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Manual handling electricians

Manual handling injuries result in more lost time for electricians than any other type of injury. This document provides practical examples of how all stakeholders in the building and construction industry can assist in reducing the risk of manual handling injury to electricians.

Contents

1. Introduction
2. Legal obligations
3. Designers and manufacturers
4. Principal contractor
5. Electricians

1. Introduction

Electricians are at a higher risk than most workers of sustaining a manual handling injury. Manual handling injuries are the largest single cause of injury resulting in electricians having to take time off work. As well as costing millions of dollars per annum these injuries result in pain and suffering to the injured worker and their families and a loss of experience, skills and productivity to the industry.

Manual handling injuries are caused by more than just lifting. Manual handling involves any activity requiring the use of force exerted by a person to lift, lower, push, pull, carry or otherwise move, hold or restrain a person, animal or thing. Common manual handling activities that result in injuries among electricians include pulling cables, completing work in cramped postures, working overhead and lifting, carrying, manoeuvring and placing awkward loads.

Manual handling problems need to be addressed systematically through the three-step process of:

• Hazard identification (hazard means anything that may result in injury or harm to health);
• Risk assessment (this involves looking at the possibility of injury or harm occurring to a person if exposed to a hazard. A number of manual handling risk factors, for example the weight and size of an object, the work environment and the workers' posture, need to be considered in this step); and
• Risk control (this involves introducing measures to eliminate or reduce the risk of a person being injured or harmed. The order in which controls should be considered is elimination, substitution, isolation, engineering control, administration control, and personal protective equipment; note - more than one control can be used at one time to reduce the exposure to a manual handling hazard).

To get the best result everyone should be involved in the process. The Manual handling code of practice contains more detail on the manual handling risk management process and training requirements.

2. Legal obligations

The Occupational Safety and Health Act contains general duties, which describe the responsibilities of people who affect safety and health at work. Employers, employees, self employed persons, persons who have control of workplaces, designers, manufacturers, importers and suppliers of plant and hazardous substances and designers and constructors of buildings or structures, all have duties of care they must fulfil to comply with the legal requirements of the Act.

Regulation 3.4 of the Occupational Safety and Health Regulations specifically details the requirement to manage manual handling hazards in the workplace. The regulation outlines the three-step risk management process of hazard identification, risk assessment and risk control.

3. Designers and manufacturers

Designers

Risks from manual handling can be avoided or minimised during the design stage. The duty of care of designers outlined in the Occupational Safety and Health Act places a legal obligation on designers to ensure the design of the building or structure does not expose persons properly constructing, maintaining, repairing or servicing the building or structure to hazards. Designers therefore must consider the manual handling risks to electricians that may arise from their designs and plan to reduce or eliminate the risks. Examples include:

• Specify the lightest weight product that meets the design criteria;
• Coordinate service designs to optimise the installation sequence of all services so that mechanical lifting aids can be used for heavy/awkward installations;
• Consider the location and access to the plant/switch room. For example, take into account if the door to the plant room is large enough to fit the switchboards/panels through. Plan and design safe access for construction and future maintenance. Ensure there is enough space for access with mechanical handling equipment if it is required, for example to shift large switchboards/panels, heavy motors in/out of the plant/switch room;
• Consider how large cables can be laid during design. For example, consider if the design allows for the use of mechanical cable pulling devices and the mechanical movement of cable drums. Design the job to minimise the length of the large cables by considering the location of the sub-mains/switchboard/plant room. Where possible design the cables to enable them to be laid "top down" where gravity can assist, rather than the cables having to be laid from the "bottom up". Always minimise the change of direction of the cables;
• Design electrical services so that the requirements for electricians to work in confined spaces during construction and/or maintenance is minimised. Ensure there is adequate lighting where electrical maintenance work will need to be completed;
• Where practicable within the design criteria/construction method, pre-install conduit to eliminate the need to chase walls;
• Ensure specifications and plans are clearly marked with the weights of the materials; and
• Design, specify and mark lifting points into large/heavy building components.

