevent injuries. This
includes using appropriate equipment and techniques, securing the load properly, and ensuring that the equipment
is on stable ground.

21. Avoid Unexpected Start-Up

Operators should never leave heavy equipment unattended without properly securing it. Unexpected start-up can
occur if someone inadvertently activates the equipment, leading to accidents or injuries. Operators should engage
the parking brake, lower attachments, and turn off the engine before leaving the equipment.
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COLLEGE OF ENGINEERING
2nd Term: Academic Year: 2023-2024

22. Familiarity with Operator

Manual

Operators should be familiar with the operator manual specific to the equipment they are operating. The manual
provides essential information on safe operation, maintenance requirements, and troubleshooting. Operators
should refer to the manual whenever needed and follow the manufacturer’s instructions.

23. Excavation Safety

Maintaining a safe distance from the edge of an excavation is essential to prevent cave-ins and protect workers
from being buried. This distance should be strictly maintained during excavation operations.

24. Boom Safety

To prevent accidents, operators should never allow anyone underneath the boom of heavy equipment. This
precaution helps avoid potential injuries caused by falling objects or accidental movements of the boom.

25. Compactor Safety

For compactors, it is important to ensure that the on/off switch functions properlyand that there are no leakages.
Employees operating compactors should wear ear muffs to protect against excessive noise exposure.

Conclusion

Heavy equipment safety should be a top priority in industries that rely on these powerful machines. By
understanding the hazards, implementing effective control measures, and adhering to safety guidelines, companies
can significantly reduce the risk of accidents and injuries in the workplace. Proper operator training, equipment
inspection and maintenance, personal protective equipment usage, clear communication, and adherence to load
limits are essential for ensuring heavy equipment safety. Additionally, measures such as seat belt usage, the three-
point rule for mounting and dismounting, safe loading and unloading, and recognizing physical and emotional limits
further enhance safety. By prioritizing heavy equipment safety, we can create a safer working environment and
protect the well-being of operators, workers, and everyone involved in heavy equipment operations.