This document provides an overview of occupational health and safety (OHS) topics including: 1. Definitions of OHS, its objectives, and benefits. Common workplace hazards like noise, chemicals, and ergonomic issues are discussed. 2. Training requirements for topics like fire safety, material handling, working at heights, and forklift operation. 3. The importance of OHS worldwide in terms of lives lost and economic costs from work-related injuries and illnesses each year. 4. Specific workplace hazards are explored in more depth like machines, confined spaces, temperature extremes, and electricity. Control strategies for mitigating risks are also addressed.

1. 2015
Belete Demeke (OHS)
4/1/2015
Occupational Health and
Safety Training Manual

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Contents Page
1. Occupational Health and safety at working environment
1.1 Definition of OccupationalHealth and safety
1.2. Objectives of OccupationalHealth andsafety
1.3. Benefitsof OccupationalHealth andsafety
1.4. Causes of accident
1.5. Occupationalhazards at work place
1.6 First AidService
2. Theoretical and practical implementation on fire fighting
2.1. Theory and definition of fire
2.2. Classes of fire and types of fire extinguisher
2.3. Proper usage and operation of fire extinguisher equipments
3. Proper manual material handling
3.1. Identify the appropriate load
3.2. Observe conducive working environment
3.3. Operate the task accordingly
4. Working at Height
4.1 Requirements
4.2 Risk Assessment
4.3 Routine and Non Routine work
4.4 Work positioning system
4.5 Individual fall arrest system
Safety for Forklift Operating
5.1 Know Your Lift Truck
5.2 Fork Lift Physicals
5.3 Lift Truck Operation & Lift Truck Safety
6. Safety Rules

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Training on Occupational Health & Safety
Occupational Health & Safety Overview
 Introduction
 Occupational Health as Human Right
 Decent work and development
 Occupational Safety & Health
 Joint Press release ILO/WHO
 Pertinent Occupational Hazards
 General Mitigation/control strategies
Now a day health & safety at work place becoming a burning issues of the world population presenting
major public health problems leading to serious social, psychological, economical consequences that can be
prevented if appropriate measures taken.
The need for occupational safety/ hygiene in the protection of workers' health cannot be overemphasized.
Even when feasible, the diagnosis and the cure of an occupational disease will not prevent further
occurrences, if exposure to the etiological agent does not cease. So long as the unhealthy work environment
remains unchanged, it’s potential to impair health remains.
The Main Objectives of OHS
 Maintenance & Promotion of worker’s health & working capacity
 Improvement of working environment & work to become conducive to Safety & Health.
 Development of work organization &working culture in a positive social climate & smooth operation &
enhance productivity of the factory.
The OHS Service Must Practiced Due to
The Labour proclamation 377/2003 emanates from the grand proclamation the constitution proclamation
No.1 1995 enacted on August 21, 1995 pertinent article in the constitution are:-
 Art.14.Right to life, security of persons & liberty
 Art.16.Every one has the right to protect against badly harm.
 Art.44.Environmental right and Art.92. Environmental Objective
Occupational Health as Human Right
 According to the Universal Declaration of Human Rights (UDHR), proclamation in 1948 Art.3 every
one has the Right to life, liberty & security of persons.
 United Nation Commission on Human Right (UNCHR) resolution 1990 Art.31 pay attentions those
Hazards underscoring the need to implement existing mechanisms for compliance with International
Human Rights to Occupational Health & Safety.

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Decent work and Development
 The ILO decent work agenda was endorsed by the world summit of 150 global leaders in September
2005, 7 UN in July 2006.
 The four pillars of decent work
1. Employment, Remuneration &benefits
2. Fundamental Rights at work
3. Social protection i.e. Occupational Health & Safety.
4. Social Dialogue
Safety Program Development
 Hazard identification & control , Assignment of responsibility, Training & communication and
Documentation & enforcement of Safety rule
Safety Program
 Maintenance of safe working condition
 Setting Performance goal
 Rewarding safety performance
 Rewarding circumstances involved in incidents by taking appropriate correction action
 Establishing Safety performance Objectives for all levels of Mgt.
 Including Safety as part of Mgt. performance reviews
 Measuring effectiveness
Benefits of Safety Program
 Reduced worker’s compensation claims
 Reduced expenses related to injuries & illnesses
 Reduced absenteeism
 Reduced insurance cost
 Improve employee morale & satisfaction
 Increase productivity and Reduction of hidden cost and Lower employee complaints
Fundamentals of Health and Safety in the Workplace
 Health and safety in the workplace and is suitable for all people in training and employment. It is
intended to raise your awareness of the dangers of your work so that you will not get injured. It is also

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designed to help you understand your duties to your fellow workers, as well as your employer's duties
towards you.
 The course will help identify risks and hazards in the workplace and describe the steps involved in a
risk assessment.
 You will learn about the different types of fires and which type of fire extinguisher should be used to
extinguish them.
 You will also review health and safety issues involving electricity and computers, the working
environment and chemicals and other hazards.
 This free online course will be of great interest to all workers wishing to learn more about the
fundamentals of health and safety in the workplace.
 Learn more about the fundamentals of health and safety in the workplace.
OCCUPATIONAL SAFETY AND HEALTH (OSH) also commonly referred to as occupational health and
safety (OHS) or workplace health and safety (WHS) is an area concerned with protecting
the safety, health and welfare of people engaged in WOrk or employment.
 The goals of occupational safety and health programs include fostering a safe and healthy work
environment.
 OSH may also protect co-workers, family members, employers, customers, and many others who might
be affected by the workplace environment.
 In the United States the term occupational health and safety is referred to as occupational health and
occupational and non-occupational safety and includes safety for activities outside of work.
Occupational safety and health can be important for:-
 Moral, legal, and financial reasons.
All organizations have a duty of care to ensure that employees and any other person who may be affected
by the companies undertaking remain safe at all times. Moral obligations would involve the protection of
employee's lives and health.
 Legal reasons for OSH practices relate to the preventative, punitive and compensatory effects of laws
that protect worker's safety and health.
 OSH can also reduce employee injury and illness related costs, including medical care, sick leave and
disability benefit costs.
 Hazards:- Inherent potential of any machine, material or ambient factors to cause illness or injury from
contact with exposure to it.
 Risk:- The probability of particular outcome will occur and the severity of that harm.
 Occupational Accident:- An accident arising out of or in the cause of work which results in :
1. Fatal occupational Injury or
2. Non-fatal occupational Injury.
 Occupational Diseases:-a disease contracted as a result of an exposure to risk factors arising from work
activity surrounding in which the worker is obliged to work. It does not include endemic or epidemic
disease which is prevalent contracted in the area the work is done.

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 The most common work place Illness are cancer from exposure to Hazardous substance, MCD, RD,
Hearing loss, Circulatory disease and communicable disease
The importance of health and safety worldwide
 2.2 million
- workers lose their lives globally every year
- due to work-related accidents and diseases
 Over 4.1 million
- US workers suffer serious illness or injury
- every year
 26.4 million
- UK working days were lost due to work
- Related illnesses and workplace injuries
 4%
- The world’s GNP is lost due to work related
- Accidents and diseases
 6,300
- workers die every day as a result of
- Occupational accidents or work-related
- Diseases
Workplace Hazards
Although work provides many economic and other benefits, a wide array of workplace hazards also present
risks to the health and safety of people at work. These include but are not limited to, "chemicals, biological
agents, physical factors, adverse ergonomic conditions, allergens, a complex network of safety risks," and a
broad range of psychosocial risk factors.
At-risk workers without appropriate safety equipment Physical hazards are a common source of injuries in
many industries. They are perhaps unavoidable in many industries such as construction and mining, but over
time people have developed safety methods and procedures to manage the risks of physical danger in the
workplace.
Employment of children may pose special problems. Falls are a common cause of occupational injuries and
fatalities, especially in construction, extraction, transportation, healthcare, and building cleaning and
maintenance.
Hazards: - Inherent potential of any machine, material or ambient factor to cause illness or injury, f fatality.
Employment of children may pose special problems.
Falls are a common cause of occupational injuries and fatalities, especially in construction, extraction,
transportation, healthcare, and building cleaning and maintenance.
In a fabrication and welding workshop an employer would be required to provide face and eye protection,
safety footwear, overalls and other necessary PPE.

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Machines are commonplace in many industries, including manufacturing, mining, construction
and agriculture, and can be dangerous to workers.
Many machines involve moving parts, sharp edges, hot surfaces and other hazards with the potential to
crush, burn, cut, shear, stab or otherwise strike or wound workers if used unsafely. Various safety measures
exist to minimize these hazards, including tag out procedures for machine maintenance and roll over
protection systems for vehicles. According to the United States Bureau of Labor Statistics, machine-related
injuries were responsible for 64,170 cases that required days away from work in 2008.
More than a quarter of these cases required more than 31 days spent away from work. That same year,
machines were the primary or secondary source of over 600 work-related fatalities. Machines are also often
involved indirectly in worker deaths and injuries, such as in cases in which a worker slips and falls, possibly
upon a sharp or pointed object. The transportation sector bears many risks for the health of commercial
drivers, too, for example from vibration, long periods of sitting, work stress and exhaustion. These problems
occur in Europe but in other parts of the world the situation is even worse. More drivers die in accidents
due to security defects in vehicles.
Long waiting times at borders cause that drivers are away from home and family much longer and even
increase the risk of HIV infections.
Confined spaces also present a work hazard. The National Institute of Occupational Safety and Health
defines "confined space" as having limited openings for entry and exit and unfavorable natural ventilation,
and which is not intended for continuous employee occupancy. Spaces of this kind can include storage tanks,
ship compartments, sewers, and pipelines. Confined spaces can pose a hazard not just to workers, but also
to people who try to rescue them.
Noise also presents a fairly common workplace hazard: occupational hearing loss is the most common work-
related injury in the United States, with 22 million workers exposed to hazardous noise levels at work and an
estimated $242 million spent annually on worker's compensation for hearing loss disability.
Noise is not the only source of occupational hearing loss; exposure to chemicals such as aromatic solvents
and metals including lead, arsenic, and mercury can also cause hearing loss.
Temperature extremes can also pose a danger to workers. Heat stress can cause heat
stroke, exhaustion, cramps, and rashes. Heat can also fog up safety glassesor cause sweaty palms
or dizziness, all of which increase the risk of other injuries.
Workers near hot surfaces or steam also are at risk for burns. Dehydration may also result from
overexposure to heat. Cold stress also poses a danger to many workers. Overexposure to cold conditions or
extreme cold can lead to hypothermia,frostbite, trench foot, or chilblains.
Electricity poses a danger to many workers. Electrical injuries can be divided into four types: fatal
electrocution, electric shock, burns, and falls caused by contact with electricener
Vibrating machinery, lighting, and air pressure can also cause work-related illness and injury.
Asphyxiation is another potential work hazard in certain situations.
Musculoskeletal disorders are avoided by the employment of good ergonomic design and the reduction of
repeated strenuous movements or lifts.

