Tuesday, May 21, 2024



Loading and unloading operations are essential in many industries, but they also carry inherent risks. These risks can cause injuries to workers, damage to products, and even pose dangers to bystanders.

A risk assessment for loading and unloading is a crucial first step in mitigating these risks. This assessment involves identifying potential hazards, evaluating their likelihood and severity, and then implementing controls to minimize the chance of an incident.

By proactively addressing these risks, businesses can ensure the safety of their employees, protect their products, and promote a smooth and efficient operation.

1.  Workplace/Activity/ Process/ Equipment/Materials

  • Checking the site.
  • Equipment Mobilization.
  • Installing the Lifting equipment/lifting gears.
  • Working close to heavy elements.
  • Lifting Operation.
  • Housekeeping.

2.  Hazards

  • Falling, Slipping, and tripping
  • Collision, unsecured load, Hit
  • Slips, falling from height. Incompetent Rigger.
  • Moving Plant, Machinery, and Elements. Persons being struck by the suspended load. Persons being struck by moving equipment.
  • Lifting equipment failure.
  • Load Dislodgement.
  • Uncontrolled movement of the load
  • Communication breakdown and language barrier
  • (Misunderstanding).
  • Unplanned lifting operation
  • Trip / Slip / Fall

3.  Risks Issue (Possible incident) [What can go wrong] (Accident/ill health to persons, fire or property loss)

  • Personal injury.
  • Personal, Equipment, Load, or nearby structure.
  • Damage to equipment/lifting Gears or nearby structures, (serious injury or fatality).
  • Serious injury, fatality. Collapse or asset damage
  • Damaged load or nearby structures.
  • The use of the Tagline to control the load.
  • Taking suitable measures to the weather conditions (wind speed, visibility, thunders, and storms).
  • The operator shall refrain from unexpected maneuvers.
  • The lifting operator shall be certified, competent, and experienced.
  • Serious injury, fatality, Assets Damaged, or nearby structures Collapse

4.  Existing Controls

  • Proper housekeeping, Signs, and barricade
  • Ensure Tool Box Talk.
  • The driver should be competent and have all documents (Local Driving license, operator license, etc.).
  • Maintain road speed limit when using access roads.
  • With a valid third-party inspection certificate.
  • The area should be barricaded and signs should be in place. Proper W@H equipments.
  • All lifting gear must undergo a thorough inspection and certification by a qualified third-party inspection (TPI) company to ensure compliance with safety regulations and maximum load capacity.
  • Before installation, the designated area must be entirely cleared of any nearby structures, personnel, or equipment that could obstruct the safe operation of the lifting equipment.
  • Never approach any moving machinery or equipment until you have confirmed that the operator or banksman is aware of your presence and has acknowledged you.
  • High-visibility clothing (Hi-Vis) is mandatory for all personnel on-site at all times. Additionally, all machinery must be equipped with functioning reverse beepers.
  • Workers must maintain a safe distance from any moving machinery. Only approach the machinery when signaled by the designated operator.
  • The appropriate Personal Protective Equipment (PPE) must be worn by all personnel at all times, as outlined in the site's safety protocols.
  • A color-coding system should be implemented to identify the capacity of each lifting equipment/gear.
  • Conduct a thorough visual inspection of all lifting equipment/gear before use to identify any potential damage or defects.
  • Ensure proper rigging procedures are followed for safe and secure lifting operations.
  • Checklist to be used.
  • Certified, Competent, and well-experienced team.
  • Continuous supervision.
  • The working area is restricted & barricaded well.
  • A competent, certified, and experienced Rigger should be in place to choose the correct lifting gears (SWL and length), C or G for the shape of the load.
  • Utilization of a tagline for load control
  • Taking suitable measures to the weather conditions (wind speed, visibility, thunders, and storms).
  • The operator shall refrain from unexpected maneuvers.
  • The lifting operator shall be certified, competent, and experienced.
  • A competent signalman/banksman should be in place.
  • During blind corners, more than one signalman/banksman or Radio shall be used.
  • Conducting a pre-lift radio communication check
  • The lifting equipment operator shall be informed about the load weight before starting the lifting activity.
  • Halt the lifting operation in the event of any communication breakdown
  • A lifting plan shall be in place.
  • A more detailed sketch for the non-routine lifting operations.  The lifting supervisor shall divide the lifting team by their roles. The designated unloading area will be clearly identified in the lifting plan and subsequently reviewed with the lifting team members.
  • Always use proper PPE at all times. Manual loading and unloading should be limited, not to exceed 20 kilos per person, or use of mechanical means of loading. Clear the area of unwanted materials; keep the area clean and tidy. Barricade the area for unauthorized.

5.  Improved Existing Controls / Implementing New Controls

  • To ensure safety, please refrain from using mobile devices while operating equipment
  • The load should be secured by straps.
  • The ground condition shall be verified by a competent person before positioning the crane (bearing capacity).
  • W@H Training and Drills. Certify and experienced rigger.
  • Prior to operation, perform a thorough visual inspection of all lifting equipment and gear.
  • Flashing Beacons.
  • Competent & experienced plant operators. Assessment needs to be performed for the operator before the usage of equipment.
  • Effective communication must be maintained between the lifting supervisor and the designated signaler (often referred to as the "sketch holder").
  • Only authorized personnel should be permitted within the designated lifting zone.
  • At no time shall any personnel be positioned directly beneath a suspended load.
  • Stopping the lifting operation if the wind speed exceeds 10 M/S can be changed taking the consideration the shape of the load.
  • Tailored Taglines for Diverse Loads: This revision clarifies the use of multiple taglines and avoids informal language ("Using more than 2 Taglines"). 2. Operator Familiarity with Lifting Procedures:
  • This rephrases the second sentence while maintaining the meaning. It uses "procedures" instead of "operation" for a more general and formal tone.
  • The signalman/banksman shall be familiar with the standard lifting operation signals.
  • The operator shall be familiar with the lifting team members to prevent any composition.
  • I am reviewing the lifting plan with the staff involved in the lifting operation (TBT).
  • The presence of the Lifting planner during non-routine lifting operations.
  • Lifting team members shall be recognized by others.
  • Use a Dust mask or spraying water to control dust.

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