Manufacturers and suppliers

Manufacturers and suppliers of electrical equipment and fittings can assist in reducing manual handling risks to electricians. Examples include:

• Consider the manual handling implications in regard to the length and weight of cables. Always try to minimise the length of large cable;
• Whenever practicable use lightweight plastic cable drums instead of heavy wooden cable drums;
• Consider mechanically assisted spools on the cable drums to unwind large cables;
• Consider methods for manoeuvring and placing switchboards/panels. For example, build in rollers/wheels, fit lifting lugs to assist in mechanical lifting or reduce the weight and dimensions by manufacturing the switchboard in sections;
• Clearly mark the load to indicate the weight of products. For example, note the weight of the large components on the delivery docket;
• Consider fitting detachable rollers or utilising flat bed trolleys to deliver/place large switchboards/panels;
• Consider the size and the type of packaging of items such as light fittings so they can be safely handled by the end users;
• When delivering equipment and/or supplies, the point of delivery should be as close to the point of use as possible; and
• Include purpose designed, reinforced lifting points clearly marked on the load to provide for the safe use of cranes, hiabs or other mechanical lifting equipment.

4. Principal contractor

Planning and coordination phase

The Occupational Safety and Health Act sets out a duty of care for the principal contractor. This duty of care requires safe systems of work to be established and maintained and be supported by adequate information, instruction, training and supervision. Correct planning can make sure safe systems of work are established and adequate information, instruction, training and supervision is provided. Good planning will avoid or reduce many of the manual handling hazards associated with electrical work and will benefit the productivity of the job as well as promote safety. The following guidelines provide some practical ideas.

Access/Egress

At the beginning of the job, it is essential to establish a clear access/egress way to allow for the safe movement of materials and equipment around the site, for example install limestone driveways during the site preparation stage. As a minimum, adequate access/egress ways must be established by using planks or other suitable alternatives.

Access to the plant/switch room needs to be established and maintained for both construction and ongoing maintenance. The size of the doorway needs to be suitable for the equipment and tools. The timing of fitting doors needs to be considered in the planning stage.

Confined Space

Electricians inevitably have to work in confined space or areas that have limited space. Working in confined spaces has many safety implications. More detailed information can be obtained from the Occupational Safety and Health Regulations 1996 and AS/NZS 2865:2001, Safe Working in Confined Space.

Confined spaces make access/egress and manual handling awkward. Consideration should be given to these issues in the planning stage. Examples include:

• Provide a safe walkway in roof spaces and service ducts. For example, plank out walkways where practicable;
• Institute construction and/or maintenance systems so that as much work as possible is completed in other locations i.e. not in the confined area to minimise the time electricians have to spend in awkward postures;
• Where working in confined spaces is unavoidable make sure adequate resources are allocated to allow the electricians to take appropriate breaks from working in awkward postures;
• All environmental conditions need to be considered. For example, adequate lighting, noise, ventilation and temperature control is required so the job can be completed safely; and
• All electrical sources must be isolated before any work likely to come into contact with the electrical supply; fitting or fixture commences, particularly in refurbishments, extensions and demolitions.

Scaffold/Working Platform

Appropriate working platforms must be provided. For example, equipment such as a mobile scaffold or suitable elevated working platform (EWP) must be used instead of a ladder when significant work is being completed. A ladder is not an acceptable working platform.

Large, heavy components must be mechanically lifted onto the scaffold whenever practicable. The capacity of the scaffold must be appropriate for the loads. A loading bay should be located appropriately, giving consideration to access/egress.

The Code of practice for the prevention of falls at workplaces provides detailed information on working platforms etc.
 
Inappropriate work platform Cherry picker provides safe work platform
Works Programming and Coordination

The programme of works should take into consideration the implications for electricians. Examples include:

• Sequence work to prevent "rush jobs" as far as practicable. For example plan work to liven areas to provide power and light for other trades so as to avoid putting unnecessary pressure on electricians;
• Sequence work in plant/switch rooms to minimise access difficulties. For example, install electrical equipment/fittings prior to installing pipe work that blocks access for the electrician;
• In consultation with all service trades coordinate the work to allow the electrician to complete tasks as free from obstruction as possible. This is particularly important when all of the service trades are completing work in confined areas such as roof and ceiling spaces; and
• Allow for the progressive clean up of the work area to prevent debris/rubbish becoming a trip hazard.

