General

1. Identify the risk

2. Identify people at Risk

3. Identify precautions already in place

Identify the Risk

Walk round and observe the tasks
Look at plans and diagrams
Look at existing safe operating procedures
Ask employees and other persons
Check manufacturers instructions
Check Safety Data Sheets
Check Accident & Incident Records
Check National Standards
Check National Law requirements
Check Industry Guidance
Look at Inspection Records
Look at Audit Reports
DO NOT FORGET high risk activities such as
maintenance, some cleaning work and work not
usually carried out on a day-to-day basis

Affects on risk
Number of times it occurs
Position of hazard
Time/length of exposure
Nature of hazard
Competence of people
Quantities used
Individual capability
Condition of equipment
Adequacy of existing controls
Etc.

Identify persons at riskAt the Plant

Production workers
Office staff
Cleaners
Maintenance staff
Temporary workers
Company and visiting drivers
Visitors
Contractors
Clients
Away from the Plant
Outside Sales persons
Home workers

4. Identify im

Mobile Equipment
Fork lifts- Suitable for intended use; goo
fitted with mirrors, horn, lights, reverse lig
speed limiter.
Cranes, hoists & lifting accessories- S
beacon; up / down limits; hook safety clip
Drivers / Crane Operators - Trained and
Pre-Operational Checklists
Maintenance of vehicles / cranes / hois
Medicals (Fork lift & Crane) - Done prio
Delivery vehicles (to and from site)
Other vehicles
Other traffic (including rail)
Vehicle routes- segregated from pedest
marked; wide enough for the largest vehi
Pedestrian routes segregated from vehic
reversing kept to minimum
Pedestrian routes - Segregated from ve
from pedestrian exit barriered off from ve
opening gates at crossing points; clear si
Loading / Unloading - Passing pedestria
steep gradients; uneven road or yard sur
creep (sunken loading bays); driver not a

Fall Control
Identify all tasks where a fall could injure
Lack of fall prevention platforms
Lack of fall protection equipment and cer
Portable and fixed ladders
Scaffolding
Mobile access platforms ("Sky Lifts")
Falling objects
Roof work
Same level falls
Fragile surfaces

Confined Spaces
Fire and explosion
Fire and explosion from oxygen enrichme
Loss of consciousness or asphyxiation fro
Asphyxiation from lack of oxygen
Loss of consciousness from increase in b
Hypothermia from decrease in body temp
Asphyxiation or trapping from free flowing
Poisoning from toxic dusts, vapours or ga
Burns from corrosives
Restricted access / exit

Office staff
Cleaners
Maintenance staff
Temporary workers
Company and visiting drivers
Visitors
Contractors
Clients
Away from the Plant
Outside Sales persons
Home workers
Good vehicle drivers
Others working away from site
The public affected by plant's activities
Neighbours affected by plant's activities
Neighbour's activities / type of business
Contractors may include
Engineering and building projects
Routine maintenance, servicing and repair
Catering
Cleaning
Security
Transport services
Temporary cover services

Confined Spaces
Fire and explosion
Fire and explosion from oxygen enrichme
Loss of consciousness or asphyxiation fro
Asphyxiation from lack of oxygen
Loss of consciousness from increase in b
Hypothermia from decrease in body temp
Asphyxiation or trapping from free flowing
Poisoning from toxic dusts, vapours or ga
Burns from corrosives
Restricted access / exit
Restricted working space
Falls from height
Slips, trips, falls (same level)
Falling objects
Poor visibility
Energy isolation procedures (LTV)
Noise
Rescue procedures

Groups especially at risk

Young
New
Inexperienced
Pregnant
Disabled
Lone workers

Likelihood of harm Rating

5. Almost certain
4. High
3. Medium
2. Low
1. Improbable

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General Health and Safety Risk Assessment

