ISO 45001 Cl. 8.1 • Manual Handling Operations Regulations 1992 (as amended) — Manual handling assessment for engineering equipment
Excel format for operational use — editable risk scores, additional hazards, print-ready
HPOL19 (Manual Handling Policy) and HPOL04 (Health & Safety Policy).| # | Activity / Process | Foreseeable Hazard | Who / What Affected | Existing Controls | C | L | R | Exposure | New Controls & Further Action | C | L | R | Exposure |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 1 | Lifting 3D scanning equipment | Back injury from lifting scanner head units (8–12kg), heavy-duty tripods and transport cases; twisting while positioning equipment on uneven surfaces | Staff handling Leica RTC360, FARO Focus or similar scanning equipment on client sites | • Manual handling training at induction • Correct lifting technique • Equipment cases designed for transport • Weight awareness |
3 | 3 | 9 | Moderate | • Individual item weight limit of 15kg for single-person lift • Equipment inventory with weights published to all staff • Mechanical aids (trolley/sack truck) for multi-item transport • Pre-plan scanning positions to minimise repeated lifts |
3 | 1 | 3 | Very Low |
| 2 | Carrying equipment on stairs and ramps | Loss of balance, trip or fall while carrying equipment on stairs, ramps or uneven access routes; restricted vision when carrying large cases | Staff transporting equipment through client facilities with multi-level access | • One hand free for handrail at all times • Adequate lighting on access routes • Two-person carry for bulky items • Route reconnaissance before equipment moved |
4 | 2 | 8 | Moderate | • Lightweight carry bags with shoulder straps for stairs (hands-free where possible) • Never carry equipment and operate phone simultaneously • Request goods lift/service lift at client facilities • Refuse carry if route is unsafe |
4 | 1 | 4 | Low |
| 3 | Loading and unloading vehicles | Back strain from loading/unloading equipment from vehicle boots; awkward postures; heavy sliding loads | All staff transporting scanning and survey equipment by vehicle | • Vehicle loading guidance • Heavy items at waist height in boot • Slide rather than lift where possible |
3 | 3 | 9 | Moderate | • Vehicle boot mat to reduce friction • Equipment arranged heaviest at tailgate • Two-person loading for items >10kg where practicable • Folding ramp recommendation for equipment trolleys |
3 | 1 | 3 | Very Low |
| 4 | Setting up and levelling scanning equipment | Shoulder and upper limb strain from repetitive tripod adjustment; sustained arm elevation while positioning scan targets; kneeling on hard surfaces | Staff performing 3D scanning setup, target placement and equipment calibration | • Ergonomic techniques in scanning training • Knee pads provided • Breaks between scan positions • Lightweight targets where available |
2 | 3 | 6 | Low | • Power-assisted tripod recommendation for frequent scanners • Knee pad use mandatory on hard surfaces • Target height planning to avoid overhead work • Rotation of scanning duties on multi-day projects |
2 | 1 | 2 | Very Low |
| 5 | Working in confined or awkward positions | Musculoskeletal injury from scanning in restricted spaces (plant rooms, ceiling voids, crawl spaces); sustained awkward postures | Staff scanning in confined areas of client facilities | • Pre-assessment of scanning locations • Alternative scanning methods considered (longer range, windowless mode) • Time limits in awkward positions |
3 | 2 | 6 | Low | • Maximum 20 minutes in sustained awkward posture before break • Portable kneeling mat/pad • Consider mini/handheld scanner for confined spaces • Confined space assessment if atmosphere risk exists (see RA001 H12) |
3 | 1 | 3 | Very Low |
| 6 | Repetitive movements during survey work | Upper limb disorders from repetitive actions during hand measurements, target placement, cable routing; sustained gripping of measurement tools | Staff performing manual measurement and survey tasks alongside scanning | • Task variety built into survey plans • Ergonomic hand tools • Stretch breaks |
2 | 3 | 6 | Low | • Digital measurement tools preferred over manual where accuracy permits • Rotating tasks between team members on multi-person surveys • Grip-reducing tool handles • Report early symptoms to Ops Manager |
2 | 1 | 2 | Very Low |
| Likelihood ↓ / Consequence → | 1 Negligible | 2 Minor | 3 Moderate | 4 Major | 5 Catastrophic |
|---|---|---|---|---|---|
| 5 Almost Certain | 5 | 10 | 15 | 20 | 25 |
| 4 Likely | 4 | 8 | 12 | 16 | 20 |
| 3 Possible | 3 | 6 | 9 | 12 | 15 |
| 2 Unlikely | 2 | 4 | 6 | 8 | 10 |
| 1 Rare | 1 | 2 | 3 | 4 | 5 |
HPROC01 (Risk Assessment Procedure): any hazard scoring High (13–16) or Very High (17–25) after existing controls must be escalated to the CEO for formal risk acceptance before work proceeds. All residual risks are recorded in HREG01 (Risk & Opportunity Register). OH&S hazards feed into HREG03 (Hazard Register) and environmental aspects into HREG02 (Environmental Aspects Register).
HFORM20 (Risk Assessment Acknowledgment Form) and tracked in HREG06 (Training & Competency Matrix).