Materials Delivery/Storage

Material delivery and storage areas should have enough space and lighting to allow for the safe movement of materials. The ground conditions of storage and lay down areas should be even and firm. Examples of safe work practices include:

• Locate lay down areas so the equipment is delivered and stored as near to the point of end use as practicable;
• Wherever practicable ensure mechanical aids are used to move and place large, heavy loads. Ensure the doorway is large enough for mechanical aids to be manoeuvred in/out; and
• Have adequate secure storage space/ lay down area and systems in place to ensure there is minimal double handling of large items such as cables, switchboards/panels, motors or pumps.

Selection of Material

Selecting materials that are lighter and easier to handle decreases the overall workload of the electrician. Examples include:

• Use the lightest products possible. For example, ensure plastic cable drums are used;
  Ensure purchasing systems stipulate the requirement to supply smaller quantities and/or smaller sized product where applicable; and
• Whenever practicable minimise the length of large cable

Provision of Mechanical Lifting and Handling Equipment

Mechanical lifting and handling equipment must be considered to move/install heavy/awkward products, tools and equipment around the site and/or in situ. The provision and maintenance of the equipment should be planned at the beginning of the job. Special consideration should be given to remotely located sites. Examples of equipment that may need to be considered and directly or indirectly budgeted for include:

• The use of a crane, forklift or other mechanical lifting devices to lift and place large/heavy components;
• The use of flat bed trolleys to move large/heavy tools and equipment around site;
• Mechanical lid lifters, such as the swift-lift to access concrete pits;
• Mechanical cable pulling devices and cable rollers;
• The provision of mechanical lifting device such as a materials hoist to ensure the safe movement of tools/equipment from ground to upper levels;
• The use of hiabs, winches or ramps to load and unload work vehicles; and
• Mechanical digging devices suitable for the task whenever practicable, such as a bobcat, backhoe or ditch-witch. If it is necessary to dig manually using a shovel ensure the most appropriate shovel for the job is available, such as:
• Trench shovels for digging cable trenches;
• Shovels with shock absorbing handles when digging around tree roots, rubble etc;
• Long and short handle shovels to suit the task/person.
  

If digging near retaining walls or concrete mounting plinths is required, make sure an adequate risk assessment or engineering check is done prior to digging. For further information refer to the Excavation Code of Practice.

Selection of Tools and Equipment

When selecting tools and equipment the safety of the operator must be considered. The lightest weight tool with the least amount of vibration and noise that is suitable for the job should be provided. For example, to chase walls select a light weight cutter that minimises dust in preference to large, heavy, awkward, high revolution tool such as a quickcut (refer to the Code of Practice for Concrete and Masonry Cutting and Drilling).

Team Lifting

Team lifting can be utilised for one-off lifts of tools and equipment. Team lifting has inherent risks and does not provide a long-term solution for moving heavy materials. The risks of uneven load distribution between the lifters increases when the tools/equipment/materials are moved from ground to roof level. When team lifting, the heavier the materials the higher the risk of manual handling injury. Team lifting is often neither time nor cost effective. Alternatives to team lifting should be considered during the planning phase. If team lifting is utilised all workers involved must be trained and the lift coordinated. A risk assessment should be conducted prior to the lift giving consideration to the size and weight of the object, the workplace layout and lifter postures and the individual capabilities of the lifters.

Team Cable Laying

Whenever practicable cables should be laid mechanically. Specialised cable pulling equipment such as winches, rollers and pulleys can be hired. If cables must be laid manually appropriate resources should be considered in the planning phase. There must be enough people involved to safely complete the task as well as a safe system of work established. Areas that require consideration include:

• The establishment of an adequate communication system to ensure the handling is coordinated;
• Having adequate team members, located appropriately, to ensure the pulling can be completed safely;
• Whenever possible feeding cables in a downward direction rather than in an upward direction. This way gravity can assist;
• Having standardised operating methods and procedures documented; and
• Having all team members adequately trained and familiar with the operating methods and procedures.

Training

Everybody involved in manual handling must receive adequate training to be able to complete the job safely. The Manual handling code of practice outlines the manual handling training requirements.

