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Manual tasks and plumbers (water, drainage, gas, sanitary and maintenance)

Manual task injuries result in more lost time for plumbers 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 plumbers.

Contents

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

1. Introduction

Within the building and construction industry in Western Australia plumbers sustain the second highest number of manual task injuries. Manual task injuries are the largest single cause of injury resulting in plumbers 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 tasks refers to any activity or sequence of activities that requires a person to use their physical body (musculoskeletal system) to perform work including:

  • manual handling (the use of force in lifting, lowering, pushing, pulling, carrying or otherwise moving,holding or restraining any person, animal or thing);
  • performing repetitive actions;
  • adopting awkward or sustained postures; and
  • using plant, tools or equipment that exposes workers to vibration.

Common manual tasks that result in injuries among plumbers include, moving gas bottles, digging, carrying pipes and plumbing fixtures and lifting heavy equipment such as tank covers, drain cleaning machines and heavy valves/pumps.

Manual tasks 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 tasks code of practice contains more detail on the manual tasks 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 tasks 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 tasks risks to plumbers, 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, such as using lightweight plastic soak wells where practicable instead of concrete soak wells; 
  • plan and design safe access for both during construction and for maintenance. Ensure enough space for access with mechanical handling equipment, eg if heavy components need to be fitted in a plant room consider if there is adequate access for a mechanical lifter to lift, place or remove the components; 
  • review the placement of pipes in ceilings considering access for ongoing maintenance; 
  • consider alternative designs for service pipe work eg design service pipe work into prefabricated modules with the major work being carried out more easily in a controlled environment either off site or in a clear work area on site; 
  • ensure specifications and plans are clearly marked with the weights of the materials; and 
  • design and specify reinforced lifting points into components such as pipes, tanks, soak wells, pumps, large valves and heavy fixtures.

Manufacturers and suppliers

Manufacturers and suppliers of plumbing products can assist in reducing manual handling risks to plumbers. Examples include:

  • reduce the weight of bagged products, eg reduce the size of cement bags from 40kg to 20kg; 
  • secure the products so that the load doesn't move unexpectedly, eg ensure bundles of pipe are securely fixed to hold the bundles together when they are moved around site. Bundles should be kept to a manageable size; 
  • consider manual handling implications when manufacturing pipes, eg excessively long lengths of pipe are extremely awkward to handle. The larger the diameter of pipe the more the more hazardous it is to handle long lengths; 
  • use mechanical handling equipment, such as a crane or hiab, when delivering equipment and/or supplies. The point of delivery should be as close to the point of use as possible; 
  • mark the load to indicate the weight, eg, the weight of large diameter concrete pipes etc; and 
  • include purpose designed, reinforced lifting points on the load, for eg concrete soak wells, tanks, pipes etc, 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 plumbing and will benefit the productivity of the job as well as promote safety. The following guidelines provide some practical ideas.

Access/egress

Consideration needs to be given to access/egress for maintenance work and provisions made before the job is started. For example if a roof level plant room is only accessible via narrow stairs consider how the plumber can get tools and equipment to the work area. It may be necessary to have an alternative access such as via the roof.

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

Confined spaces

Plumbers inevitably have to work in confined spaces. Working in confined spaces has many safety implications. More detailed information can be obtained from the Occupational Safety and Health Regulations 1996 and AS 2865 Safe Working in a Confined Space.

Confined spaces make access/egress and manual handling awkward. In some confined spaces, such as in a roof space or plumbing duct, there is often no walking platform. Consideration to these issues should be given in the planning stage and appropriate action taken. Examples include: 

  • provide a safe walkway in roof spaces and plumbing 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 plumbers have to spend in awkward postures; 
  • where working in confined spaces is unavoidable make sure adequate resources are allocated to allow the plumbers to take appropriate breaks from working in awkward postures; 
  • all environmental conditions need to be considered, that is adequate lighting provided, noise controlled and adequate temperature control provided how and where practicable; and 
  • all electrical sources must be isolated before any work likely to come into contact with the electrical supply, fitting or fixture commences. 

Works programming

The programme of works should take into consideration the implications to plumbers' fitting/installing plant/equipment. Examples include:

  • place bulky, awkward heavy items into the bathroom areas when there is adequate access eg place and fit the spa/bath before other fitting so there is adequate room; 
  • in kitchen areas, where practical sequence work such that wall mounted appliances fitted by plumbers are installed before lower fittings such as cupboards; 
  • sequence work to prevent “rush jobs” as far as practicable; and 
  • coordinate the trades to allow the plumber to complete work as unobstructed as possible.

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 compacted. Examples of safe work practices include:

  • ensure the pipes and other materials are delivered as close as possible to the job, eg the site supervisor can fax the site plans specifying delivery points to the delivery company with the order; 
  • have adequate storage space and systems in place to maintain pipes etc so there is minimal double handling; and 
  • make sure gas bottles are stored correctly, i.e. secured in an upright position and away from the immediate work area.

Selection of material

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

  • use the lightest products possible eg use light weight sanitation systems instead of traditional concrete soak wells and leach drains; 
  • provide small gas cylinders rather than large bulky cylinders when practicable; 
  • minimise the use of excessively long lengths of pipe;
  • provide 20kg bags of cement instead of 40kg bags of cement, or consider bulk cement alternatives, if appropriate.

