01
Hazard
Dropped load
Potential Consequence
Crushing or serious injury
Persons at Risk
Handling crew
Existing Controls
Suitable lifting equipment and capacity verification
Additional Controls
Keep personnel clear of load path
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Ready Risk AssessmentMaterial Handling9 Hazards
Mechanical Material Handling Risk Assessment
Review the critical hazards, potential consequences, persons at risk and recommended control measures for Mechanical Material Handling in one professional HSE workspace.
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Mechanical Material Handling Hazards & Controls
Review the key hazards, consequences and control measures for Mechanical Material Handling in a structured professional HSE format.
02
Hazard
Pinch point
Potential Consequence
Hand or finger injury
Persons at Risk
Handling workers
Existing Controls
Controlled positioning
Additional Controls
Use hands-free or suitable handling aids where possible
03
Hazard
Equipment overload
Potential Consequence
Equipment failure
Persons at Risk
Handling crew
Existing Controls
WLL and load-weight verification
Additional Controls
Do not lift loads with unknown weight by estimation
04
Hazard
Uncontrolled load movement
Potential Consequence
Crushing or pinch injury
Persons at Risk
Material-handling crew
Existing Controls
Controlled lifting and handling
Additional Controls
Keep personnel outside load movement and pinch zones
05
Hazard
Incorrect handling equipment selection
Potential Consequence
Equipment failure or dropped load
Persons at Risk
Handling personnel
Existing Controls
Capacity and equipment-suitability check
Additional Controls
Verify SWL/WLL against load weight
06
Hazard
Obstruction in handling route
Potential Consequence
Trip, impact or loss of load control
Persons at Risk
Handling crew
Existing Controls
Planned handling route
Additional Controls
Clear the route before handling starts
07
Hazard
Load slipping from handling equipment
Potential Consequence
Dropped load or personnel being struck
Persons at Risk
Workers performing the activity and nearby personnel
Existing Controls
Authorized personnel, pre-work checks, suitable equipment and site procedures
Additional Controls
Secure the load using a suitable attachment or restraint system
08
Hazard
Mechanical handling equipment overloaded
Potential Consequence
Equipment failure or dropped load
Persons at Risk
Workers performing the activity and nearby personnel
Existing Controls
Authorized personnel, pre-work checks, suitable equipment and site procedures
Additional Controls
Verify load weight and equipment SWL/WLL before handling
09
Hazard
Personnel entering the load movement area
Potential Consequence
Entrapment, crushing or struck-by injury
Persons at Risk
Workers performing the activity and nearby personnel
Existing Controls
Authorized personnel, pre-work checks, suitable equipment and site procedures
Additional Controls
Barricade the load travel path and keep personnel outside the line of fire
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