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Roof carpenters and manual handling

Manual handling injuries result in more lost time for roof carpenters 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 roof carpenters.

Contents

  1. Introduction
  2. Legal obligations
  3. Designers and manufacturers
  4. Principal contractor
  5. Roof carpenters
  6. Further information

1. Introduction

Roof carpenters 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 roof carpenters 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 roof carpenters include, moving timber and steel from ground to roof level, manually lifting and carrying heavy materials and fixing timbers in awkward postures.

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 1.03mb] 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 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 roof carpenters, which 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.  Consider the choice of material, for example use lightweight pine or laminated lumbar products instead of heavy hardwoods, within the design criteria;
  • consider the method of construction. For example consider if components of the roof can be prefabricated at ground level;
  • plan and design safe access for construction and future maintenance.  Ensure there is enough space for access with mechanical handling equipment. For example if large support beams need to be fitted ensure there is adequate access for a mechanical lifting device;
  • consider how the roof components can be fitted. For example with a steep pitched roof consider how the roof carpenter can reach the ridge to fix the rafters;
  • 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 roof components can assist in reducing manual handling risks to roof carpenters.  Examples include:

  • consider manual handling implications in regard to the length and weight of roof components.  For example excessively long timbers are extremely awkward to handle;
    package the timbers in the order of use so the first timbers to be used are on the top of the stack, that is the wall plates. This minimises the need for restacking to access the appropriate timbers;
  • clearly mark the load to indicate the weight of products, for example, note the weight of the large components on the delivery docket;
  • when delivering timber bundles do not tip off the bundles as this results in the stack being very disorganised and requiring significant restacking and double handling. Deliver the bundles using alternative means, such as a hiab, to minimise the disruption of the bundle;
  • 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 1984 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 roof carpentry 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.

Scaffold

Large, heavy components must be mechanically lifted whenever practicable. Generally a heavy-duty scaffold must be used to make sure the load is within the capacity of the scaffold. A loading bay should be located appropriately, giving consideration to access/egress. The code of practice for the Prevention of falls at workplaces [PDF 973kb] provides detailed information on working platforms etc.

Works programming

The programme of works should take into consideration the implications to roof carpenters. Examples include:

  • sequence work to prevent “rush jobs” as far as practicable;
  • coordinate the trades to allow the roof carpenter to complete work free from obstruction; 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 the materials.  The ground conditions of storage and lay down areas should be even and firm.  Examples of safe work practices include:

  • ensure that timbers, steel beams etc are delivered as close as possible to the job. For example the site supervisor can specify delivery points to the delivery company with the order;
  • wherever practicable ensure mechanical aids are used to move and place large, heavy loads; and
  • have adequate storage space/ lay down area and systems in place to ensure there is minimal double handling of timber and steel.

Selection of material

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

  • use the lightest products possible, for example use lighter weight timber such as pine where practical;
  • minimise the use of excessively long timbers; and
  • consider the use of prefabricated trusses, lifted and placed by mechanical equipment.

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 use of a crane or other mechanical lifting device to lift and place large/heavy components;
  • the use of a crane or other mechanical lifting device to move timbers/steel up onto the first storey slab or scaffold;
  • the provision of mechanical lifting device such as a materials hoist must be considered to ensure the safe movement of tools/equipment to roof level; and
  • the use of hiabs, winches or ramps to load and unload work vehicles.


Selection of tools and equipment

When selecting tools and equipment the safety of the operator must be considered. There should be consultation with the roof carpenter to identify the most appropriate tool/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. 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 such as occurs with roof carpenters. The heavier the materials the higher the risk of manual handling injury when team lifting.  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.

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 continuously monitored and regularly 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 before all materials have been put in place.

Work sequencing/planning

In consultation with the roof carpenters coordinate the work so that all heavy/large components can be craned into place at one time thus minimising crane time and maximising the use of mechanical lifting;

Work layout

Working platform planks must be secured and maintained.  Where practicable the working platform should allow the roof carpenter to complete their work in a good posture, ideally between knee and shoulder height.

Any cutting work should be completed on a workbench or a sawhorse on a stable surface so that work is completed at an optimal working height, that is between hip and waist height.

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 ensure the work areas are free of obstructions that may prevent the safe movement of materials and people.

5. Roof Carpenters

All roof carpenters 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 roof carpenters 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 roof carpenters include:

  • maximise the time spent working between knee and shoulder height by altering the height of the working platform whenever practicable;
  • reduce the time spent stooped by completing all cutting and marking work on a bench/sawhorse instead of the ground;
  • 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;
  • 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 details are outlined in the Code of practice for the Prevention of falls at workplaces [PDF 973kb]);
  • use mechanical lifting and handling equipment when and as required (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 if necessary ensuring team lifts are coordinated.

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;
  • maintain all cutting equipment. Excessive force is required when using dull blades;
  • always use two hands to operate power saws; and
  • use a cordless power saw when cutting within the roof area.

Power tools have inherent risks and should always be used in accordance with the manufacturers specification. Never modify machine guarding or other safety features. For example never modify a nail gun so it free fires.  Electrical safety requirements, outlined in AS/NZS 3012:2003 Electrical installations - Construction and demolition sites, must be complied with. Appropriate signage needs to be in place when power tools are used. 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 [PDF 1.55mb].

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, vehicle loading crane;
  • modify the tailgate so it is mechanically lifted and lowered;
  • have fold down tailgate and sides;
  • 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 – Moving timber/steel

Timber/steel inevitably need to be moved around site. The loads can be heavy and in some cases awkward to move. Some solutions include:

  • never do single person manual lifts to move heavy steel/timber;
  • never prop up large steels, particularly with sharp edges. Always use mechanical lifting devices;
  • use a minimum of two people to move long lengths of material around site; and
  • minimise the movement of timber/steel around site, including minimising the restacking of timber.

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 workday. Working on a tidy, well-maintained site makes the job easier and safer.

Team lifting

Training must be provided for all roof carpenters 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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