1. Chapter 3 PHYSICAL INJURY AND CONTROLS 3.2 Mechanical Safety
BWU Occupational Safety & Health
Presented by
Dr. Mohd Nasrull Abdol Rahman

2. Learning Outcomes:
At the end of this section, students will be able to:
Summarize the legislative requirements related to mechanical handling.
Explain the definition of mechanical handling
Explain five types of mechanical handling.
Compare the advantages and disadvantages of mechanical handling.
Summarize four important components of mechanical equipment.
Continue….

3. Learning Outcomes:
At the end of this section, students will be able to:
Classify mechanical hazards related to lift, conveyor, forklift, crane and escalator.
Plan safety action plan for mechanical handling.
Plan the hazards preventive and control steps for mechanical handling.
Explain five types and causes of mechanical handling weaknesses.

4. Legal Requirements
Occupational Safety and Health Act 1994
General Duties of Employers and self employed person:
Section 15 (2) (b)
To ensure as far as is practicable the safety and no risk to the health related to the usage or handling, storage and transportation of plant and substance
General Duties of a person who designs, manufactures, imports, or supply: Section 20
To ensure that there is adequate research and test on the substance / plant for the purpose of customers / users safety.
General Duties of an employee: Section 24(d)
To comply with any instruction on safety and health given or issued by the employer or any other person having the authority to give such instruction.

5. Legislative Requirements
Factory and Machinery Act 1967
Regulations on factory and machinery (Electrical lift for passengers and goods):
Conditions:
Design approval
Inspection, load test, and operation test.
Registration and issuance of Certificate of Fitness (if pass the test)

6. Definition: Usage of any powered equipment (hydraulic, pneumatic, electric or mechanical) for the purpose of:
Moving
Lifting
Relocate
Remove
load / goods inclusive of human
Type of equipments are:
Lift ,dumbwaiter
Escalator, travellator, walkalator
Crane and hoist
Conveyor
Forklift

7. Mechanical Handling Equipment
Why mechanical handling is required?
Heavy load
Large size / very large load
Variations in loads shape
To speed up the work process
Advantages of mechanical handling?
Ease the task / job
Speed up the work
Reduce ergonomic risk to the employee
The equipment can reach the ‘difficult to reach’ area
Increase the productivity
Save storage space because material can be arranged in vertical direction.

8. Disadvantages of mechanical handling
Requires competent operator (crane, forklift)
Some mechanical handling equipment requires Certificate of Fitness
Equipments need maintenance
Increase of initial cost
Equipment can increase the risk related to safety and health
Major components of mechanical equipments
Wire rope
Chain
Lifting motor
Counterweight
Lifting Tackle (which consists of):
Sling, hook, grip, Eyebolts, spreader bar and Shackle

9. Hoisting machinery that requires certificate of fitness (from DOSH)
2004/2
Hoisting machinery that requires certificate of fitness (from DOSH)
Lif
Penumpang
Barang
Dumbwaiter
Hoist Penumpang (Passenger Hoist)
Hoist Bahan (Material Hoist)
Hoist Langkau (Skip Hoist)
Hoist Barang (Goods hoist)
Gondola
Eskalator
Walkalator
Travellator
Hoist Rantai Elektrik (Electric chain Hoist)
Hoist Numatik (Pneumatic Hoist)
Truck mounted
crane
Kren Bergerak Beroda (Mobile Crane)
Kren Bergerak Berantai (Crawler Crane)
Kren Menara (Tower Crane)

10. 2004/2

11. Sijil Perakuan Kelayakan (Certificate of Fitness)

13. Jenis Lif (Types of Lifts)
2004/2
Jenis Lif (Types of Lifts)
Lif Penumpang
Lif Barang
Passenger Lifts
Goods Lifts

14. Hazards of mechanical handling equipments
2004/2
Hazards of mechanical handling equipments
MACHINE
HAZARDS
Lift
(For maintenance employee)
Caught between lift and shaft wall
In contact with rotating parts
Fall from lift roof
Ergonomic related problems
Electric shock

15. 2004/2
Forklift

16. Hazards of mechanical handling equipments
2004/2
Hazards of mechanical handling equipments
MACHINE
HAZARDS
Fork lift
Getting hit by equipment
Hit by fallen load from the equipment
Caught between equipment and object

17. 2004/2
Dumbwaiter

18. Hoist Penumpang (Passenger Hoist)
2004/2
Hoist Penumpang (Passenger Hoist)

19. Hoist Bahan (Material Hoist) Hoist Barang (Goods hoist)
2004/2
Hoist Bahan (Material Hoist) Hoist Barang (Goods hoist)

20. Hoist Langkau (Skip Hoist)
2004/2
Hoist Langkau (Skip Hoist)

21. 2004/2
Gondola

22. ESKALATOR (Escalator)
2004/2
ESKALATOR (Escalator)

23. Hazards of mechanical handling equipments
2004/2
Hazards of mechanical handling equipments
MACHINE
HAZARDS
Escalator
For passengers
Caught between moving parts
Fall
For maintenance employees
Caught between rollers or chain
Ergonomic related problems
Electric shock

