General H

1. Identify the risk 2. Identify people at Risk 3. Identify precautions already in place 4. Identify impro

Identify the Risk Mobile Equipment

Walk round and observe the tasks Fork lifts- Suitable for intended use; good s
Look at plans and diagrams fitted with mirrors, horn, lights, reverse lights
Look at existing safe operating procedures speed limiter.
Ask employees and other persons Cranes, hoists & lifting accessories- Suita
Check manufacturers instructions beacon; up / down limits; hook safety clips; s
Check Safety Data Sheets Drivers / Crane Operators - Trained and ce
Check Accident & Incident Records Pre-Operational Checklists
Check National Standards Maintenance of vehicles / cranes / hoists
Check National Law requirements Medicals (Fork lift & Crane) - Done prior to
Check Industry Guidance Delivery vehicles (to and from site)
Look at Inspection Records Other vehicles
Look at Audit Reports Other traffic (including rail)
DO NOT FORGET high risk activities such as Vehicle routes- segregated from pedestrian
maintenance, some cleaning work and work not marked; wide enough for the largest vehicle;
usually carried out on a day-to-day basis Pedestrian routes segregated from vehicles;
reversing kept to minimum
Pedestrian routes - Segregated from vehic
from pedestrian exit barriered off from vehicl
Affects on risk opening gates at crossing points; clear signa
Number of times it occurs Loading / Unloading - Passing pedestrians
Position of hazard steep gradients; uneven road or yard surface
Time/length of exposure creep (sunken loading bays); driver not awa
Nature of hazard
Competence of people Fall Control
Quantities used Identify all tasks where a fall could injure or k
Individual capability Lack of fall prevention platforms
Condition of equipment Lack of fall protection equipment and certifie
Adequacy of existing controls Portable and fixed ladders
Etc. Scaffolding
Mobile access platforms ("Sky Lifts")
Falling objects
Roof work
Identify persons at riskAt the Plant Same level falls
Production workers Fragile surfaces
Office staff
Cleaners Confined Spaces
Maintenance staff Fire and explosion
Temporary workers Fire and explosion from oxygen enrichment
Company and visiting drivers Loss of consciousness or asphyxiation from
Visitors Asphyxiation from lack of oxygen
Contractors Loss of consciousness from increase in bod
Clients Hypothermia from decrease in body tempera
Asphyxiation or trapping from free flowing so
 Roof work
Identify persons at riskAt the Plant Same level falls
Production workers Fragile surfaces
Office staff
Cleaners Confined Spaces
Maintenance staff Fire and explosion
Temporary workers Fire and explosion from oxygen enrichment
Company and visiting drivers Loss of consciousness or asphyxiation from
Visitors Asphyxiation from lack of oxygen
Contractors Loss of consciousness from increase in bod
Clients Hypothermia from decrease in body tempera
Asphyxiation or trapping from free flowing so
Away from the Plant Poisoning from toxic dusts, vapours or gase
Outside Sales persons Burns from corrosives
Home workers Restricted access / exit
Good vehicle drivers Restricted working space
Others working away from site Falls from height
The public affected by plant's activities Slips, trips, falls (same level)
Neighbours affected by plant's activities Falling objects
Neighbour's activities / type of business Poor visibility
Energy isolation procedures (LTV)
Contractors may include Noise
Engineering and building projects Rescue procedures
Routine maintenance, servicing and repair
Catering
Cleaning
Security
Transport services
Temporary cover services

Groups especially at risk

Young
New
Inexperienced
Pregnant
Disabled
Lone workers

Likelihood of harm Rating L

5. Almost certain i
4. High k
3. Medium e
2. Low l
1. Improbable i
h
o
Likelihood of harm Rating L
5. Almost certain i
4. High k
3. Medium e
2. Low l
1. Improbable i
h
o
o
d
 General Health and Safety Risk Assessment
precautions already in place 4. Identify improvements required 5. Prioritise and carry out corrective actions 6.