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1. Physical Hazards
Noise, Vibration, Extreme Temp Radiation, Illumination, Pressure Cold Stress, Electromagnetic caused by
exposure to pathogens.
2. Chemical Hazards
 Air born exposure eg. Dust, mist, gases, fumes, vapors
 Through Skin contact
-Corrosive action on the skin e.g. acid, alkaline, Allergic action to skin
- Direct absorption through skin e.g. Pesticide
- Photo sensitizing agent to skin e.g. Creosols
3. Biological Hazards
- Poor waste management system (solid & effluents)
- Bacterial infection
- Viral infection
- Fungal - Snake & Rodent bits
4. Ergonomics
Ergo & Nomis from a Latin word that mean work & man respectively.
Ergonomics (human engineering) is a way of thinking & planning work so that it is organized to suit the
abilities & needs of the people doing it.
 Basic principles of Ergonomics
 Enhance Safety & well being
 Improve Quality & Quantity of Products
Ergonomically Hazards
 Working position-standing
 Working position-sitting, inconvenient of eat & work bench
 Visual condition from illumination
 Strenuous work
 Inconvenient & inappropriate hand tools
5. Psychosocial Hazards
 Routine & stressful work - Violence
 Low payment standard - Work dissatisfaction Lack of job security

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 Lack of participation in decision making - Non-supporting atmosphere
 In adequate compensation - In adequate training
 In adequate resources to accomplish job. - Shift work
 Racial inequality - Sexual harassments
 Performance evaluation done poorly or not all
General Mitigation/Control Strategies
1. Engeneering Control Measure Clinical 3. Control Measure
2. Adminstrative Control Measure 4. General Control Measure
Occupational Asthma
Occupational asthma is an occupational condition defined as: "a disease characterized by variable airflow
limitation and/or airway hyper-responsiveness due to causes and conditions attributable to a particular
occupational environment and not stimuli encountered outside the workplace".
Asthma is defined as a respiratory disease caused by narrowing of the air passages. Symptoms
include shortness of breath, tightness of the chest, nasal irritation, coughing and wheezing.
The first person to use it in reference to a medical condition was Hippocrates, and he believed
that tailors, anglers and metalworkers were more likely to be affected by the disease.
Although much research has been done since, the inflammatory component of asthma was recognized only
in the 1960s.
Today, asthma affects as much as 15% of the Canadian population (and this is true of other developed
countries too) and has increased fourfold in the last 20 years.
Various reasons can be identified for this increase - Of course better diagnosis and facilities along with a
greater awareness regarding the disease have played a major role. But, one cannot deny the part of
increased environmental pollution.
Researchers have been working on the relation between the environment and human health since long and
the air we breathe is the primary cause for lung diseases like asthma, rhinitis, COPDs, etc. that affect us
today.
Approximately 10 to 15% of the adults affected by the disease report an aggravation of
their symptoms while at work and an improvement when away, which implies that they may be suffering
from Occupational Asthma. Thus, when an individual’s Asthma is caused, not aIn the USA, OA is considered
the most common occupational lung disease.
At present, over 400 workplace substances have been identified as having asthmagenic or allergenic
properties. Aggravated, by workplace materials, it is defined as Occupational Asthma.
Their existence and magnitude vary from region to region and the type of industry and can be as varied as
wood dust (cedar, ebony, etc.), per sulfates (Hairsprays), zinc or even seafood like prawns.
For example, in France the industries

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Most affected in order of importance are Bakeries and cake-shops, automobile industry and hairdressers,
whereas in Canada the principal cause is wood dust, followed by isocyanates.
Hypersensitivity pneumonitis is a related condition, with many occupational examples (e.g. "Farmer's Lung",
"Malt Worker's Lung" and "Humidifier Lung" etc.).
However, although overlapping in many cases, hypersensitivity pneumonitis may be distinguished
from occupational asthma in that it isn't restricted to only occupational exposure, and involves type III
hypersensitivity and type IV hypersensitivityrather than type I hypersensitivityof asthma. Unlike asthma,
hypersensitivity pneumonitis targets lung alveoli rather than bronchi.
Less than five years of exposure to an occupational agent can be enough for the appearance of the first
OA symptoms.
This depends on whether the reason for the OA to occur was exposure to the causative agent over a period
of time (with a latency period) or a single exposure to an irritant but at a very high concentration (without
latency period).
Both eventually result in OA. Coughing, wheezing, nasal irritation, difficulty in breathing, tightness of chest
are the most common symptoms and can be recognized more easily by asking oneself the following
questions:
 Are any of the above symptoms recurrent /chronic?
 Are they present at work?
 Do they worsen towards the end of the work day and/or end of the week?
 Does the employee/worker feel an improvement in his condition when away from work, on vacation
or on weekends?
 If these symptoms persist, the person is most likely suffering from OA. Like for any other disease
correct diagnosis is important.
According to Dr. Susan Tarlo: “It is important to recognize, since if due to a workplace sensitizer and, if
undetected and if the patient continues to work with even small exposure to the relevant sensitizing agent,
the prognosis is worse”.
She also concluded that, “the chance of eventual improvement in Asthma severity after stopping exposure
decreases with the duration of exposure after the onset of the symptom
However, one must be aware that this could also be because the person is already suffering from asthma
and his condition was simply aggravated by workplace irritants (Work-aggravated asthma). In this case,
although he will suffer similar consequences as someone who is suffering from OA (loss of work, medical
expenses, etc.), his disease cannot be considered as having an occupational origin.
The best chance of asthma clearing or significantly improving is associated with early diagnosis and early
removal from ongoing exposure”.
However, the biggest challenge is the first step – Family doctors and patients alike do not have sufficient
knowledge about Occupational Asthma - only 15% of the asthmatic patients are asked by their doctor if their
symptoms are related to work.

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And often, patients do not mention this possibility due to the fear of losing their jobs or simply because they
are not aware of the association between their work and asthma. What they do not realize is that if they
continue working under such circumstances, not only are they sure to lose their job in the long run but their
asthma will also reach an irreversible stage. Clearly, an incorrect diagnosis will have considerable medical,
social and financial consequences.
Diagnosis of OA is a process and has to be done over a period of time. First, the patient’s occupational and
clinical history is taken and his symptoms are charted (Charting is usually done at the end of a typical work
week and within 24 hours of the occurrence of symptoms in order to get objective information). Once this
has been established, the following diagnostic methods are used:
FIRST AID SERVICE
FIRST AID SERVICE
The five life saving methods (ABCDE)
1. Air check up the airway
2. Bleeding (stop the bleeding)
- Bandage rolling (pressured the wound
- Upward position - Tourniquets
3. Circulation (prevent shock)
- Elevate the bed Cold compressed on bed forehead
4. Dressing the wound by sterilized bandage
5. Evacuate the patient to the referral by any transport
Safety And Hygiene
Worker co-operates in safety by taking reasonable care for their own and work mates' safety. Every worker
is trained to observe safety instructions, including the proper use of safety devices and protective
equipment. A system is established for reporting hazards, accidents or illness. Appropriate facilities are
available, so that the hands and the exposed parts of the body are regularly washed. Substances such as
solvents (thinner), alkalis and machine oils are not used for cleaning dirty from skin. Working and street
clothes are not mixed. Arrangement is made to clean.
Glove Specification
 PVC glove for humidity and cold
 Leather glove for heavy duty use in dry work
 Rubber glove for corrosive substance

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Fundamentals of Health and Safety in the Workplace
"Occupational health should aim at: the promotion and maintenance of the highest degree of physical,
mental and social well-being of workers in all occupations; the prevention amongst workers of departures
from health caused by their working conditions; The protection of workers in their employment from risks
resulting from factors adverse to health; the placing and maintenance of the workerinan occupational
environmentadaptedtohisphysiological andpsychological capabilities;and,tosummarize,the adaptationof workto
man and of each manto his job."The mainfocusin occupational healthisonthree differentobjectives:
The maintenance and promotion of workers’ health and working capacity;
The improvement of working environment and work to become conducive to safety and health and
Development of work organizations and working cultures in a direction which supports health and safety at
work and in doing so also promotes a positive social climate and smooth operation and may enhance
productivity of the undertakings. The concept of working culture is intended in this context to mean a
reflection of the essential value systems adopted by the undertaking concerned. Such a culture is reflected
in practice in the managerial systems, personnel policy, principles for participation, training policies and
quality management of the undertaking. "Joint ILO/WHO committee on Occupational Health. The research
and regulation of occupational safety and health are a relatively recent phenomenon. As labor movements
arose in response to worker concerns in the wake of the industrial revolution, worker's health entered
consideration as a labor-related issue. In 1833, HM Factory Inspectorate was formed in the United
Kingdom with a remit to inspect factories and ensure the prevention of injury to child textile workers. In
1840 a Royal Commission published its findings on the state of conditions for the workers of the mining
industry that documented the appallingly dangerous environment that they had to work in and the high
frequency of accidents. The commission sparked public outrage which resulted in the Mines Act of 1842.
The act set up an inspectorate for mines and collieries which resulted in many prosecutions and safety
improvements, and by 1850, inspectors were able to enter and inspect premises at their discretion.
Hazard identification
Hazard identification or assessment is an important step in the overall risk assessment and risk management
process. It is where individual work hazards are identified, assessed and controlled/eliminated as close to
source (location of the hazard) as reasonable and possible.
As technology, resources, social expectation or regulatory requirements change, hazard analysis focuses
controls more closely toward the source of the hazard. Thus hazard control is a dynamic program of
prevention.
Hazard-based programs also have the advantage of not assigning or implying there are "acceptable risks" in
the workplace. A hazard-based program may not be able to eliminate all risks, but neither does it accept
"satisfactory" – but still risky – outcomes.
Those who calculate and manage the risk are usually managers while those exposed to the risks are a
different group, workers, a hazard-based approach can by-pass conflict inherent in a risk-based approach.
RISK ASSESSMENT
Further information: Risk assessment & Risk assessment in public health
Modern occupational safety and health legislation usually demands that a risk assessment be carried out
prior to making an intervention. It should be kept in mind that risk management requires risk to be managed
to a level which is as low as is reasonably practical.

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 This assessment should:
 Identify the hazards
 Identify all affected by the hazard and how
 Evaluate the risk
 Identify and prioritize appropriate control measures
The calculation of risk is based on the likelihood or probability of the harm being realized and the severity of
the consequences.
This can be expressed mathematically as a quantitative assessment (by assigning low, medium and high
likelihood and severity with integers and multiplying them to obtain a risk factor), or qualitatively as a
description of the circumstances by which the harm could arise.
The assessment should be recorded and reviewed periodically and whenever there is a significant change to
work practices.
The assessment should include practical recommendations to control the risk.
Once recommended controls are implemented, the risk should be re-calculated to determine of it has been
lowered to an acceptable level.
Generally speaking, newly introduced controls should lower risk by one level, i.e., from high to medium or
from medium to low.
Education
There are multiple levels of training applicable to the field of Occupational Health and Safety (OSH).
Programs range from individual non-credit certificates, focusing on specific areas of concern, to full doctoral
programs.
Graduate programs are designed to train educators, as well as, high-level practitioners. Many OSH
generalists focus on undergraduate studies; programs within schools, such as that of the University of North
Carolina's online Bachelor of Science in Environmental Health and Safety, fill a large majority of hygienist
needs.
However, smaller companies often don’t have full-time safety specialists on staff, thus, they appoint a
current employee to the responsibility.
Individuals finding themselves in positions such as these, or for those enhancing marketability in the job-
search and promotion arena, may seek out a credit certificate program. For example, the University of
Connecticut's online OSH Certificate provides students familiarity with overarching concepts through a 15-
credit (5-course) program.
Programs such as these are often adequate tools in building a strong educational platform for new safety
managers with a minimal outlay of time and money. Further, most hygienists seek certification by
organizations which train in specific areas of concentration, focusing on isolated workplace hazards.
World Day for Health and Safety at Work
o Main article: Workers' Memorial Day
o On April 28 The International Labour Organization celebrates "World Day for Safety and Health“to raise
awareness of safety in the workplace.
o Occurring annually since 2003, each year it focuses on a specific area and bases a campaign around the
theme.