24. Walkalator / Travellator
2004/2
Walkalator / Travellator

25. Electric chain / Pneumatic Hoist
2004/2
Electric chain / Pneumatic Hoist

26. Kren Bergerak Beroda (Mobile Crane)
2004/2
Kren Bergerak Beroda (Mobile Crane)

27. Kren Bergerak Berantai (Crawler Crane)

28. Kren Menara (Tower Crane)
2004/2
Kren Menara (Tower Crane)

29. Hoisting machinery that requires certificate of fitness (from DOSH)
2004/2
Hoisting machinery that requires certificate of fitness (from DOSH)
Overhead traveling crane
Kren Gantri
(Gantry Crane)
Kren Portal
(Portal Crane)
Kren Kontena (Container Crane)
Sky lifter
Cherry picker
Two & Four post lift
Table Lifter
Letak kereta
mekanikal

30. Overhead traveling crane
2004/2
Overhead traveling crane

31. Kren Gantri (Gantry Crane)
2004/2
Kren Gantri (Gantry Crane)

32. Kren Portal (Portal Crane)
2004/2
Kren Portal (Portal Crane)

33. Kren Kontena (Container Crane)
2004/2
Kren Kontena (Container Crane)

34. Sky lifter / Cherry picker
2004/2
Sky lifter / Cherry picker

35. Hazards of mechanical handling equipments
2004/2
Hazards of mechanical handling equipments
MACHINE
HAZARDS
Kren
Bergerak Berantai
(Crawler Crane)
Bergerak Beroda
(Mobile Crane)
Menara (Tower Crane)
Overhead travelling
crane
Hit by equipment
Caught between load and equipment
Hit by fallen load from the equipment

36. 2004/2
Post lift

37. 2004/2
Table Lifter

38. Letak kereta mekanikal (Mechanical Car park)
2004/2
Letak kereta mekanikal (Mechanical Car park)

39. Source of Hazards: Types of frequently occurred defects
Wire rope size decreases
The length of wire rope or chain increases
Eroded chain surface
Eroded lifting equipment
Loose hooks
Malfunction of braking system
Broken wire rope
Bending girder structure
Bending boom
Malfunction of limit switch system
Safety latch for hook is not in place

40. Causes of defects
No maintenance
Over loaded
Error in design of equipment and structure
Environmental factors
Tools used do not comply to the standards
No periodical inspection

41. Types of accident
Caught between objects
Fallen objects from elevated area
Lifting machine tipped off
Boom / crane structure broken / fall down
Hit by object
Fallen of load from lifting machine
Electric shock

42. Caught between objects
Example: While executing the task of lifting a load or maintaining the wire rope mechanism / chained equipment
Causing factors:
Limited working space
No fencing
Fallen objects from elevated area
Poor housekeeping at working area
No toe-board at the working platform
Safety net is not installed
Unsafe lifting method
Improper position of hook and sling during lifting
Mechanical failure

43. Lifting machine tipped off
Causing factors:
Error in estimating the weight of load
Soft soil at the lifting site
Wrong lifting technique
Ground condition is not suitable (cliff, not a flat land)
Boom / crane structure broken / fall down
The load is over weight
Damaged boom is used
Design mistake
The installation does not follow standard procedure

44. Hit by object
Causing factors:
Working environment condition
Limited working space
Insufficient lighting
Slippery floor
Vehicle mechanical failure (brake system)
Operators mistake
The load size is not suitable (big, heavy)

45. Safety Plan
Step 1
Identify hazards related to work
Assess the risk of each identified
Arrange preventive and control actions
Monitor the executed actions

46. Factors to be considered before and after lifting process
Types of load (solid, liquid or gas)
Weight of the load to be lifted
Size of the load to be lifted
Shape of the load
Type of lifting machine
Condition of the working area for the lifting process
Type of lifting tackle to be used
Operator handling the work
Type of activity to be executed (lifting, removing)
Load stability
Lifting machine capacity
Lifting technique and procedure
Environment conditions
Pathway for the lifting activity

47. Methods for hazards preventive and control
Conducting periodical inspection to machinery and its component
Establish periodical maintenance plan for lifting machines
Establish safe work procedure for handling activities
Select appropriate and competent employees
Provide training to selected employees
Choose and use safe and suitable handling machines
Supervise the execution of job
Fence the working area
Put warning signboard (to warn other employees about the hazard at the designated area)
Install safety device at the machines
Use effective communication system

48. Conclusions
Mechanical handling functions to allow working task be done easier and faster.
There are specific legislative provisions related to mechanical handling.
Mechanical handling hazard can be prevented by establishing safety planning before and at the time of executing the handling activities.

49. Class Activities
Summarize the legislative requirements related to mechanical handling.
Explain the definition of mechanical handling
Explain five types of mechanical handling.
Compare the advantages and disadvantages of mechanical handling.
Summarize four important components of mechanical equipment.
Classify mechanical hazards related to lift, conveyor, forklift, crane and escalator.
Plan safety action plan for mechanical handling.
Plan the hazards preventive and control steps for mechanical handling.
Explain five types and causes of mechanical handling weaknesses.

50. Group Discussion (Bincangkan dalam kumpulan masing-masing)
1. Kenalpasti 3 jenis KEMALANGAN yang berlaku dalam pengendalian mekanikal (cth; 1. Forklift = Dihempap bebanan ketika memandu, 2. Lift = kabel lift terputus ketika beroperasi)
2. Huraikan Faktor-Faktor Penyebab berlakunya KEMALANGAN tersebut (lebihan beban, tiada housekeeping di tempat kerja etc)
3. Langkah Keselamatan / Pencegahan yang perlu diambil untuk mengelakkan KEMALANGAN tersebut berlaku