Plasterers and manual handling

Manual handling injuries result in more lost time for plasterers 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 plasterers.

1. Introduction

Manual handling injuries are the largest single cause of injury resulting in plasterers 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 plasterers include plastering in awkward and extreme postures, repetitively applying plaster and working to deadlines that result in working at a rapid pace without rest breaks.

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 of an object 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 [PDF 1.02mb] contains more detail on the manual handling risk management process and training requirements.

2. Legal obligations

The Occupational Safety and Health Act 1984 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 1996 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 1984 places a legal obligation 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 plasterers that may arise from their designs, and plan to reduce or eliminate the risks. Examples include:

consider the method of plastering. Where practicable consider if the plaster/render can be applied mechanically;

provide safe access/egress for plasterers and materials. For example ensure that appropriate work platforms can be accessed so plasterers can adopt safe working postures;

integrate joints into the design to achieve segregated work areas that do not expose plasterers to manual handling risks. For example if the plastering requires work to completed at different heights, such as with a high wall, segregate the areas to be completed by the inclusion of a joint so each section can be completed separately;

consider including skirting boards in the design to eliminate plastering at floor level; and

utilise and integrate new plastering products that reduce manual handling risks as they develop.

Manufacturers and suppliers

Manufacturers and suppliers of plastering materials can assist in reducing manual handling risks to plasterers. Examples of how include:

limiting the weight of bagged products. For example keep bags of cement/plaster to 20kg or below;

clearly marking the load to indicate the weight of products. For example, mark the weight on the bags of cement/plaster;

where practicable organising site delivery for cement/plaster. Where possible the delivery must be unloaded by mechanical means; and

when delivering equipment and/or supplies the point of delivery should be as close to the immediate work area as possible.

4. Principal contractor

Planning and coordination phase

The Occupational Safety and Health Act 1984 sets out a duty of care for the principal contractor. This duty of care requires safe systems of work to be established, maintained and be supported by adequate information, instruction, training and supervision. Tools such as Job Safety Analysis (JSA) or Work Method Statements assist in achieving this duty. Good planning will avoid or reduce many of the manual handling hazards associated with plastering and will benefit the productivity of the job as well as promote safety. The following guidelines provide some practical ideas to assist in reducing the risks arising from manual handling.

Access/egress

At the beginning of the job, it is essential to establish clear access/egress 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.

Consideration must be given to how materials can be moved in/out and around areas. For example if multi levels are involved consider the position of man and material hoists and the layout and type of scaffold used having regard for access/egress for the plasterers, their materials and equipment.

Works programming

The programme of works should take into consideration the implications for plasterers. Consider:

preparing JSA's or similar to sequence work to prevent "rush jobs" as far as practicable;

coordinating the trades to allow the plasterer to complete work free from obstruction; and

allowing for the progressive clean up of the work area to prevent debris/rubbish becoming a hazard, in particular where access/egress is limited.

Materials delivery/storage

Adequate materials delivery and storage areas need to be established at the beginning of the job. They must have enough space and lighting to allow for the safe movement and storage of the materials. The ground conditions of storage and lay down areas should be even and compact. Safe work practices include:

ensuring the plastering materials are delivered as close as possible to the job. This may include the site supervisor liaising with the delivery personnel and/or supplier;

wherever practicable ensuring mechanical aids are used to move and place large, heavy loads;

having adequate storage space/ lay down area to safely store materials/equipment and to minimise double handling; and

if work is going to be completed from a scaffold ensuring the loading bays are maintained for plasterers to load their materials and equipment. The materials hoist or alternative mechanical aids should be available for plasterers to move plaster/cement and other equipment to first floor slabs.

Selection of material

Selecting materials that are lighter and easier to handle decreases the overall workload of the plasterer. Always consider the weight of materials such as bags of plaster/cement. Bagged products should not exceed 15-20kgs.

Provision of mechanical lifting and handling equipment

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

the provision of a mechanical lifting device such as a materials hoist to facilitate the safe movement of tools/equipment between working levels;

the use of hiabs, vehicle mounted hoists, winches or ramps to load and unload work vehicles;

the use of mechanical plaster applicators such as a spray on device;

the provision of conveyors to move sand and bagged products around site; and

the use of a telescopic loader/fork.

Scaffold/working platform

Consider the scaffold requirements of plasterers, and plan accordingly. Ensure suitable scaffold and attachments such as aluminium frame hop-ups are provided where necessary. A loading bay should be located appropriately, giving consideration to access/egress. The capacity of the scaffold must be appropriate for the loads.

Selection of tools and equipment

When selecting tools and equipment the safety of the operator must be considered. There should be consultation with the plasterer to identify the most appropriate tools/equipment. Consideration needs to be given to factors such as the weight, vibration and kickback of the tools/equipment and to the work environment in which they will be used.