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Fire & Emergency Prevention & Rescue
The firefighting operation motion has an important impact on the safety and comfort of firefighting operation.
As a judgment criterion of the firefighting efficiency, the comfort level is hard to judge in that it is completely
decided by human feeling.
Secondly, the joint angles of some particular motions are determined by motion capture equipment, the
moment is obtained by ergonomic engineering software, and then the comprehensive comfort evaluation on
firefighting operation motion is completed.
Finally, the objective evaluation system of firefighting operation comfort is established.
Firefighting grows more and more difficult owing to many types of fire accidents nowadays.
The operation efficiency becomes the important factor on the firefighting according to statistics of fire
accidents. Therefore, the rationality and reliability of firefighting operation directly affect the rescue work.
Motion analysis can be used to optimize and standardize human operation motion by means of detecting and
tracking human operation. The motion analysis of firefighting is based on the collection, classification, and
evaluation of particular rescue motion of fire men and the research results will be the fundamentals for
firefighting product design and fire man training optimization.
The motion analysis can be classified into two methods: visual motion observation method and image motion
observation method.
The ergonomics analysis of firefighting operation and fire men mainly focuses on firefighting training, fire
extinguisher, and fire man uniforms.
The comprehensive evaluation on the basic information, training methods, training contents, training
management, and achievement of the tested groups are discussed
Through motion capture equipment, the human biomechanics data will be obtained and then ergonomic
software is used for motion simulation, the comfort level judgment for typical firefighting motions.

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FIRE SAFETY
Fire prevention is everyone's responsibility at work. Promptly report any fire hazards so that
they can be eliminated.
Follow these guidelines of fire prevention:
1. Maintain electrical equipment properly to avoid short circuit & overloading.
2. Do not overload circuits.
3. Store materials safely. Flammable materials should be stored safely.
4. Dispose of oil rags properly in covered containers.
5. Keep prophetic waste in specific containers and in wet condition.
6. Know the fire extinguisher and how to use it.
7. Fire extinguisher must be maintained and recharged as per schedule.
8. Do not obstruct fire extinguishers.

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Classification of Fire
Class “A” Fire -Wood, paper, textiles, and other ordinary combustibles of Fires
Class “B” Fire - Flammable liquids, oils, solvents, paint, grease, etc.
Class “C” Fire - Electrical: Live or energized electric wires or equipment
Class “D” Fire - Flammable metals K
Class “K” Fire - Combustible cooking media / appliances using oils and fats cooking
Recommended Type of Extinguisher
Class “A” or “ABC” Extinguisher
 Uses water, water-based chemical, foam, or multi-purpose dry chemical. A strictly Class A
extinguisher contains only water.
Class “ABC” or “BC” Extinguisher
 Uses foam, dry chemical, or carbon dioxide to put out the fire by smothering it or cutting off the
oxygen.
Class “ABC” or “BC” Extinguisher
 Uses foam, dry chemical, or carbon dioxide to put out fire by smothering it or cutting off the oxygen.
Class “D” Extinguisher
 Uses dry chemical to put out fire by smothering it or cutting off the oxygen.
Class “K” Extinguisher
 Uses wet chemical or dry chemical type to put out fire by smothering it or cutting off the oxygen.
FIRE EXTINGUISHER USE – P.A.S.S.
The ACRONYM “P.A.S.S.” describes the four-steps used in operating a fire extinguisher.
Pull: Pull the safety pin on the extinguisher.
Aim: Aim the hose of the extinguisher at the base of the fire.
Squeeze: Squeeze the handle to discharge the material.
Sweep: Sweep the hose across the base of the fire from side to side.

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Proper Manual Material Handling
Manual material handling operations are carried out in most industrial plants. Each handling task
Poses unique demands on the worker. However, workplaces can help workers to perform these tasks
Safely and easily by implementing and upholding proper policies and procedures.
Manual handling is the single biggest cause of workplace injuries! This course highlights the risk of injury that can
result from improper manual handling and it provides an overview of safe practices related to manual handling. It is
designed as an awareness program and is suitable for all staff that is exposed to manual handling. It may be
undertaken as a separate short course, or combined with other courses as part of a broader program of Occupational
Health and Safety. This course is essential for anyone exposed to manual handling duties as part of their employment,
or who are committed to best practice in safety and risk minimization.
Objectives
On completion of this course, you should be able to:
 Define and understand the importance of safe manual handling.
 Outline the legal framework and identify your duty in the legislation to ensure a safe workplace for everyone.
 Identify some common manual handling injuries and know what to do to prevent them in your workplace.
Identify some common risks and hazards in your workplace and how to prevent injury.
 Assess risk and undertake Workplace Consultation.
 Elements of this syllabus are subject to change. Training programs and their availability may vary by location.

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Good Materials Handling Is Important Because It Will Help You
Eliminate accidents. If good materials handling is applied, accidents can be prevented and eliminated as this means
proper and careful handling is performed. Reduce stress and effort. Through good materials handling, stress and effort
can be minimized. If you are handling materials the right away and you are eliminating all the factors that would make
material handling a risky and challenging such as a non-functional equipment, ineffective workers, etc., then materials
handling would be a stress-free process. Minimize time spent on distribution, storage, etc.
If you are applying good materials handling, then you are definitely making storage, manufacture, distribution, or
consumption of materials and goods less time-consuming. This is because good materials handling means applying
solutions that can help make this process quick and easy. Eliminate redundant work. If there is good material handling,
there is no need for you to utilize redundant workers that will only take time and cost extra expenses. When you
apply good materials handling, you are also saving money since you are not jeopardizing the quality and condition of
the products as well as you are no longer spending a lot to pay extra workers just to ensure that the materials or
product are handled well. There are two essential things needed to apply good materials handling
These are: Expert material handlers.
If you are manually handling materials and products for distribution, storage, etc. this refers to utilizing workers who
will serve as material handlers. They are the ones who are going to store, distribute, etc. all the goods to their proper
destination. Efficient material handling storage systems. If you also want to apply materials handling, efficient storage
systems are also necessary. This refers to storage systems that are really functional and automated and can really
handle materials well so your time, money and effort would be saved.
Advantages of Proper Manual Material Handling
 Eliminate accidents
 Reduce stress and effort
 Minimize time spent on distribution
 Eliminate redundant work
The Key to Greater
 Productivity, Customer, Service and Profitability
PLANNING PRINCIPLE
All material handling should be the result of a deliberate plan where the needs, performance objectives and functional
specification of the proposed methods are completely defined at the outset.
Definition: A plan is a prescribed course of action that is defined in advance of implementation. In its simplest form
a material handing plan defines the material (what) and the moves (when and where); together they define the
method (how and who).
PLANNING PRINCIPLE Key Points
The plan should be developed in consultation between the planner(s) and all who will use and benefit from the
equipment to be employed. Success in planning large scale material handling projects generally requires a team
approach involving suppliers, consultants when appropriate, and end user specialists from management, engineering,
computer and information systems, finance and operation.

19. 19
The material handling plan should reflect the strategic objectives of the organization as well as the more immediate
needs. The material handling plan should reflect the strategic objectives of the organization as well as the more
immediate needs. The plan should document existing methods and problems, physical and economic constraints, and
future requirements and goals.
The plan should promote concurrent engineering of product, process design, process layout, and material handling
methods, as opposed to independent and sequential design practices
Standardization Principle
Material handling methods, equipment, controls and software should be standardized within the limits of achieving
overall performance objectives and without sacrificing needed flexibility , modularity and throughput.
Standardization Principle Key Points
Definition: Standardization means less variety and customization in the methods and equipment employed.
The planner should select methods and equipment that can perform a variety of tasks under a variety of operating
conditions and in anticipation of changing future requirements.
Standardization applies to sizes of containers and other load forming components as well as operating procedures and
equipment. Standardization, flexibility and modularity must not be incompatible
Work Principle Key Points
The shortest distance between two points is a straight line.
Ergonomic Principle
Human capabilities and limitations must be recognized and respected in the design of material handling tasks and
equipment to ensure safe and effective operations.
Ergonomic Principle Key Points
Equipment should be selected that eliminates repetitive and strenuous manual labor and which effectively interacts
with human operators and users. The ergonomic principle embraces both physical and mental tasks. The material
handling workplace and the equipment employed to assist in that work must be designed so they are safe for people.
UNIT LOAD PRINCIPLE
Unit loads shall be appropriately sized and configured in a way which achieves the material flow and inventory
objectives at each stage in the supply chain.
Definition: A unit load is one that can be stored or moved as a single entity at one time, such as a pallet, container
or tote, regardless of the number of individual items that make up the load.
UNIT LOAD PRINCIPLE Key Points
Less effort and work is required to collect and move many individual items as a single load than to move many items
one at a time. Load size and composition may change as material and product moves through stages of manufacturing
and the resulting distribution channels. Large unit loads are common both pre and post manufacturing in the form of
raw materials and finished goods.

20. 20
During manufacturing, smaller unit loads, including as few as one item, yield less in-process inventory and shorter
item throughput times. Smaller unit loads are consistent with manufacturing strategies that embrace operating
Objectives such as flexibility, continuous flow and just-in-time delivery. Unit loads composed of a mix of different
items are consistent with just-in-time and/or customized supply strategies so long as item selectivity is not
compromised.
SPACE UTILIZATION
Effective and efficient use must be made of all available space.
Definition: Space in material handling is three dimensional and therefore is counted as cubic space.
SPACE UTILIZATION Key Points
In work areas, cluttered and unorganized spaces and blocked aisles should be eliminated. In storage areas, the
objective of maximizing storage density must be balanced against accessibility and selectivity.
When transporting loads within a facility the use of overhead space should be considered as an option.
SYSTEM PRINCIPLE
Material movement and storage activities should be fully integrated to form a coordinated, operational system which
spans receiving, inspection, storage, production, assembly, packaging, unitizing, order selection, shipping,
transportation and the handling of returns.
Definition: A system is a collection of interacting and/or interdependent entities that form a unified whole.
SYSTEM PRINCIPLE Key Points
Systems integration should encompass the entire supply chain including reverse logistics. It should include suppliers,
manufacturers, distributors and customers. Inventory levels should be minimized at all stages of production and
distribution while respecting considerations of process variability and customer service. Information flow and physical
material flow should be integrated and treated as concurrent activities. Methods should be provided for easily identifying
materials and products, for determining their location and status within facilities and within the supply chain and for
controlling their movement. Customer requirements and expectations regarding quantity, quality, and on-time
delivery should be met without exception.
Automation Principle
Material handling operations should be mechanized and/or automated where feasible to improve operational efficiency,
increase responsiveness, and improve consistency and predictability, decrease operating costs and to eliminate
repetitive or potentially unsafe manual labor.
Definition: Automation is a technology concerned with the application of electro-mechanical devices, electronics and
computer-based systems to operate and control production and service activities. It suggests the linking of multiple
mechanical operations to create a system that can be controlled by programmed instructions.
Automation Principle Key Points
Pre-existing processes and methods should be simplified and/or re-engineered before any efforts at installing
mechanized or automated systems. Computerized material handling systems should be considered where appropriate
for effective integration of material flow and information management.