Construction phase

During the construction phase the principal contractor has a legal responsibility to ensure the maintenance of site safety. Safety and health policies, procedures and safe systems of work should be established in consultation with sub contractors at the beginning of a project and be continuously monitored and reviewed throughout the job. Site inductions, appropriate training and ongoing supervision are required throughout the construction phase to ensure safe systems are implemented and maintained.

Access/egress

The ongoing maintenance of clear routes to and from work areas to enable the safe movement of materials, equipment and people around site is essential. Adequate rubbish receptacles need to be provided and maintained in dedicated areas. Material hoists should not be removed until all materials have been put in place.

Work sequencing/planning

In consultation with the electricians coordinate the work so that all heavy/large components can be craned into place at one time. This will minimise crane time and maximise the use of mechanical lifting. Schedule the electrical work in plant/switch room to minimise obstructions for the electrician.

Work layout

Working platform planks must be secured and maintained. Where practicable the working platform should allow the electrician to complete their work in a good posture, ideally between knee and shoulder height. A ladder is not a suitable working platform.

As work progresses consider moving lay down areas to minimise the distance that equipment / components need to be moved.

Good Housekeeping

Good housekeeping on a site has many positive effects including increased harmony between different sub contractors, decreased probability of accidents and increased productivity. The site supervisor should conduct regular inspections to ensure the work areas are free of obstructions that may prevent the safe movement of materials and people.
 
Poor housekeeping no rubbish receptacles Good housekeeping with adequate rubbish receptacles

5. Electricians

All electricians have a legal responsibility to ensure their own safety and health at work and to avoid adversely affecting the safety and health of any other person. Some practical examples of how electricians can fulfil these responsibilities in relation to manual handling are outlined below.

Safe Work Practices - General

Developing and maintaining safe work practices reduces the risk of injury. Specific examples for electricians include:

• Maximise the time spent working between knee and shoulder height by altering the height of the working platform whenever practicable;
• If the work has to be completed below knee or above shoulder height regularly alternate the working posture. For example, if work below knee height has to be completed alternate postures from kneeling (with suitable kneeling pads), squatting and sitting. Always take regular breaks when working in awkward postures;
• Reduce the time spent stooped by completing all cutting/preparatory work on a bench rather than the ground; Consider completing as much of the preparatory work off site as possible. For example in a workshop with purpose built benches and adequate lighting;
• If working from a scaffold ensure it has an adequate load capacity and there is adequate workspace and access/egress to safely move the materials;
• Use appropriate working platforms, for example equipment such as a mobile scaffold or suitable elevated working platform (EWP) must be used instead of a ladder when significant work is being completed;
• Do not walk directly on ceiling joists, as there is a high risk of the joists not supporting the weight, particularly when tools and equipment are being carried. As a minimum always put planks down for access/egress and ensure there is an adequate working platform. More information on working at heights is provided in the Code of Practice for the Prevention of Falls at Workplaces;
• Do warm-up/stretching exercises at the beginning of the day and cool down/stretching exercises at the end of the workday to avoid injury to muscles, ligaments and other soft tissues. This is what athletes do to reduce the risk of soft tissue injury;
• Use mechanical lifting and handling equipment when and as required to move equipment/materials around site (refer to "Provision of mechanical lifting and handling equipment" section for more detail);
• Do not manually lift or move anything if there is any uncertainty that it can be done safely; and
• Always seek assistance to complete manual handling tasks when required. Ensure team lifts are coordinated and that there has been an adequate risk assessment completed.

Safe Work Practices - Digging

A number of injuries are associated with digging. Problems include using inappropriate tools, hitting an unexpected object and having to get into awkward positions. Before digging commences always identify the location of all gas, electrical, water, waste and sewage services likely to be encountered during excavation work. Examples of solutions include:

• Use excavator/bobcat or other mechanical digging device such as a ditch witch whenever possible; and
• If using hand held shovels:
• Use trench shovel for cable trenches;
• Use shovels with shock absorbing handles when digging around tree roots, brick rubble etc; and
• Use long or short handled shovels to suit task/person.

For further information on safe work practices associated with excavation refer to the Excavation Code of Practice.

