Case study 1 – rubber manufacturing industry, eliminating manual pushing and pulling

The task

A firm had pallets weighing about 1250k (about the average weight of 17 men), which were delivered by fork lift truck (FLT) to a split floor level-loading bay. Employees were required to push these, using a hand pallet truck, a distance of up to 10 metres along uneven metal flooring, approximately five times a day each.

Assessing the risk

Workers carrying out the task showed they were exerting considerable force to move the pallets. A dynamometer or spring balance was used to measure the force to check that it was within the guideline figures in the guidance booklet L23 “Manual Handling”. The forces measured were 742 Newtons peak (74kg of force – weight of an average male) and 510 Newtons (51kg of force) average for moving for only one metre. This required force could be an effect of not just the weight of the load but the interaction between the uneven metal flooring and the small hard wheels on the hand pallet truck.

The figures above are much higher than the guideline figure in Manual Handling Operations Regulations of 20kg (200 Newtons) and therefore the task posed a serious risk of injury to the worker. In fact the forces were so great it suggested that a large proportion of the workers would not be able to carry out this task. A further full risk assessment had to be made.

The solution

FLTs that initially brought the pallets to the loading bay were used on the next floor via a ramp. This eliminated the risk to the employees moving the heavy pallets.

Other solutions were also suggested to eliminate or reduce the risk, these were:

• A small battery powered hand pallet truck could be introduced to replace the un-powered hand pallet truck. This would remove the need to apply large forces to move the pallets. Employees should be trained on proper and safe use of the new trucks and systems for reporting for faults and incidents put into place.
• Change the uneven metal flooring to a suitable type taking into consideration that slip resistance should still be maintained. In this case, given the huge forces involved, this suggestion alone may not reduce the force required to move the pallet by the worker to an acceptable level.
• Load the pallet lighter to an acceptable weight. This would reduce the required force to move the pallet with the un-powered hand truck.