21. 21
All items expected to be handled automatically must have features that accommodate mechanized and automated
handling. Treat all interface issues as critical to successful automation, including equipment to equipment, equipment
to load, equipment to operator, and control communications.
Environmental Principle
Environmental impact and energy consumption should be considered as criteria when designing or selecting
alternative equipment and material handling systems.
Definition: Environmental consciousness stems from a desire not to waste natural resources and to predict and
eliminate the possible negative effects of our daily actions on the environment.
Environmental Principle Key Points
Containers, pallets and other products used to form and protect unit loads should be designed for reusability when
possible and/or biodegradability as appropriate.
Systems design should accommodate the handling of spent damage, empty containers and other by-products of
material handling. Materials specified as hazardous have special needs with regard to spill protection, combustibility
and other risks.
Life Cycle Cost Principle
A thorough economic analysis should account for the entire life cycle of all material handling equipment and resulting systems.
Definition: Life cycle costs include all cash flows that will occur between the time the first dollar is spent to plan or procure a
new piece of equipment, or to put in place a new method, until that method and/or equipment is totally replaced.
Life Cycle Principle Key Points
Life cycle costs include capital investment, installation, setup and equipment programming, training, system testing
and acceptance, operating (labor, utilities, etc.), maintenance and repair, reuse value, and ultimate disposal. A plan for
preventive and predictive maintenance should be prepared for the equipment, and the estimated cost of maintenance
and spare parts should be included in the economic analysis. A long-range plan for replacement of the equipment
when it becomes obsolete should be prepared. Although measurable cost is a primary factory, it is certainly not the
only factor in selecting among alternatives. Other factors of a strategic nature to the organization and which form the
basis for competition in the market place should be considered and quantified whenever.
To assess the hazards of manual material handling
Operations, consider the load, the task, the environment in which the task is performed, and the operator. When these
factors interact with each other, they can create hazards that result in injuries.
A load may be hazardous because of:
● Weight, size, shape (making it awkward to handle), coupling (type of grip on the load) ,slippery or damaged
surfaces, absent or inappropriate handles, and imbalance (i.e., changing centre of gravity)
The task or method of handling may be hazardous, when it involves:

22. 22
● lifting or lowering, repetitively, quickly, for extended periods of time, while seated or kneeling, immediately after
prolonged flexion, shortly after a period of rest an inability to get close to the load moving the load over large
distances accuracy and precision required because of fragile loads, or specific unloading locations
● Materials positioned too low or too high
● Hazardous movements or postures (e.g. twisting, extended bending and reaching)
● Multiple handling requirements (e.g., lifting, carrying, unloading)
 Environmental factors include:
Temperature (beyond a 19–26°C range)
Relative humidity (beyond a 35–50% range)
Lighting, noise, Time constraints (e.g., machine–paced work or deadline pressures)
 Physical conditions such as
– Obstacles, floor surfaces (e.g., slippery, uneven or damaged)
Operator characteristics that affect the handling of
Loads include: general health, physical factors, height, reach, flexibility, strength, weight, aerobic capacity, pre-existing
musculoskeletal problems
 Psychological Factors
- Motivation, stress
Control Measures
The best control measure is to eliminate the need for workers to perform manual handling tasks. Since this is not
always possible, design manual handling tasks so that they are within the workers’ capabilities. Considerations include
the load itself, the design of the workstation and work practices.
Providing mechanical handling devices or aids can often eliminate the task itself or ease the demands on the worker.
Task Design
The Load
Reduce the weight of the load by decreasing the:
● Size of the object (specify size to suppliers)
● Weight of the container (e.g., plastic is lighter than steel)
● Capacity of containers load in the container
Conversely, consider increase.
Work Station Design
Reduce the distance over which the load has to be moved by relocating production and storage areas.

23. 23
Design work stations so that workers:
● can store and handle all material between knuckle and shoulder height; waist height is most desirable
● can begin and end handling material at the same height
● can face the load and handle materials as close to the body as possible
●do not have to handle loads using awkward postures or an extended reach, and
● do not handle loads in confined spaces that prevent them from using good body mechanics
Facilitate access to material by:
●providing work benches and other work stations with toe cut-outs, so that workers can get closer to the load
● supplying bins and totes with removable sides
● removing obstructions, such as unnecessary railings on bins
Work Practices
Lifting and Lowering eliminate the need to lift or lower manually by providing and ensuring proper use of:
● lift trucks, cranes, hoists, scissor lifts, drum and barrel dumpers, stackers, work dispensers, elevating conveyors,
articulating arms and other mechanical devices
● Gravity dumps and chutes
● Power lift tail gates on trucks, and hand trucks to ensure easy transfer of material from the truck to ground level
and portable ramps or conveyors to lift and lower loads on to work stations.
Pushing and Pulling
Eliminate pushing or pulling by ensuring the use of: powered conveyors, powered trucks, slides, chutes, monorails, air
tables and similar mechanical aids
Make loads easier to push or pull by ensuring the use of: carts, hand trucks and dollies with large diameter casters
and good bearings, and grips or handles on loads or mechanical aids, placed to provide optimal push force and
prevent awkward postures.
Instruct employees to:
● push rather than pull
● avoid overloading – limit the load pushed or pulled at one time
● ensure the load does not block vision
● never push one load and pull another at the same time
Carrying and Holding
Reduce carrying and holding forces by:

24. 24
● evaluating the work flow – determine if heavy loads can be moved mechanically over any distance
● converting the operation into a pushing or pulling task
● providing carts, slings or trolleys
● providing portable containers in which to place awkward loads
● providing grips or handles on loads
● limiting the distance over which the load is moved
Environmental Factors
Maintain an optimum environment by ensuring that: the temperature of the work area is at an acceptable level in a
hot environment workers take frequent breaks away from the heat workers drink frequently from liquids provided
near the work site in a cold environment, workers wear good insulating clothing loads are easy to handle when gloves
and heavy clothing are worn humidity is at an acceptable level Lifting instructions can be heard in a noisy
environment Lighting levels are adequate for the work place the layout of the work area provides better access to the
load the aisles are clear of obstacles signs are posted where there are gradients in the slope of the floor; whenever
possible, limit such slopes to 10 degrees.
Work At Height
Work at height includes work being performed in a situation where there is potential for a person or an object,
including equipment, material, tools and debris, to fall or be emitted sideways or upwards or otherwise hit persons
during work from a scaffold, permanent work platform, through a ceiling or floor and the like. Examples are hosing
material from elevated structures, opening drain valves that discharge at height, tools falling off a working platform,
rock and soil falling into a trench and falling material deflected off the side of a building.
The need for occupational safety/hygiene in the protection of workers' health cannot be overemphasized. Even when
feasible, the diagnosis and the cure of an occupational disease will not prevent further occurrences, if exposure to the
etiological agent does not cease. So long as the unhealthy work environment remains unchanged, its potential to
impair health remains.
Work at height can either be external, performed outside of any confining structure, or internal where work is
performed above or inside a confining structure (e.g. tank, boiler internality), that has access holes or openings below
or above allowing any falling object to enter or exit the work area.
• For light routine and non-routine work at heights between 2 and maximum 6 meters:
• To use industrial ladders complying with in or equal standards unless a risk assessment
(e.g. taking into account weather conditions) or prevailing legislation requires another solution;
• To inspect and maintain the ladders according to the supplier’s instructions;
• For light routine work above 6 m height and heavy routine work above 2 m height:
• To take sufficient engineering measures (like fixed stairs, work platforms with railing) such that special PPE for
working at height (like a fall arrest systems) is not required;

25. 25
• For light non-routine work above 6 meters and heavy non-routine work above 2 meter height (or lower height
when demanded by prevailing legislation):
• To carry out a risk assessment being part of the Safe Work Permit System (documented);
• To reduce risks following the hierarchy of risk control;
• To follow the requirements of this procedure in case PPE such as work restraint systems, work positioning
systems or personal fall arrest systems are to be used;
• To ensure that only competent and trained personnel is allowed to use PPE for working at height;
• To ensure that non-routine work at height is inspected frequently;
• To ensure that a rescue plan and resources are available to rescue a person when suspended after a fall to
prevent suspension trauma;
• Work at height entails, but is not restricted to: works on stationary equipment such as silos, ferreters, storage
tanks (repairs, inspections);
• works outside and on buildings (painting, roof repairs, window cleaning, mounting signs);
• Works on mobile equipment such as trucks (loading, unloading, securing the load, inspection); . the fall height;
the nature of the task (light or heavy); whether the task is routine or non-routine;
The preventive measures depend on:
Table 1: Classification of light and heavy works at height. Industrial ladders are only allowed for light work.
Parameter Light work Heavy work
Duration of work < 30 min > 30 min
Carrying < 10 kg > 10 kg
Points of contact 3 < 3
Height Max 2 meter > 2 meter
Parameter Routine work Non-routine work
Frequencyof work
Scheduled at regular intervals at
least 1x per year
Not scheduled, less often than 1x per year
Duration of work Within 1 shift More shifts
Description of the
work
Complete task has been described
in detail in the capacities for their
intended use
Task execution determined by job safety
analysis
Experience of
worker
Worker has been trained to follow Worker knows all aspects of the work and
can carry this out safely
Work conditions Known Anticipated as far as possible

26. 26
Table2: Classification of routine and non-routine work. Special consideration should be given for the work executed
by contractors which is likely a non-routine task.
Anchorage A component fixed onto a building or structure
(scaffold) for the purpose of attaching a safety line
(EN 795). The anchor point should be able to carry
400 kg static weight.