Possible Risks Topics (Non - ex

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
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
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
Risk Rating and Priority
3. Medium. Temporary disability
2. Low. Significant injuries
1. Minor. Minor injuries RISK
RATING

1-9
Consequence

L 1 2 3 4 5
i 10-15
k 1 1 2 3 4 5
e 16-25
l
i
h
o
L
i
k 1 1 2 3 4 5
e 16-25
l 2 2 4 6 8 10
i
h 3 3 6 9 12 15
o
o 4 4 8 12 16 20
d
5 5 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
cessories injuries such as:
ry 3 years. Entanglement, Trapping and / or nipping, Crushing, Impact, Burns (heat and chemical),
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
, gates; suitably Cutting and / or severing
d and sharp corners; Entanglement
y; speed limit; Trapping and / or nipping
Impact
/ exit doors; route Stabbing and / or puncture
(zebra); inward Friction and / or abrasion
High pressure fluid or air injection
overhead cables; Slips, trips, falls
n 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
 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
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 PRIORITY FOR TIME SCALE

ATING ACTION

9 Low <120 days

0-15 Medium <90 days

6-25 High
6-25 High
<30 days
sessment

Manual Handling
plex" machinery Weight Guideline - must be within the capability of the individual but as a guide
"Simple" machinery for a standing person:
d energy. Female: Floor level 7kg next to the body; 3 Kg at arms length. Waist level 16kg next
o persons of to the body; 10kg at arms length. Head level 7kg next to the body; 3kg at arms length
Male: Floor level 10kg next to the body; 5kg at arms length. Waist level 25kg next to
at and chemical), the body; 15kg at arms length.
wning, High Head level 10kg next to body; 5kg at arms length.
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, hot
etc?
Working area - Lack of space? Slippery, unstable or uneven floors? Steps to have to
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.
tant, Carcinogens, Welding, burning, contact with hot surfaces. High visibility clothing for vehicle
ke, Liquids, Vapour, movements. Fall arrest equipment for risk of falls. Respiratory protection for
hazardous substances.

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
 Other - Body protection against Chemical exposure, Hot / Cold / Wet conditions.
tant, Carcinogens, Welding, burning, contact with hot surfaces. High visibility clothing for vehicle
ke, Liquids, Vapour, movements. Fall arrest equipment for risk of falls. Respiratory protection for
hazardous substances.

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 locked
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 carried
out
C) peak sound.
 ual but as a guide

ist level 16kg next

3kg at arms length
level 25kg next to

ying weights
quiring excessive
tooping at the

e? Load sharp, hot

s? Steps to have to
of wind or

lth?

urning. Powered

sound.
micals. Oils.

mical. Molten

Wet conditions.
for vehicle
ection for
Wet conditions.
for vehicle
ection for

Blocked or locked

e.

checks. Not carried

Hierarchy of Improvements.
1. Eliminate the risk 2. Reduce the risk or Substitute the risk with a less harmful alternative 3. Isola

Date of Assessment:

Department/area and task being carried

Number Group
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 Rack suitability

1.05
1.06
 The use of Racks (Cradles, skips, stillag
a less harmful alternative 3. Isolate the risk 4. Control the risk 5. Provide PPE 6. Ensure Discipline & T

Revision Number: Carried out by:

Risk Topic Risk Identified

Racks must not be overfilled or

exceed the top of the rack. This is
particularly important when
Stability of stack handing scrap
Poorly designed racks or racks
that are used beyond their design
capacity can become unstable
Stability of stack during stacking

Damaged racks can become

Stability of stack unstable during stacking

Only compatible racks must be

Stability of stack used together
cks (Cradles, skips, stillages etc) for moving long length Profiles
5. Provide PPE 6. Ensure Discipline & Training

People at Risk Current Control Measures Overview

Driver training and awareness and regular

Operators, visitors inspections and audits

Racks must be identified with their safe

Operators, visitors
Operators, visitors
working loads and be certified for lifting and
regularly inspected
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

Only racks that have been designed to be

Operators, visitors stackable are to be used.
ng length Profiles

Current Control Measures

Current Control Measures 1 Current Control Measures 2
3

Driver training Inspections and audits

Clear identification on
Driver training racks

Inspection process by
Operator training operators

Inspection process by
Driver training operators
 4
Current Control Measures
Consequence of
Harm

5
5
5
5
Likelihood of Harm
Being Caused

2
4
2
2
Risk Rating

10
20
10
10

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
 Heath and Safety

Action Plan
Reference
Law
Additional Control Measures Required Priority of Action.

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
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