precautions already in place

4. Identify improvements required

5. Prioritise and carry out corrective actions

Possible Risks Topics (Non Mobile Equipment

Fork lifts- Suitable for intended use; good stability; bright colour; good all round visibility;
fitted with mirrors, horn, lights, reverse lights & alarm, seat belt, driver roll over protection,
speed limiter.
Cranes, hoists & lifting accessories- Suitable for intended use; horn or alarm; flashing
beacon; up / down limits; hook safety clips; suitable & certificated accessories
Drivers / Crane Operators - Trained and certificated. Retested every 3 years.
Pre-Operational Checklists
Maintenance of vehicles / cranes / hoists
Medicals (Fork lift & Crane) - Done prior to training and annually after test
Delivery vehicles (to and from site)
Other vehicles
Other traffic (including rail)
Vehicle routes- segregated from pedestrians; separated from doors, gates; suitably
marked; wide enough for the largest vehicle; overhead hazards; blind and sharp corners;
Pedestrian routes segregated from vehicles; ventilated as necessary; speed limit;
reversing kept to minimum
Pedestrian routes - Segregated from vehicle movements and entry / exit doors; route
from pedestrian exit barriered off from vehicle door; crossing points (zebra); inward
opening gates at crossing points; clear signage
Loading / Unloading - Passing pedestrians & vehicles; contact with overhead cables;
steep gradients; uneven road or yard surfaces; unsuitable or uneven load stability; trailer
creep (sunken loading bays); driver not away from vehicle
Fall Control
Identify all tasks where a fall could injure or kill
Lack of fall prevention platforms
Lack of fall protection equipment and certified anchor points
Portable and fixed ladders
Scaffolding
Mobile access platforms ("Sky Lifts")
Falling objects
Roof work
Same level falls
Fragile surfaces
Confined Spaces
Fire and explosion
Fire and explosion from oxygen enrichment
Loss of consciousness or asphyxiation from gas, fume or vapour
Asphyxiation from lack of oxygen
Loss of consciousness from increase in body temperature
Hypothermia from decrease in body temperature
Asphyxiation or trapping from free flowing solids
Poisoning from toxic dusts, vapours or gases
Burns from corrosives
Restricted access / exit

Confined Spaces
Fire and explosion
Fire and explosion from oxygen enrichment
Loss of consciousness or asphyxiation from gas, fume or vapour
Asphyxiation from lack of oxygen
Loss of consciousness from increase in body temperature
Hypothermia from decrease in body temperature
Asphyxiation or trapping from free flowing solids
Poisoning from toxic dusts, vapours or gases
Burns from corrosives
Restricted access / exit
Restricted working space
Falls from height
Slips, trips, falls (same level)
Falling objects
Poor visibility
Energy isolation procedures (LTV)
Noise
Rescue procedures

Consequence of harm Rating

5. Major. Death
4. High. Permanent disability
3. Medium. Temporary disability
2. Low. Significant injuries
1. Minor. Minor injuries

Risk Rating and Priority

RISK
RATING
1-9

Consequence
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10

12

15

12

16

20

10-15
16-25

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12

16

20

10.

15

20

25

ety Risk Assessment

rioritise and carry out corrective actions

6. Record the results

7. Routinely review the assessment

Possible Risks Topics (Non - exhaustive list)

Energy Isolation
od all round visibility; "Energy Isolation" to cover Lock Out, Tag Out and Verify for both "Complex" machinery
er roll over protection, (i.e. an extrusion press and all handling plus ancillary equipment) and "Simple" machinery
(i.e. a lathe). Energy isolation will include all forms of energy and stored energy.
orn or alarm; flashing Risk - due to no or only partial Energy Isolation Procedures risk to persons of
injuries such as:
cessories
Entanglement, Trapping and / or nipping, Crushing, Impact, Burns (heat and chemical),
ry 3 years.
Scalding, Cutting and / or severing, Falling and / or falling objects, Drowning, High
pressure fluid or air pressure injection, Electric shock.
fter test
Machinery Safety - Mechanical
Crushing
Shearing
Cutting and / or severing
, gates; suitably
d and sharp corners; Entanglement
Trapping and / or nipping
y; speed limit;
Impact
Stabbing and / or puncture
/ exit doors; route
Friction and / or abrasion
zebra); inward
High pressure fluid or air injection
Slips, trips, falls
overhead cables;
load stability; trailer Falling objects
Burns
Electrical
Direct contact
Indirect contact
Short circuit / overload
As a source of ignition
Electrostatic potential

Hazardous Substances / Chemicals

Exposure risk byInhalation, Ingestion, Skin contact
To substances classified asVery Toxic, Toxic, Corrosive, Harmful, Irritant, Carcinogens,
Mutagens, Biological Agents In the form of Solids, Dusts, Fume, Smoke, Liquids, Vapour,
Mists, Aerosols, Gases.
Workplace exposure limits not known.
Exhaust Extraction and Breathing Zone monitoring / analysis not carried out.
Housekeeping (minimum)
Slips, trips, falls
Spillages
Lack of spill kits
Lack of waste removal
Lack of waste containers
Flammable waste not segregated
Flammable items not in fire proof storage

Mists, Aerosols, Gases.