27. 27
Routine work
The risk assessment leads normally to engineering measures (such as fixed stairs with handrail, work platforms) which
should aim to avoid usage of PPE. A safe way of working in line with the engineering measures has to be laid down in
Standard Operating Procedures.
Non-routine work
The risk assessment has to be part of a Safe Work Permit system in case of non-routine work. Special attention has to
be paid at contractors. Their competences for work at height have to verify first before to starting the work
Anchorage Point – a secure point for attaching a lanyard, lifeline or other component of a travel restraint system or
fall-arrest system. Anchorages require specific load and impact.
Barricade (Edge Protection) – a barrier to prevent access to a work area or to prevent a person falling which has been
erected along the edge or an opening in the surface of a building or other structure or from the surface from which
work is to be done and is adequately fixed and capable of withstanding the weight of a person falling against or
leaning on it. Examples are: Clamped or secured scaffold tubes
Bottoming out See Fall clearance
Brittle roofing Consists of any flat or corrugated material such as asbestos cement, plastic or glass whether
reinforced or otherwise, or any roofing material that due its properties, age or weathering will not
safely support a person at all points on its surface.
Deceleration
device
Any mechanism such as a rope grab, specially woven lanyard or deforming lanyard, or automatic self
retracting lifeline which serves to dissipate a substantial amount of energy during a fall arrest or
otherwise limits the energy imposed on a worker during fall arrest
Fall clearance
or bottoming
out
An often overlooked hazard is that of fall clearances. You must ensure there is sufficient distance
beneaththe usertoensure theydonot hita lowerlevel (bottomingout), or the ground, before the
fall arrest system is fully deployed. The illustration here
shows the necessary fall clearance is 6.55 meters when
using a 2 meters shock absorbing lanyard.
Fall or travel
restraint
system
A systemwhichallowsthe workertotravel
just farenoughto reachthe edge of a building
but not far enoughtofall over

28. 28
Free Fall
Arrest A fall or the arrestof a fall where the fall
distance before the fall-arrestsystembegins
to take any loadingisinexcessof 600mm
eitherverticallyorona slope whichisnot
possible towalkwithoutassistance of a
handrail or handline.Maximumfree fall
distance permittedis2m,withashock
absorbinglanyard.(Please note fall clearance
requirements)
Full body
harness
A bodysupportdevice (EN 361) consistingof :
- connectedstrapsdesignedtodistribute afall arrestingforce
- withprovisionforattachingalanyard,lifelineorothercomponent
Harness Hang
Syndrome
See Suspensiontrauma
Lanyard flexible line of webbing,syntheticrope orwire rope thatis usedtosecure a
safetybeltof full bodyharnesstoa lifelineoranchorage (EN 354)
Lifeline A syntheticorwire rope,riggedfromone ormore anchorsto whicha
worker’slanyardorotherpart of a personal fall protectionsystemis
attached.There are three basic typesof lifelines:vertical,horizontal or
retractable.
LimitedFree Fall A fall or the arrest of a fall where the fall distance
prior to the system taking the load, and the
maximumdistance of anyfree fall component will
not exceed 600mm.
Orthostatic shock
or syndrome
See : suspensiontrauma

29. 29
Swing fall or
pendulumeffect
If the lifelineisnotanchoredverticallyoverthe workingplace,
the workerwill swinglaterallyinthe eventof a fall andcan
injure himself byhittingeitherthe groundbeloworan obstacle
to the side of him.If it is notpossible touse ananchorage point
close to the workstation,twoanchorage pointseitherside of
the workercan be usedtopreventanyswing.
Total Restraint To control a person’smovementbymeansof
a combinationof a harness,arestraintline
and line anchorage pointthatwill physically
preventthe personfromreachingaposition
at whichthere isa risk of a free fall
Personal Fall Arrest
System
A system used to arrest a person in a fall from a working level. It
consists of :
- a body harness
- a lanyard
- connectors
- and anchorage
And may include :
- deceleration device
- lifeline
Or a combination of these.
A bodybelt(astrap withmeansforsecuring it about the waist and for attaching it to a lanyard or
lifeline) is not safe and shall not be used as personal fall arrest system.
RestrainedFall - A fall or the arrest of a fall where the person
suffering the fall is partially restrained by a
restrainingdevice such as a pole strap, restraint
line or is sliding down a slope on which it is
normallypossible towalkwithoutthe assistance
of a hand rail or hand line.
Rope grab A decelerationdevice whichtravelona lifelineandautomaticallyby friction, engages the lifeline
and locks so as to arrest the fall of a worker.

30. 30
Structural mesh or members which have been welded, nailed, securely tied or clamped Wire rope slings which have
been shackled or secured
Plastic barricading mesh (fluorescent red/orange) firmly attached to fixed supports/posts
Catch / Overhead Platform – a platform designed to provide overhead protection to persons by catching falling
objects.
Competent Person: - a person who has acquired, through training, qualifications or experience and has been assessed
to have the knowledge and skill to do the task in a safe way.
Cordons - provide warning of a hazard but are of little or no structural significance and shall not be used to protect
people falling from height, including when walkway floor plate / mesh, guard rails, or piping and plant are removed
creating an opening. Examples of, but not limited to, are:
Tapes Plastic barricade mesh (fluorescent red/orange) attached to portable stands Rope attached to stands which are
free standing and unattached Bunting/ropes with flags
Elevating Work Platform – a telescoping device, scissor device or articulating device or any combination thereof used
to position personnel, equipment and materials at work locations and to provide a working area for persons elevated
by and working from the platform. Fall-arrest Harness System – a system designed to arrest the fall of a person using
it and to prevent or minimize the risk or injury to the person as the fall is arrested.
Safety belt,body belt
or waist belt
Work positioning
system
A strap with means both for securing it about the waist
and for attaching it to a lanyard or lifeline (EN 358). It is
only suitable for fall or travel restraint systems
A bodyharnesssystemriggedtoallow aworkerto be
supportedonan elevatedvertical surface suchasa wall andwork
withbothhandsfree while leaning.
Self-retracting
lifeline/lanyard
A deceleration device containing a drum-wound line which
can slowly extracted from, or retracted onto , the drum
under slight tension during normal employee movement,
and which,afteronsetof a fall,automaticallylocksthe drum
and arrests the fall
Shock absorber A device intendedtolimitthe decelerationforcesexertedonaworkerduringfall
arrest (EN 355)

31. 31
It consists of a harness attached to a lanyard or line that has a device to absorb the energy of the person falling and is
attached to a static line or anchorage point.
Free-fall – for a fall-arrest harness system, this means a vertical fall before the system starts to take load and is more
than 600 mm but not more than 2 meters.
Fall-Arrest Harness – an assembly of interconnected shoulder and leg straps, with or without a body belt, designed to
spread the load over the body and to prevent the wearer from falling out of the assembly. May also be referred to as a
full body harness.
Fall Arresting Platform – a platform installed to arrest the fall of a person.
Fall Protection Cover - a structure that:
Is placed over an opening in a surface of a building or other structure to prevent a person falling through the
opening; and
Consists of solid sheets of sturdy material, for example, timber, plywood, metal or mesh.
Gantry (Hoarding) – a structure that has an overhead platform and a hoarding at least 1800 mm high that is fully
sheeted with timber, plywood, metal or sturdy synthetic sheets running along its length.
Inertia Reel – a type 2 or 3 fall-arrest device that arrests a fall by locking onto a line and at the sometime allows
freedom of movement, also known as a self-retracting lanyard or fall-arrest block.
Type 2 meteroff the
ground
2 till 6 meteroff the ground
"easytasks"
Duration of work: lessthan 30
minutes
Carrying lessthan 10 kg
3 contact points(one hand is free for
work, the secondhand is neededto
hold the ladder)
2 till 6 meter
"difficulttasks"
Duration of work: more
than 30 minutes
Carrying more than 10
kg
or contact points < 3
(i.e.both hands are
neededforthe tasks,
dismantlingor placing
of valves)
6 m off the ground
Ladder No special
safeguardsare
necessary.
Before starting
to workvisual
checkof the
ladderbythe
operator.
A second operator has to hold the ladder
or one bar is fixed with a fixed- point.
Operators have to pass the"release
certification for workingin heights"
annually.
Until 5 m off the
ground
a safety belt or a safety
harness is obligatory.
All difficult tasks carried
out on ladders above 2
metersoff the ground are
forbidden!
All difficult tasks carried out
on ladders above 2 meters
off the ground are
forbidden!

32. 32
JSEA– Job Safety and Environment Analysis
Step-
ladder
No special
safeguardsare
necessary.
Before starting
to workvisual
checkof the
step- ladderby
the operator.
A second operator has to hold the step-
ladder or one bar is fixed with a fixed-
point. Operators have to pass the
"trainingfor working in heights" annually.
Until 5 m off the ground a safety belt or
a safety harness is
obligatory.
All difficult tasks carried
out on step- ladder above
2 metersoff the ground
are forbidden!
All difficult tasks carried out
on step- ladder above 6
metersoff the ground are
forbidden!
Type 2 meter off the
ground
2 till 6 meter off the
ground
"easy tasks"
Duration of work: less
than 30 minutes
Carrying less than 10 kg
3 contact points (one
hand is free for work,
the second hand is
needed to hold the
ladder)
2 till 6 meter
"difficult tasks"
Duration of work:
more than 30 minutes
Carrying more than 10
kg
or contact points < 3
(i.e. both hands are
needed for the tasks,
dismantling or placing
of valves)
6 m off the ground
Platform No special
safeguards are
necessary.
Before starting to
work visual
check of the
platform by the
operator.
Operators have to pass the
"trainingfor working in
heights" annually.
At leastuse a safety belt with
a 1, 5 m safety rope.
At leastuse a safety belt
with a 1, 5 m safety rope.
Mobile platform No special
safeguardsare
necessary.Before
startingto work
visual checkof the
platformbythe
operator
Always a safety harness or
safety belt with a safety rope
of 1,5 m clipped on the railing,
has to be weared, as soon as
the platformis extended higher
than 2 m. This has to be
applied for visual checks etc.
and if the
auto
hoistis
used as
elevator.
Always a safety harness or
safety belt with a safety rope
of 1,5 m clipped on the
railing,has to be weared, as
soon as the platformis
extended higher than 2 m.
This has to be applied for
visual checks etc.and if the
auto hoistis used as
elevator.
Always a safety harness
or safety belt with a
safety rope of 1,5 m
cliped on the railing,has
to be weared, as soon as
the platformis extended
higher than 2 m. This has
to be applied for visual
checks etc. and if the
auto
hoistis
used as
elevato
r.
Explanation:
till a level of 2 m height off the ground: A release certification for work in heights is not necessary
from a height of 2 m height off the ground: an annual instruction about working in heights is obligatory.
from a height of 2 m height off the ground: an annual instruction about wokring in heights is obligatory.
Additional a. determination of risks, b. risk analysis and c. release certification for sever working in
heights is necessary.
all operations are forbidden!

33. 33
Lanyard- an assembly consisting of a line and components which will enable connections between a harness and an
anchorage point and will absorb energy in the event of a fall. A tool lanyard is a line to connect a tool to a person,
structure or static line to eliminate the potential for the tool to fall.
Limited Free-Fall - for a fall-arrest harness system, means a vertical fall before the system starts to take load and is not
more than 600 mm.
Perimeter Containment Screening – a screen designed to stop objects falling on persons from a level of building or to
redirect a falling object onto a catch platform.
Personal Energy Absorber – a device which reduces the deceleration force imposed when a fall is Suddenly arrested,
and correspondingly reduces the loadings on the anchorage and the person’s body. The energy absorber may be a
separate item or manufactured into the lanyard.
Personal Energy Absorber – a device which reduces the deceleration force imposed when a fall is
Suddenly arrested, and correspondingly reduces the loadings on the anchorage and the person’s body. The energy
absorber may be a separate item or manufactured into the lanyard.
Rescue Plan – a documented list of steps on how to initiate a rescue response in the event of a fall. Depending on the
risk assessment, this may include steps on how to initiate the rescue until the First Response Team arrives.
Restraint Belt - a body belt designed for attachment to a restraint line and not designed for either free or restrained
fall.
Rope Grab, Backup Type – A manufactured device which is designed to slide along a safety line and whose purpose is
to arrest a limited free fall?
Safety Line – a line used as a backup to arrest a limited free fall in the event of failure of the working line or its
attachments.
Scissor Lift – a compact self-propelled mobile scaffold capable of moving in an extended state.
Static Line – means a flexible line to which a lanyard is attached and is supported by at least 2 anchorage points
located so that the angle between the horizontal and an imaginary straight line between any anchorages point and the
other or nearest anchorage point is –not more than the size specified by the manufacturer of the flexible line, or not
more than 5° if the manufacturer has not specified the size of the angle
Supervision–Supervision is a generic term used to describe people who control work processes. This term covers titles
such as, Team Leader, In Charge Person, Red Tagger, Leading Hand, Supervisor, Acting Supervisor, Foreman, Co-
Coordinator, Responsible Person or Mentor.
Suspended Load – A load suspended by lifting equipment and not fully supported by a structure or stands from below
or fixed into position.eg. Welded or bolted.
The Board –for a surface means an upright timber or metal board securely fixed in place at an edge of the surface.
Total Fall Distance - the total distance a person is likely to fall during both the free and restrained parts of a fall,
including the maximum dynamic extension of all supporting components.
Travel Restraint System (Fall Prevention System) – means a system that consists of a harness,