Team lifting

Team lifting can be utilised for one off lifts of tools and equipment however it has inherent risks and does not provide a long-term solution for moving heavy materials. Additionally team lifting is often neither time nor cost effective and alternatives should be considered during the planning phase.

The risks of uneven load distribution between the lifters increases when the tools/equipment/materials are moved between working levels. The heavier the materials, the higher the risk of manual handling injury when team lifting. If team lifting is utilised all workers involved must be trained and the lift coordinated. Always try to have lifters of a similar height complete team lifts to facilitate the safest possible lift.

Training

Everybody who completes tasks involving manual handling must receive adequate training to be able to complete the job safely. The Manual handling code of practice [PDF 1.02mb] 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 at the beginning of a project, be reviewed with the plasterers prior to the commencement of plastering and be continuously monitored and regularly reviewed throughout the job. Site inductions, appropriate information, 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 to control waste.

Work sequencing/planning

The ongoing sequencing/planning of a job should facilitate safe systems of work for the plasterer. For example the principle contractor should ensure:

the planning and installation of the scaffold so that the plasterers' access/egress is facilitated; and

facilitating communications between plasterers and other trades to assist plasterers completing their work without obstruction.

Work layout

The work layout influences how the work can be completed. Examples of achieving the optimal work layout for plasterers include:

ensuring any mixing/preparation work is completed on a workbench, sawhorse or on an alternative stable surface so that work is completed at a good working height, that is between hip and waist height; and

ensuring the bulk of the plastering is completed between knee and shoulder height by providing suitable scaffolding, elevating work platforms or other adjustable height working platforms such as purpose design hop-ups or mast climbers.

Environmental conditions

In windy squally conditions do not complete work on scaffolds. Keep mixing away from main work areas particularly in extreme conditions. Petrol mixes should be in a well ventilated area.

Good housekeeping

The site supervisor should ensure the work areas are free of obstructions that may prevent the safe movement of materials and people. Good housekeeping on a site has many positive effects including increased harmony between different sub contractors, decreased probability of accidents and increased productivity.

5. Plasterers

All plasterers 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 plasterers 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 plasterers include:

wherever practicable maximising the time spent working between knee and shoulder height. This can be facilitated by utilising equipment such as aluminium frame hop-ups;

using 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;

if working from a scaffold ensuring it has an adequate load capacity and there is adequate workspace and access/egress to safely move the materials;

if taking plaster off a mortarboard raising the height of the mortarboard to decrease stooping.

reducing the time spent stooped by completing all preparation work on a bench/sawhorse instead of the ground;

selecting personal protective equipment such as gloves giving consideration to how they affect manual handling;

whenever practicable rotating between jobs. For example interchange between rendering, applying the finish coat and patching;

using mechanical lifting and handling equipment when and as required (refer to "Provision of mechanical lifting and handling equipment" section for more detail); and

not manually lifting or moving anything if there is any uncertainty that it can be done safely.

Safe work practices - Moving plaster/render around site

Plasterers have to move materials around site. Using equipment such as conveyors, trolleys and wheelbarrows reduce the load for plasterers. To minimise manual handling consider the following:

always avoiding carrying loads around site. For example use a suitable wheelbarrow, trolley or conveyor system;

always using a wheelbarrow suitable for the task such as industrial wheelbarrows with wide based tyres, designed to move heavy loads; and

planning the work so as to eliminate double handling of products.

Safe work practices - tools and equipment

Always select the tools/equipment that are the best suited for the job. Some general considerations are, whenever practicable:

using cement mixers specifically designed with larger bowls for mixing plaster and mechanical tipping devices;

always selecting power tools that are the most suitable for the job giving consideration to weight, vibration and kickback; and

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 - Construction and Demolition 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 - Preparation for work

Research has shown that workers that complete work where the shoulder is in elevated postures such as plastering benefit significantly from home exercise programmes. Consideration also needs to be given to preparing your body for work to reduce the risk of injury. Recommended practices include:

doing 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. Tasks completed by ceiling fixers put comparable loads on the body; and

considering a specific shoulder stretching and strengthening home exercise programme.

Safe work practices - Loading and unloading work vehicles

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

getting a purpose-designed trailer to accommodate the normal plastering materials and equipment;

using mechanical assistance such as a hiab or vehicle mounted hoist;

modifying the tailgate so it is mechanically lifted and lowered;

having fold down tailgate and sides;

using the lightest weight tools and equipment practical for the job;

organising the load so the frequently accessed and heavy items are the easiest to unload/load; and

installing rollers on the roof rack to assist with taking ladders, trestles or planks on/off the vehicle.

Good housekeeping

All workers involved in all trades on site have a responsibility for maintaining site tidiness. Routine, regular cleanups should be scheduled as part of the work day. Working on a tidy, well-maintained site eliminates many trip hazards and makes the job easier and safer.

Team Lifting

Training must be provided for all plasterers and labourers 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.

6. Further information

For further information on this publication, contact:

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