Workplace exposure limits not known.
Exhaust Extraction and Breathing Zone monitoring / analysis not carried out.
Housekeeping (minimum)
Slips, trips, falls
Spillages
Lack of spill kits
Lack of waste removal
Lack of waste containers
Flammable waste not segregated
Flammable items not in fire proof storage
Smoking in unapproved areas
Blocked walkways, doorways, vehicle routes
Incorrect storage leading to any above
Noise
Noise levels in working areas not known.
Noise level known to be at or above 85dB(A) daily exposure or 137dB(C) peak sound.
Engineering control measures not in use.
Hearing protectiion not issued / not worn.
Personnel Hearing Tests (audio) not carried out.

Risk Rating and Priority

SK
ATING

PRIORITY FOR TIME SCALE

ACTION

Low

0-15

Medium

6-25

High

<120 days
<90 days
<30 days

ew the assessment

Manual Handling
Weight Guideline - must be within the capability of the individual but as a gui
both "Complex" machinery
ment) and "Simple" machinery for a standing person:
Female: Floor level 7kg next to the body; 3 Kg at arms length. Waist level 16kg ne
and stored energy.
to the body; 10kg at arms length. Head level 7kg next to the body; 3kg at arms leng
res risk to persons of
Male: Floor level 10kg next to the body; 5kg at arms length. Waist level 25kg next t
the body; 15kg at arms length.
Burns (heat and chemical),
Head level 10kg next to body; 5kg at arms length.
jects, Drowning, High
Seated work at waist level; Female 3kg. Male 5kg
Risks
Actions - Lifting and lowering weights outside the guidelines. Carrying weights
without resting above 10m distance. Pulling and pushing loads requiring excessive
force to start and maintain movement. Twisting the body (trunk). Stooping at the
waist. Sudden movement of the load.
Frequent or prolonged physical effort. Effects of PPE and clothing.
Load - Load too heavy? Load difficult to hold on to? Load unstable? Load sharp, h
etc?
Working area - Lack of space? Slippery, unstable or uneven floors? Steps to have
walk up or down? Extremes in high and low temperatures? Gusts of wind or
inadequate ventilation?
Other - Pregnant worker? Young worker? Previous injury or ill-health?

Personal Protective Equipment

Note - Equipment provided must suit the particular risk found.
Head - Falling objects. Hitting head. Bumping head
Eye - Chips (swarf). Chemical. Oils. Sawing. Grinding. Welding. Burning. Powered
tools. Molten metal. Liquids under pressure. Radiant heat.
Ear- Noise at or above 85dB(A) daily exposure or 137dB(C) peak sound.
Arms & hands - Sharp edges. Hot / Cold / Molten surfaces. Chemicals. Oils.
Electricity.
Foot - Falling objects. Blow injuries. Sharp objects. Electrical. Chemical. Molten
metals. Manual & mechanical handling. Cold conditions.
Other - Body protection against Chemical exposure, Hot / Cold / Wet conditions.
armful, Irritant, Carcinogens, Welding, burning, contact with hot surfaces. High visibility clothing for vehicle
ume, Smoke, Liquids, Vapour, movements. Fall arrest equipment for risk of falls. Respiratory protection for
hazardous substances.

lysis not carried out.

Fire Safety
Potential fire fuels and sources of ignition not identified.
Portable electrical appliance testing not carried out.
Evacuation alarm system. None provided or inadequate.
Contacting the Fire Service. No system in place.
Emergency lighting. None, too few, incorrectly positioned.
Fire Extinguishers - None, incompatible to risk or too few
Escape Routes and Fire exits - None or too few. Blocked route. Blocked or locke
Fire Exit. None or incorrect signs leading to and out of exit.
Evacuation Assembly Areas. None provided.
Emergency Plan including Evacuation Procedure - Not in place.

lysis not carried out.

or 137dB(C) peak sound.