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Attached to one or more lanyards, each of which is attached to a static line or anchorage point. It is designed to
restrict the travelling range of a person wearing the harness so the person cannot fall off an edge of a surface of
through a surface.
Workbox – a personnel-carrying device, designed to be suspended from a crane, or attached to a forklift or similar,
that provides a working area for persons elevated by and working from the box.
Requirements
When work at height will be carried out, the following persons play a role: Production Unit Manager, Logistics
Operations Manager, Supervisor and Authorized Person.
The Production Unit Manager and the Logistics Operations Manager are responsible that:
The legal requirements and ELSEWEDY procedures for working at height are followed; (Human and financial)
resources are available:
To train a Safety Expert to implement fall prevention measures;
To assess the risks for working at heights > 2 meter, or other lower height when demanded by the prevailing
legislation;
To install and maintain fixed stairs and platforms for routine tasks;
To introduce and maintain safe working procedures;
To purchase and maintain PPE for working at height in case of non-routine tasks.
To train personnel to be fit for working at height;
Supervision is present while work at height is carried out;
Unsafe practices are discouraged (sanctions);
The Supervisor (who assigns tasks to authorized personnel) is responsible:
To have knowledge about working at height risks, to be qualified to supervise such works;
To ensure that the Safe Work Permit system is followed for non-routine tasks
To inspect temporary scaffolds, platforms, barriers before work at height are carried out, and after erection at a
regular basis;
To inspect personal fall arrest system before use
To prevent violation of ―working at height rules;
To start the rescue of persons immediately after a fall;
The Authorized person (who has received order to carry out the non-routine work at height) is responsible:
To have received the training to carry out the non-routine work (recognized degree, professional certificate);
To assure that he/she is allowed to execute the work at height task (signed Safe Work Permit);
To inspect PPE before use and report damages;
To assure that he/she has always been anchored;

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Other personnel is not authorized to enter work places with a risk of falls of more than 2 meter. This shall be
indicated by signs and obstacles like doors or chains.
Risk Assessment
When work at height has to be executed, the sequence of questions according to the hierarchy of control has to be
followed till an acceptable level of risk has been achieved considering the following factors: the likelihood that an
event of a fall will occur and the severity of harm that could result.
Fall or travel restraint system
A fall restraint system is restricting the movement of the worker and to prevent him from approaching an
unprotected edge on a building. The system consists of a:
• Safety belt or full body harness connected to a lanyard
• A lanyard fixed to a life line or an anchorage point
• Anchorage point can be a point on a structure
Attention points:
• Every fall hazard has to be marked in the work area (floor openings, near corners);
• Location of anchorage, capable of supporting a static load of 400 kg;
• inspect your belt before each use: if the belt is damaged or worn do not use it;
• the belt shall wear the manufacturer’s label: waist size,
• material, date of manufacture model number
• fasten the belt properly around your waist
Work positioning system
• The function of a work positioning system is to allow a worker to execute tasks while hanging in the full body
harness on a vertical rope, firmly fixed to a construction.
• The system consists of: full body harness connected to a lanyard; a lanyard attached to a lifeline;
Individual fall arrest system
• The function of the fall arrest system is to stop a worker from falling, and to reduce the impact of a fall.
• The system consists of:
• full body harness connected to a lanyard;
• a lanyard with shock absorber connected to a fall arrestor; the fall arrestor has been attached to a lifeline;
Attention points:
• never use a safety belt in a fall arrest situation: sever back and abdominal injuries could result from a fall
• a body harness protects the user more as the force of impact is distributed over a greater area
• For vehicles two options exist:

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• mobile or fixed stairs to climb on trucks mobile or fixed structure with fall arrest to execute tasks on top of trucks
• The following documents have to be present (e.g. in case of an internal or external audit):
• Inspection and maintenance program for (step) ladders;
• Instruction for safe use of ladders for light work tasks between 2 and 6 meter height;
• Fixed stairs, work platforms for heavy routine work and light work above 6 meters;
• Standard Operating Procedures for routine work at height;
• Hazard identification and risk assessment for non-routine tasks with a risk of fall > 2 meter;
• Application of the Safe Work Permit System for non-routine tasks;
• Training records of personnel authorized to carry out non-routine work out at height;
• Well-maintained PPE, suitable to protect personnel working at height;
• Inspection records of tasks with work at height;
• Signs and obstructions (like doors or chains) to prevent non-authorized personnel to enter places with a risk of
falls > 2 meter;
• The documents have to be kept for 3 years.
IMPLEMENTATION SCHEDULE
The procedure has to be implemented within 6 months after approval. The implementation time is 12 months in case
engineering measures like fixed stairs with handrail, work platforms with protection have to be taken for routine tasks.
Explanations of the matrix of working in heights:
1) Determination of the working appliance, the height off the ground and, if the tasks are easy or difficult.
2. Search for the appropriate field in the matrix.
3) Depending on the colour of the field:
Green colored: no more arrangements necessary
• Colored: annually release certification for working in heights has to be verifiably passed. Above 5 m drop height
an additional safety belt has to be applied.
• Yellow colored: one SAF- pillar member and the floor manager/ Vice execute a risk evaluation at the location,
followed by a risk analysis with the planned countermeasures and the exposition of the release certification.
The certification for working in heights has to be verifiably passed, than, before the start of work, the risk evaluation,
the risk analysis and the release certification including the countermeasures discussed with the operator. Afterwards
the operator has to sign the release certification to
Attention: if a safety harness is needed as safety function, the operator must have an appropriate instruction. Further a
first- aider, specially trained in rescuing casualties (Recovery of human or recovery from heights, 24 hours course) has

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to be on- site during the whole duration of work!
4) Risk evaluation, risk analysis and the signed release certification has to be stored for 3 years.
Forklift Operation & Safety
How to Use This Training Program
To navigate through this training program, use your left mouse button to click on the green left or right arrows.
Clicking on the left arrow will take you back one screen, while clicking on the right arrow will take you forward one
screens
On some screens, you will see a question mark symbol at the far right side of the navigation bar. This question mark
indicates that a "Quick Check" screen will follow the current screen. Quick Check screens ARE NOT scored, but are
designed to help you learn the material being presented so that you will do well on the course test.
Finally, on some screens you will see yellow words that are underlined. These words are very important and each is
defined so that you will learn the language of safety, as well as the concepts and practices related to working safely in
your organization. Take a moment now to explore this page and its links. We hope you enjoy this training course, and
good luck.
Purpose of Training
Did you know that everyone cannot operate a lift truck? Operating a lift truck (often called a forklift) is a specialized
job that requires training and authorization by your organization as a qualified operator. Operating a lift truck is an
important job. So important that the federal government requires that all lift truck operators be trained and
authorized by their organizations.
Only trained and authorized operators shall be permitted to operate a powered industrial truck.
The purpose of this training is to help you become a qualified powered industrial truck (lift truck) operator -- an
operator who has the knowledge and skills to operate a lift truck in a safe and professional manner. So let's get started
Because operating a lift truck is an important job, your training will focus upon two major areas:
Lift Truck Knowledge - During this CBT program, you will learn about:
- types of lift trucks
- lift truck operation
- lift truck safety
- lift truck maintenance
- lift truck refueling and recharging.
Operating Skills - You will also have an opportunity to gain hands-on experience operating a lift truck in a variety of
situations. If you qualify at the end of your training, your employer will award you a lift truck certificate of
achievement.
 Since the beginning of time, man has needed to lift and move heavy objects.
 A lift truck? I, Sedak, dream that one day in the future, people will operate machines that will lift hundreds, no,
thousands of pounds. These machines will allow one person to do in a day what it takes us weeks to do. These

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machines will have wheels, be powered by gas or electricity, and have large forks on them which can slide under
large loads. The person who will operate this machine will be like a superhuman.
 If Sedak were alive today, he would be amazed by the number of different types of lift trucks used today. There
are four basic types of lift trucks:
1. Diesel powered
2. Electric powered
3. Gasoline powered
4. LP-Gas powered
Different types of environments require different types of lift trucks. Check with your supervisor or safety office to
confirm that you are using the correct type of lift truck for your work area.
 There are many types of powered industrial trucks that are used for lifting and transporting loads. The focus of
this course, however, is on sit down rider counterbalanced lift trucks. It should be noted, however, that the safety
precautions presented in this course are applicable to any type of powered industrial truck.
 The modern lift truck is an amazing piece of machinery. Did you know that lift trucks:
* Often weigh more than a car or light truck?
* Are extremely powerful?
* Use rear wheel steering?
* Can turn in a tighter circle than most vehicles?
* Are often less than four feet wide?
 Let's take a few moments to look more closely at the major parts of a lift truck..
Truck Gauges and How They are Read (All Industrial Trucks)
Engine Hour Meter
The Engine Hour Meter records the total number of hours that an engine has been used. Because this information is
used to schedule maintenance, you will need to record this number on your Daily Inspection Report.
 Fuel Gauge
 The Fuel Gauge indicates the fuel level and is similar to those found in cars and trucks. "F" means full, while "E"
means empty. Always check the fuel level of your lift truck during your daily inspection.
Engine Temperature Gauge
The Engine Temperature Gauge indicates the engine temperature and is similar to those found in cars and trucks. "H"
means hot, while "C" means cold. Never operate a lift truck which is overheating. Turn it off and notify your
supervisor or maintenance department.
The Amperes Gauge indicates that the engine's electrical generator is producing electricity. (+) readings mean the
generator is working. (-) readings mean something is wrong, and that battery power is being used to run the engine.
Always return a lift truck for maintenance, if the amperes gauge is showing (-) readings.
Oil Pressure Gauge

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 The Oil Pressure Gauge indicates the oil pressure inside the engine. Oil pressure readings that are low or drop to
"0" indicate that there is a serious problem with the engine. Never operate a lift truck with oil pressure problems.
Turn the engine off, and notify your supervisor or the maintenance department.
Battery Capacity Gauge
 Electric powered trucks have a Battery Capacity Gauge, instead of a fuel gauge.
Steering Wheel
 The Steering Wheel in an industrial truck operates like one in a car or truck.
 Steering Wheel: It turns the wheels on a lift truck.
Most trucks are equipped with a Directional Control, which allows you to select to move the truck forward or
backward.
Pedals
 Electric powered trucks have an accelerator pedal and a brake pedal.
All trucks have an Accelerator pedal and a Brake pedal. Some trucks have a Clutch, which allows shifting into higher
forward gears
Parking Brake
All trucks are equipped with a Parking Brake. You should always set the parking brake whenever you leave a
truck. NOTE: the top of some brake handles may be turned to adjust the tightness of the brake. Be sure to tighten the
parking brake so there is no danger of the truck rolling when it is left unattended.
All trucks are equipped with two basic hydraulic lift controls.
Raise & Lower Control
 The Raise and Lower Control allows you to raise the forks up or lower the forks down. Pull the lever back, and the
forks will go up. Push the lever forward, and the forks will go down.
Tilt Control
 The Tilt Control allows you to tilt the forks up or down. Push the lever forward, and the forks will tilt down. Pull
the lever back, and the forks will tilt up.
Switches (All Industrial Trucks)
 Trucks are equipped with a horn to sound warnings to others who may be in your operating area. Ignition or
Turn On / Off switch. Most industrial trucks require that a key be used to start and turn off the truck.
Because there are many different types of industrial trucks (lift trucks) used today, take time to read the
operator's manual for the specific truck(s) you will be operating. Be sure to learn the location and operating
procedures for all:
* Gauges
* Controls (levers and pedals)
* Switches
Data Plates

