6.3 Load Handling Equipment

Hazards and controls for common load handling aids and equipment

Using mechanical equipment to handle, move and store materials can improve efficiency, but it can also raise the potential for injury. To protect themselves, employees need to know the safe operating procedures for the equipment. Problems to watch for include:

• overloading the equipment by exceeding its rated load capacity
• using the wrong equipment for the size and shape of the material being moved
• operating the equipment in areas it was not designed for
• failing to take precautions when stacking materials
• manual handling risks from pushing or pulling the truck
• moving up, down or across slopes, causing loss of control

General precautions for the safe use of manually operated equipment include:

• avoiding uneven ground and slopes
• using ramps rather than steps
• observing the safe working load of the truck
• securing the load if necessary
• using the brakes, if fitted
• taking care when moving or lowering the load
• parking and storing safely so that nothing is obstructed
• routine inspection and maintenance
• wearing safety shoes or boots to avoid crush injuries

The common load handling equipment covered here is: sack trucks and trolleys, pallet trucks, people handling aids, forklift trucks, hoists for loads and people, conveyors and cranes.

Sack trucks and trolleys

The most common dangers with sack trucks, trolleys and hand carts are:

• Caught-in hazards. Fingers and hands are caught between the hand truck and a fixed object such as a wall, corner, barricade or rack.
• Crushed-by hazards. Toes and feet are crushed by the wheels of the cart, or by materials dropped from or falling off the hand truck.
• Slips, trips and falls. A hand truck that is badly loaded, used at a steep angle or used on uneven ground can cause slips and falls, and one that is stored unsafely is a trip hazard for people in the work area.
• Overexertion. Strain injuries to the back, shoulders and arms are common when loading, unloading or moving a heavily loaded hand truck.

Common rules for the safe use of sack trucks, trolleys and hand carts:

• Check for uneven surfaces. If the load is to move on a slope, up or down, or on a platform or an area with steps, keep the wheels away from edges and make sure you are not straining as you push. Going downhill, stay in full control with two hands instead of letting the truck pull you.
• Check for other people. Watch for others in the work area. Go slowly, because they may not see you, and leave enough room to get round people and objects without bumping any part of the truck.
• Check the load capacity. Make sure the load does not exceed the weight limit marked on the truck. It may need to be split into two trips. Trying to move a load that is too heavy risks breaking the truck and injuring the operator or anyone nearby.
• Load it properly. Put the heaviest items at the bottom and lighter ones on top. This protects the lighter items from being crushed, and it puts most of the load close to the wheels, which are the pivot point of the truck, so less force is needed to lift it.
• Keep your view clear. Make sure you can see over and around the load so you can spot obstacles in your path.
• Stand with your back straight. Pull gently on the handles to bring the top of the truck towards you. The truck tilts about the wheel axle and the load rests against the back plate.
• Move the truck gently. Push it forwards gently. It should move easily. Keep your feet well clear of the load and walk at normal walking pace. If you struggle to move it, check the weight limit again and check that the wheels are fully inflated.

Summary notes for Element 6 · Cheat sheet · Glossary. A study aid, not published or endorsed by NEBOSH.