Fire Safety
Potential fire fuels and sources of ignition not identified.
Portable electrical appliance testing not carried out.
Evacuation alarm system. None provided or inadequate.
Contacting the Fire Service. No system in place.
Emergency lighting. None, too few, incorrectly positioned.
Fire Extinguishers - None, incompatible to risk or too few
Escape Routes and Fire exits - None or too few. Blocked route. Blocked or locke
Fire Exit. None or incorrect signs leading to and out of exit.
Evacuation Assembly Areas. None provided.
Emergency Plan including Evacuation Procedure - Not in place.
Evacuation Drills (Practises). Not carried out.
Fire Marshalls / Fighters. None in place
Fire Fighter Training. Not carried out
Extinguisher, Fire Alarm and Emergency Light servicing and checks. Not carr
out

lity of the individual but as a guide

at arms length. Waist level 16kg next

g next to the body; 3kg at arms length
arms length. Waist level 25kg next to

h.
5kg

he guidelines. Carrying weights

d pushing loads requiring excessive
he body (trunk). Stooping at the
PPE and clothing.
to? Load unstable? Load sharp, hot

le or uneven floors? Steps to have to

peratures? Gusts of wind or

ous injury or ill-health?

ticular risk found.

ead
nding. Welding. Burning. Powered
diant heat.
or 137dB(C) peak sound.
ten surfaces. Chemicals. Oils.

cts. Electrical. Chemical. Molten

nditions.
sure, Hot / Cold / Wet conditions.
h visibility clothing for vehicle
s. Respiratory protection for

entified.
out.
adequate.
ce.
positioned.
or too few
w. Blocked route. Blocked or locked
out of exit.

dure - Not in place.

entified.
out.
adequate.
ce.
positioned.
or too few
w. Blocked route. Blocked or locked
out of exit.

dure - Not in place.

ht servicing and checks. Not carried

Hierarchy of Improvements.
1. Eliminate the risk 2. Reduce the risk or Substitute the risk with a less harmful alternative
Date of Assessment:

Number

Group

Department/area and task being carried

out

1.01 The use of racks

Rack use

1.02 The use of racks

Rack design

1.03 The use of racks

Rack condition

1.04 The use of racks

1.05
1.06

Rack suitability

3. Is

The use of Racks (Cradles, skips, still

a less harmful alternative

3. Isolate the risk

Revision Number:

Risk Topic

4. Control the risk

5. Provide PPE

Carried out by:

Risk Identified

Stability of stack

Racks must not be overfilled or

exceed the top of the rack. This is
particularly important when
handing scrap

Stability of stack

Poorly designed racks or racks

that are used beyond their design
capacity can become unstable
during stacking

Stability of stack

Damaged racks can become

unstable during stacking

Stability of stack

Only compatible racks must be

used together

6. Ensure Discipline

cks (Cradles, skips, stillages etc) for moving long length Profiles
5. Provide PPE

6. Ensure Discipline & Training

People at Risk

Current Control Measures Overview

Operators, visitors

Driver training and awareness and regular

inspections and audits

Operators, visitors

Racks must be identified with their safe

working loads and be certified for lifting and
regularly inspected

Operators, visitors

Damaged racks are not able to be stacked

correctly and must be inspected prior to use by
the operator at all departments and removed
from service

Operators, visitors

Only racks that have been designed to be

stackable are to be used.

ng length Profiles

Current Control Measures 1 Current Control Measures 2

Driver training

Inspections and audits

Driver training

Clear identification on
racks

Operator training

Inspection process by
operators

Driver training

Inspection process by
operators

Current Control Measures

3

Risk Rating

Likelihood of Harm
Being Caused

Consequence of
Harm

Current Control Measures

4

5
2
10

5
2
10

5
4
20

5
2

10
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0

Rack filling is most important when handling

scrap and should be part of the operators
works instructions
Ensure all racks SWL is clearly marked and
modification are prohibited (joining together,
extending etc) with recertification
Introduce a rack inspection programme and
damaged racks to be removed promptly from
service
Only racks of the same design to be used
together, the use of colour coding is
recommended

Action Plan
Reference

Priority of Action.

Heath and Safety

Law

Additional Control Measures Required

5
4
3
2
1

Business Case

Current Condition
Describe

Future Condition

Action Plan

See attached she

Measurements

See attached sheet

Health and Safety Action Plan

Risk assessment
Reference

Description

nd Safety Action Plan

Action

When

Who

Status