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 All industrial trucks have a Data Plate attached to the truck body. Data plates display important information
concerning the truck's:- Type
- Capacity
- Load Center
- Truck Weight
 Read and remember the data for the trucks you operate.
Tire Types
 Solid tires are designed for use inside on smooth, dry surfaces. They should not be used outdoors or on rough
surfaces.
 Pneumatic tires (tires filled with air) are designed for use on improved surfaces, and may be used outdoors, as
well as indoors.
 Tires, like industrial trucks, are designed for specific types of jobs. Always check to make sure you are using
the right type of equipment for each job.
Lifting System
 The lifting system on lift trucks includes chains attached to a hydraulic cylinder.
 When the cylinder is filled with hydraulic fluid, it forces the piston to move upward.
 The upward movement of the piston and the chains lift the forks to the desired level.
 The lifting forks on your lift truck can be moved from side to side to adjust for different types of loads. While
most lift trucks require that this be done by hand, some have special controls for adjusting the forks.
Rear Wheel Steering
Unlike a car or truck, lift trucks use the rear wheels for steering. Rear wheel steering gives you greater control of the
truck when you are using the forks. Note the larger turning arc produced by truck "A" using front wheel steering
versus the arc produced by truck "B" using rear wheel steering.
Stability Triangle
If you were to raise a lift truck up and look at its underside, you would see that the support points for the truck are
located at points A, B, and C. The triangle formed between points A, B, and C is called the Stability Triangle.
The lift truck will not tip over as long as the center of gravity remains inside the triangle. (The center of gravity is the
point within a lift truck where there is equal weight all around it.)
 However, if the center of gravity shifts outside the stability triangle, the lift truck will tip over. The center of
gravity within a lift truck can be moved by:
*Traveling with an elevated load;
*Trying to carry too heavy a load;
*Trying to turn the lift truck while it is moving too fast;
*Operating the lift truck on a hill or incline;

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*Starting or stopping too fast;
Load Capacity
The front wheels of a lift truck serve as the Fulcrum Point between the weight of the truck and the weight of the load
being carried. If the weight of the load is equal to the weight of the truck, with equal distances between the centers of
gravity, it is possible to "seesaw" a lift truck on its front wheels.
If we rearrange the load so that the load's center of gravity is farther away from the fulcrum point, this will cause the
center of gravity for both the truck and the load to shift beyond the front wheels of the truck, and the truck will tip
forward.
If, on the other hand, we arrange the load so that the load's center of gravity is closer to the fulcrum point, this will
cause the center of gravity for both the truck and the load to shift behind the front wheels of the truck. With this
arrangement, there is no danger of the truck tipping forward.
Your most immediate source of information concerning the safe load capacity of a truck can be found on its data
plate. The plate will give you information concerning the load capacity of the truck in pounds and the load center in
inches.
The lifting capacity described on this plate is 3200 pounds with an LC of 24 inches, up to a height of 188 inches from
the floor.
For example, a truck might have a capacity of 4000 pounds at a 24 inch load center (LC). This means that the truck
can lift 4000 pounds, if the center of gravity of the load is 24 inches from the face of the forks.
Inch Pound Equation
There will be times, though, when the load center will be greater than 24". When this happens, you must determine
the maximum capacity for the truck using the new load center. To do this, you must use the "Inch Pound Equation".(A
+ B) x C = Inch Pounds
Where:
A =the distance (in inches) from the center of the front wheels to the face of the forksB =the Rated Load Center (LC)
(in inches)C =the truck's capacity at the Rated Load Center (in pounds)
Example
You operate a lift truck that is rated at 5000 lbs. @ 24" LC. You must lift a load with an LC of 36". The distance
from the center of the front wheels to the face of the forks is 18". What is the maximum weight you can lift? To solve
the problem, you must break the problem into two steps.
Step 1:
You must first determine the maximum Inch Pound capacity of the truck. To do this, you must use the equation (A +
B) x C = Inch Pound, where A = 18", B = 24", and C = 5000 lbs.
( 18" + 24" ) x 5000 lbs. = Inch Pounds
(42") x 5000 lbs. = Inch Pounds
210,000 Inch Pounds

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Lift Truck Operation
Speed
Keep in mind that you are operating a lift truck, not a race car or jet fighter. In case of an accident, you don't have an
ejection seat. Always start and stop smoothly, and KEEP YOUR SPEED DOWN!
Quick Turns
The higher you lift a load, the more unstable it becomes. Always take extra care when making sharp turns with a
raised load.
The 8 Inch Rule
When transporting loads, you should never raise your load more than 8 inches from the ground. Keep your load tilted
back.
If a load blocks your view,
Travel in reverse.
Right Angle Stacking
There are times when you need to move your truck with a raised load, such as when you are right angle
stacking. SLOW DOWN. Keep in mind that the higher you raise your load, the less stable it is.
Overhead Clearance
As you lift and transport loads, it is important to watch for overhead obstructions such as beams and cables.
Chain Slack
Chain slack means there is a problem in the lift mechanism. You should always stay alert to any problems with the
lift mechanism of your lift truck. When problems do occur, DO NOT ATTEMPT to repair the chains or hydraulic
system. Call maintenance at once.
Center Your Loads
Take time to adjust the forks on your lift to fit the load you will be carrying. Adjusting the forks outward for wide
loads, helps you to center the load, and make it more stable.
Loose Loads
Never try to lift or carry loose or poorly stacked loads. Correctly stack and bind loads to prevent an accident that
could damage the load, your truck, pedestrians or YOURSELF.
Wide and Long Loads
Wide and long loads are more unstable than other loads. Wide loads require that you keep them low and watch the
balance of the load. When lifting and carrying long loads, keep in mind the load center and lift capacity of your truck.
With both wide and long loads, you will need more room to maneuver. So, slow down and watch your clearance.
Driving on Ramps and Inclines

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If you are driving an empty truck, travel in reverse up an incline, and forward down an incline. Note that the center of
gravity for the truck is above the front drive wheels.
If, on the other hand, you are driving a loaded truck, travel forward up an incline, and backward down an incline. Note
that the center of gravity for the load is above the front drive wheels.
NEVER turn while driving up or down a ramp or incline. NEVER drive across a ramp or incline. Because lift trucks are
built "narrow," the center of gravity can quickly shift outside the stability triangle, causing the truck to tip over.
Driving on Various Surfaces
Ice, mud, gravel, sand, and soft dirt all present potential problems for you and your lift truck. Avoid these unsafe
surfaces, if at all possible. They can damage your lift truck or cause an accident. Try to avoid rough spots and pot
holes. If you cannot avoid a rough spot, slow down and cross it carefully, at an angle, one wheel at a time.
Keep in mind that you are operating a piece of HEAVY equipment. Check with your supervisor to make sure that you
are operating your lift truck in areas that will support both the truck and the load.
Elevators
Always know the maximum weight capacity of elevators and lifts before you use them. Don't forget to calculate the
total weight of your truck and your load before entering an elevator.
Loading Docks
Loading docks can be dangerous places. Always be aware of the edge of the dock. A fall from a loading dock in a lift
truck can be fatal. Slow down, watch out for others, and live.
Whenever you load or unload a trailer:
1. Inspect the floor of the trailer to ensure that it will support the lift truck and the load.
2. Make sure that the wheels of the trailer are chocked to prevent the trailer from moving.
3. Make sure that dock plates, boards, and ramps are in place and secure.
Parking
 You are responsible for your truck, even when you leave or park it.
 Always park your truck in a safe area that is away from traffic.
 Never leave or park your lift truck on an incline
 Always lower the forks until they are flat on the floor.
 Set the directional control, so that it is in neutral
 Turn off the engine and remove the key.
 Set the parking brake
If you must park on uneven ground, be sure to block the wheels to prevent the lift truck from moving.

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LADDER SAFETY
Ladders (portable or fixed) are extensively used to carry out works at height. Misuse of
ladders is a cause for many accidents.
Here are some tips for safe use of ladders:
1. Use the right ladder for the job
2 - Examine the ladder for defects and damages.
3 - Keep the ladder away from electrical circuit.
4 - Place the ladder with the feet one quarter of its working height away from the
structure.
-
5- Check your footwearbefore climbing a ladder
6 - Only one person should climb the ladder at a time.
7- Face the ladder when climbing up or down.
8 - Do not carry tools or materials in your hands as you climb a ladder.
9 - Don't stand on higher than third rung from the top of the ladder.

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HANDLING CHEMICALS
The more you learn aboutthe chemicals you work with, the better your chances
of preventing an accident & protecting yourself.
Follow these guidelines for chemical handing:
1. Do not handle chemicals unless you are trained and authorized to do so.
2. Read the labels on chemical containers for the information.
3. Read Material Safety Data Sheet for information regarding the chemicals &
its hazards.
4. Follow manufacturer's instructions and your workplace training for
chemicals.
5. Wear the right personal protective equipment depending on the chemical
involved.
6. Learn the procedure for removing & disposing of contaminated clothing.
7. Close chemical containers when not in use.
8. Make sure the containers are labeled.
9. Store chemicals according to manufacturer's instructions.
10. Know what to do in case of an emergency.
11. Wash before eating, drinking etc.
12. Keep beverages, food etc. out of work area.

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COMPRESSED AIR SAFETY
Compressed air can blow particles into eyes rupture ear drum and cause
serious injuries. To use compressed air safety, keep these guidelines in mind:
1 - Make sure air tools & hoses are in good condition.
2 - Read & follow manufacturer’s instructions before using the tools.
3 - Never exceed the recommended pressure.
4 - Wear appropriate eye face ear protection.
5 - Warning signs should be posted in the area.
6 - Do not permit air hoses in traffic areas.This also presents tripping hazard.
7 - Do not use compressed air for cleaning debris in the area.
8 - Do not use compressed air for cleaning clothes. This may blow particles
into eyes and ingest compressed air into bloodstream.
9 - Never direct compressed air to yourself or any person.
10 - Never engage into or permit horseplay involving compressed air.
11 - Do not use ordinary compressed air for respiratory purposes.

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ELECTRICAL SAFETY
Following are some reminders about electrical safety:
1 - Keep electricity & moisture away from each other.
2 - Report any indication of electrical malfunction.
3 - Never attempt electrical repair unless you are qualified and authorized
4 - Do not alter plugs by removing third pin of the plug to connect into two pin
plug. This defeats the safety of a ground wire.
5 - Extension cords should be used only temporarily.
6 - Use GFCI ELCB while using electrical tools, amid moisture or outdoors.
7 - Wear correct personal protective equipment.
8 - Stay away from high voltage installation.
9 - In case of an electrical shock, do not touch the affected person unless
power has been disconnected.
10. Never put water on electrical fire. Use correct fire extinguisher.