Safe Work Practices - Switchboards/Panels

Electricians often have to work for prolonged periods on switchboards/panels as well as fit them into place. Examples of safe work practices include:

• Complete as much work as possible on the switchboard/panel before fitting;
• Ensure as far as is practicable there is adequate ventilation and cooling to decrease the risk of dehydration, tools slipping from "sweaty" hands and electrocution due to moisture;
• Where practical always use mechanical assistance to lift/place large switchboards/panels;
• Do not manually carry large switchboards/panels. Use an appropriate trolley to move the switchboards/panels around site;
• Maintain a good working posture when working on a switchboard/panel, such as the use of an appropriate work stool when practical; and
• Take regular "posture" breaks to allow the muscles and joints to rest.

Safe Work Practices - Power Tools

Safe work practices when using power tools include:

• Always select power tools that are the most suitable for the job giving consideration to weight, vibration and kickback;
• Always select the most appropriate personal protective equipment (PPE). For example select the best gloves for the job, select helmets with grips to prevent the helmet from slipping when doing overhead work and always wear eye protection when drilling overhead; and
• Use a cordless power tools when working within the ceiling space/roof area.

Power tools have inherent risks and should always be used in accordance with the manufacturers specification. Compliance with electrical safety requirements, outlined in AS/NZS 3012: Electrical installations on construction sites, must be achieved. Consideration must be given to the noise levels when using power tools. Further information is outlined in the Code of Practice for Managing Noise at Workplaces.

Safe Work Practices - Loading and Unloading Work Vehicles

Heavy equipment has to be loaded and unloaded, often several times per day. Loads can be heavy, awkward and difficult to access. To minimise manual handling consider the following:

• Use mechanical assistance such as a hiab;
• Modify the tailgate so it is mechanically lifted and lowered;
• Have "fold down" tailgate and sides;
• Organise the load so the frequently accessed and heavy items are the easiest to unload/load;
• Use the lightest weight tools and equipment practical for the job; and
• Install rollers on the roof rack to assist with taking ladders, trestles or planks on/off the vehicle.

Safe Work Practices - Laying Cables

Pulling cables can require significant force. Safe work practices include:

• Whenever practical use mechanical cable pulling devices; or
• If the cables are laid manually:
• Make sure there are enough people located appropriately, to complete the task safely;
• Use of fibreglass reach hooks as opposed to metal ones.
• Ensure the task is coordinated. A team leader must be identified to coordinate the cable pulling and laying. An adequate communication system must be established to ensure the handling is coordinated; and
• Whenever possible feed cables in a downward direction . This way gravity can assist.

Safe Work Practices - Confined Spaces

Electricians often have to work in confined areas such as ceiling spaces. This affects how manual handling tasks can be completed. Examples of how to reduce the risk of a manual handling injury when working in confined areas are listed below:

• Use appropriate aids such as a crawl board to access confined areas;
• Enhance points of access as much as possible. For example remove enough roof tiles to allow easy access for the electrician, tools and equipment;
• Ensure the environmental conditions including lighting, ventilation, noise and temperature are adequately controlled before completing work in a confined space;
• Complete as much work as practicable before installation so as to minimise the time spent in the confined areas; and
• Take regular "posture" breaks to allow the muscles and joints to rest.

More detailed information on safe work practices in confined spaces can be obtained from the Occupational Safety and Health Regulations 1996 and AS/NZS 2865:2001 Safe Working in Confined Spaces.

Safe Work Practices - Chasing Walls

Chasing walls with heavy, high revolution tools such as quickcuts or angle grinders has manual handling and other inherent safety risks. Whenever possible pre-lay cables into the walls and/or floor to eliminate the need to chase; or where this is not possible:

• Always use the lightest, most suitable tools; and
• Make sure adequate training has been received for the task to be completed in the safest possible way.

For further information refer to the Code of Practice for Concrete and Masonry Cutting and Drilling.

Good Housekeeping

All workers involved in all trades on site have a responsibility for maintaining site tidiness. Routine, regular clean-ups should be scheduled as part of the workday. Working on a tidy, well-maintained site makes the job easier and safer.

Team Lifting

Training must be provided for all electricians involved in team lifting. All team lifts require a "leader" who is responsible to coordinate the lift. Remember team lifting should not be considered an adequate long-term control. Team lifting is inherently dangerous and alternative solutions should be considered.

Training

Before undertaking any manual handling tasks ensure adequate manual handling training has been completed so the job can be done safely.

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