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PROTECT YOUR HEARING
If you are getting used to being in a noisy workplace,chancesyou are suffering
a hearingloss.Hearing loss is generally gradual,painless and invisible but it is
permanent.
1. Use ear protectiondepending on the kind of job and kind of noise exposed
to:
2. Ear plugs are inserted into ears and can be made of disposable foam,
reusable plastic or mounted on headpiece or cord.
3. Formable foam plugs expand in the ear to provide custom fit.
4. Keep them clean and throw them if they harden or do not expand.
5. Pre molded plugs fit the ear and come in differentsizes.They lastfor several
months but should be kept clean and replaced if damaged.
6. Ear muffs are filled with liquid or foam and have hard cups with soft cushion
sealing. These provide the soundest protection.

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FIRE SAFETY
Fire prevention is everyone's responsibility at work. Promptly report any fire
hazards so that they can be eliminated.
Follow these guidelines of fire prevention:
1. Maintain electrical equipment properly to avoid short circuit & overloading.
2. Do not overload circuits.
3. Store materials safely. Flammable materials should be stored safely.
4. Dispose of oil rags properly in covered containers.
5. Keep prophetic waste in specific containers and in wet condition.
6. Know the fire extinguisher and how to use it.
7. Fire extinguisher must be maintained and recharged as per schedule.
8. Do not obstruct fire extinguishers.

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FIRE SAFETY
Class “A” Fire -Wood, paper, textiles, and other ordinary combustibles of Fires
Class “B” Fire - Flammable liquids, oils, solvents, paint, grease, etc.
Class “C” Fire - Electrical: Live or energized electric wires or equipment
Class “D” Fire - Flammable metals K
Class “K” Fire - Combustible cooking media / appliances using oils and fats
cooking
Recommended Type of Extinguisher
Class “A” or “ABC” Extinguisher
Uses water, water-based chemical, foam, or multi-purpose dry chemical. A strictly Class A
extinguisher contains only water.
Class “ABC” or “BC” Extinguisher
Uses foam, dry chemical, or carbon dioxide to put out the fire by smothering it or cutting off
the oxygen.
Class “ABC” or “BC” Extinguisher
Uses foam, dry chemical, or carbon dioxide to put out fire by smothering it or cutting off the
oxygen.
Class “D” Extinguisher
Uses dry chemical to put out fire by smothering it or cutting off the oxygen.
Class “K” Extinguisher
Uses wet chemical or dry chemical type to put out fire by smothering it or cutting off the
oxygen.
FIRE EXTINGUISHER USE – P.A.S.S.

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The acronym “P.A.S.S.” describes the four-steps used in operating a fire
extinguisher.
Pull: Pull the safety pin on the extinguisher.
Aim: Aim the hose of the extinguisher at the base of the fire.
Squeeze: Squeeze the handle to discharge the material.
Sweep: Sweep the hose across the base of the fire from side to side.

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SLIPS, TRIPS & FALLS
Falls are a leading causeof injury in all level of workplaces. These are caused
by slipping on a surface,tripping on an obstacle,while stepping off an elevated
surface etc. follow these tips to prevent falls:
1. Keep workplace free of obstacles & clutter.
2. Keep walking surface clean and dry.
3. Block barricade the areas while cleaning floors.
4. Wipe up the spills immediately or barricade temporarily.
5. Report hazards on surfaces immediately.
6. Avoid running cables or cords on the walkways.
7. Use ladders safely.
8. Ensure scaffolds are erected correctly & certified.
9. Wear proper footwear.
10. Maintain adequate illumination.
11. Do not jump from elevated surfaces.
12. Floor openings shall be covered & barricaded.
13. Never engage in horseplay.

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WELDING
Welding is the method used to join metals together by heating.
Generalsafety precautions thatshould be observed:
1 - Only qualified and certified welders should carryoutwelding.
2 - Welder and helpersmustprotective equipmentsuch as leather
Aprons,safety boots,safety hats, welding shields,eye protectionand gloves
.
3 - Protectadjoining areaby proper tarpaulin cageetc.
4 - Never weld or cut when the atmosphere is dusty,when exposed to
Stroninds.
5 - When you are welding in a high - risk fire area,a fire watch should be
assigned to stand by with appropriate firefightingequipment.
6 - Arc - welding machinecables and cable connectionsmustbe clean
undamaged and of adequate capacity for the welding currentbeing used.
7 - Properear thing, groundingshould beprovided.
8 - Provide forced ventilation during weldingin confined space.

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LIFTING APPLIANCES - SLINGS
Following safetyguidelines should be followed before using lifting appliances with slings:
1. Us only properly tested and marked lifting tackle of adequate strength. Do not use
faulty or damaged lifting gear - report defects to your supervisor.
2. Never exceed the safe working load of the tackle. If in doubt about the weight of the
load, ask your supervisor. Refer always to the standard sling charts to find out the
suitability of the sling for the particular job.
3. Never drop lifting tackle or drag it from under a load - it weakens it.
4. Never tie knot in a chain to make it shorter.
5. See that there are no kinks or twists in chains or slings.
6. Use a proper safety hook - not a makeshift one.
7. Check that any support used to suspend the lifting tackle is strong enough for the job.
8. Use wood or other packing to protect the sling from any sharp edges on the load.
9. Position the lifting hook over the load so as to prevent the load swinging when it
is raised.
10.See that the load is free before the lift is taken.
11.Take your hands away from the sling before the lift begins and stand clear.
12.Keep clear of loads in motion and never stand under one.
13. Return lifting tackle to the store after use. Chains and slings must always be stored
off the floor and Check all the safety latches.

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ENTRY INTO CONFINED SPACE
Confined space entry is not something to be taken lightly and not something to do on an
impulse, even if the impulse is to save a life.
Before entering any confined space, observe the following:
1 - Have an entry authorization authorizing you to proceed.
2 - Obey the instructions containedon the authorization, e.g. wearing PPE etc.
3 - Gas testshall be done before entry and periodically as per requirement.
4 - Ensure positive isolation(blind with tag) as per the blind list.
5 - Ensure availability of an attendant all the time.
6 - Isolate electricalequipment with provision of multi lock.
7 - Neverattempt to rescue anyone unless you are trained for rescue.
8 - Use appropriate personalprotective equipment.
9 - A person detailed for rescue service is available, equipped with breathing apparatus
set
along with a rescue plan ( for critical entries ) .
10 - Provision of ventilation and communication facilities at site.
11 - Wearappropriate respiratory protection.
12 - Display all warning signs and associated permits & authorizations at the entrance.

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AVOID HAND INJURIES
Your hands are two of your most important assets.
By recognizing hazards, following established safety guidelines, and using protective
guards, shields, gloves and other personal protective devices.
Here are some safety guidelines that can help you protect your hands:
1. Inspect tools, equipment and machinery before use to make sure that they are in good
operating condition.
2. Use the appropriate personal protective equipment - gloves, guards, forearm cuffs
and barrier creams (for example, when working with chemicals).
3. Always wear gloves to protect your hands from heat, acid, caustic, oil, sharp edges
and general wear & tear. Remember not to wear gloves near moving machinery as
these can trap the hand.
4. Disconnect power and follow established lockout procedures before repairing or
cleaning machinery, and use brushes to wipe away any debris.
5. Never wear jeweler, such as rings, bracelets and watches, or loose clothing when
working with moving machine parts.
6 - Selecttools designed to keep wrists straight to help avoid repetitive motion / overuse
problems.

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POWER TOOLS
Power tools get the job done fast but these can also cause injuries such as eye injury,
electrical shock, cuttings fingers etc. while using power tools, here are some reminders
about power tool safety:
1 - Read & understand the manufacturer's instructions.
2 - Before using a portable electric tool, make sure the tool is in good order check for
cords, cables insulation etc.
3 - The tool must be grounded or double insulation.
4 - Electric cables must be kept away from water, oil, heat and sharp edges.
5 - Ensure you have the correct length of electric cables or compressed air hose serving
the apparatus if it is too short get a proper extension.
6 - Place the power switch in ' OFF ' position before plugging in the tool.
7 - Do not lift or drag power tools by their cables.
8 - Disconnect the tool before making any adjustment such as blades, bits etc.
9 - Check for tightness, all joints in air hoses to compressed air tools.
10 - Always wear appropriate personal protective equipment when using the
power tools. Avoid loose gloves or loose clothing.
11 - Pay attention to why you are doing and don't take your eyes off the job.
12 - Store tools, cables and hoses in a safe and tidy fashion.

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HAND TOOLS
Whether you have a tool cabinetfilled with expensivetools or a kitchen junk
drawercontaining a hammerand a screwdriver,you have to use hand tools
safely.When using hand tools, the following generalprinciplesshould be
followed:
1 - Use the correcttool for the job.
2 - Do not use damaged or worn out tools.
3 - Never use a file without a handle - file tangs are dangerous.
4 - Use spanners thatfit the nut or bolt head properly.
5 - Keep your hands behind the cutting edge when using cutting tools
6 - If you use knives or scissors in your work,keep them in a safe place.
7 - Use reduced- sparking tools as instructed when there is a risk from
flammable or explosive material.
8 - Keep your tools clean and in good condition.Protectthe edges of sharp
tools, both when carried and in store.
9 - Wear appropriate personalprotectiveequipment.
10 - When working on heights,place tools in a box or on a sack to prevent
them falling on to the floor below.
11 - Keep tools in boxes or racks when notin use.
12 - Tie the tools with rope to preventfalling or hitting others.

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HOUSEKEEPING
Housekeeping at workplaceis partof your job. Keeping your workplaceclean &
tidy helps avoid accidents, incidents, falls, cuts, fires & chemical exposures.
Follow these tips for safe workplace housekeeping:
1 - Keep all material & equipment in proper storage place when not.
2 - Keep aisles & walkways clear.
3 - Keep emergency equipment in good condition & free of obstacles
4 - Clean up spills immediately.Know whatto do to take care of chemical spills
and Keep properly in labeled containers.
5 - Keep trash & scrap cleaned regularly.
6 - Confine you’re eating & drinking to the food shelters only.
7 - Store prophetic waste in designated prophetic drums only in wet condition.
8 - Maintain electricalequipment,cords untangled& away from heat, moisture.

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EYE PROTECTION
1 - Eyes are one of the most vulnerable parts of the body.
 They are susceptible to all kinds of injuries if not properly protected.
2 - Protectyour eyes from:
 Splash or spray of chemicals
 Dust or flying particles
 Sharp objects or splinters
 Extreme heat,fumes or mists
 Exposureto UV light, infrared raysetc.
3 - Wear right kind of protectiveeye wear such as safety glasses, goggles,face
shields,hoods,welding helmets etc.
4 - Replace scratchedor broken lenses immediately.
5 - Learn to use eyewashand use them immediately when you get something in
your eyes.
6 - Use other safety measures to preventeye injuries such as:
 Protectivescreensfor flying particles
 Use enclosuresfor processes with dust, mist, vapor
 Exhaustsystem for dust& fumes
 Vacuuming for reducing dust
 Dampening of area to reduce dust