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. Mechanical devices must be considered to complete heavy manual tasks such as digging, removing gatic or well covers etc. 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 includes:

  • a crane, hiab or other mechanical lifting device to lift and place large bundles of pipes close to the work area; 
  • a lift truck or other mechanical lifting devices, to raise pipes or modules with pipe work already fitted to ceiling height; 
  • appropriate working platforms must be provided, for example a mobile scaffold or suitable elevated working platform (EWP) must be used instead of a ladder. A ladder is not an acceptable working platform (more details on working platforms are outlined in the Prevention of falls at workplaces code of practice); 
  • pipe stands should be provided particularly when a large number of pipes are being used;
    provide mechanical digging devices suitable for the task whenever practicable, such as a bobcat, backhoe, ditch-witch. In addition ensure all excavation work is carried out in accordance with the requirements detailed in the Excavation code of practice. If it is necessary to dig manually using a shovel ensure the most appropriate shovel for the job is available, examples include:
    • trench shovels for digging water pipe trenches; 
    • shovels with shock absorbing handles when digging around tree roots, rubble etc; 
    • have both long and short handle shovels available to suit the task/person.

If digging near retaining walls or concrete mounting plinths is required make sure an adequate risk assessment is done prior to digging to ensure there is no danger of a collapse. Engineering approval maybe required to ensure there is adequate structural support if the digging is close to the footings. 

  • detachable handles/grips to move awkward loads such as pipes around. A variety of devices are available including magnetic grips, suction caps, handling slings; 
  • trolleys with large diameter wheels specifically designed to move gas bottles in a safe manner; 
  • hiabs, winches or ramps to load and unload work vehicles; and 
  • mechanical lid lifters to remove drain /traffic/gatic or well covers.


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 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 chasing saws (refer to the Code of practice for Concrete and masonry cutting and drilling).

Team lifting

One person handling long lengths of pipe is extremely hazardous. Team lifting can in many cases reduce this risk. It must be remembered however that team lifting has inherent risks and does not provide a long-term solution for moving heavy materials. 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 and procedures and safe systems of work should be established at the beginning of a project and should be regularly reviewed throughout project. Site inductions, appropriate training, and ongoing supervision are required throughout the construction phase to ensure safe systems are achieved 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 layout

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

Pipe benches should be provided so that the work is completed at an optimal work 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. Plumbers

Sub contractors have individual responsibilities to manage site safety and health. All employees 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 for plumbers are outlined below.

Safe work practices - general

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

  • maximise the time spent working between knee and shoulder height by altering the height of the working platform when working from a scaffold whenever this is practicable; 
  • reduce the time spent in a stooped posture by completing work on a workbench instead of on the ground; 
  • to avoid injury to muscles, ligaments and other soft tissues do warm-up/stretching exercises at the beginning of the day and cool down/stretching exercises at the end of the workday. This is what athletes do to reduce the risk of soft tissue injury; 
  • use mechanical lifting and handling equipment when and as required (see above for examples of the equipment); 
  • do not manually lift or move anything if there is any uncertainty that it can be done safely;
  • always use the lightest possible tool for the job; and 
  • always seek assistance if necessary.

Safe work practices – moving gas cylinders

Large gas cylinders are heavy, bulky and awkward to move. Some possible solutions are:

    • whenever practicable use small size cylinders; 
    • use appropriate trolleys, purpose made with large wheels; 
    • use materials hoist to get cylinders to upper levels rather than carrying the cylinders up the stairs; 
    • leave the gas bottles on the work vehicle and use a long hose (maximum length should not exceed 15 metres). To ensure the flash arresters work, the operator needs to adjust the pressure at the regulator to make sure there is a sufficient supply of gas at the hand piece when using a long hose. The operator also needs to make sure the hose is not pulled over areas where it will be damaged or cause a trip hazard; and 
    • maintain good standard of housekeeping to maintain access egress for the trolley and/or the hose.

Note: There are other important associated safety issues with cylinders. Following safe work practices in the use and maintenance of gas cylinders is essential. Always store cylinders away from the immediate work area and secure them in an upright position.

Safe work practices – loading and unloading work vehicles

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

  • use mechanical assistance such as a hiab; 
  • modify the tailgate so it is mechanically lifted and lowered; 
  • install ladder rollers on the roof rack to assist with taking ladders on/off the vehicle; 
  • have removable tailgate and sides; and 
  • use the lightest weight tools and equipment practical for the job.

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 (this can be done through the relevant authorities or Dial Before You Dig). 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 water pipe trenches; 
    • use shovels with shock absorbing handles when digging around tree roots, brick rubble etc; and 
    • use both long and short handled to suit task/person, eg use “extra short” handle shovels when digging in a confined area such as a soak well.

Safe work practices – pipe installation and movement

There are problems associated with moving long, awkward pipes around site and in confined places. Often pipes need to be fitted in areas that are difficult to access. Possible solutions include:

  • work on adjustable height scaffold, or EWP where possible; 
  • use pipe stands, pipe lifters, block and tackle or a winch to hold and place pipes; 
  • use pipe benches, raising work to good working height, when cutting etc is required however it is essential that the pipe is stable and level when cutting; 
  • minimise the movement of pipes; 
  • use a minimum of 2 people to move long length pipes around site; 
  • use detachable “handles” to make handling easier; and 
  • remember to maintain good posture and follow safe handling procedures.

Safe work practices – chasing walls

Chasing walls with heavy, high revolution tools such as chasing saws has manual handling and inherent safety risks. Solutions include:

  • whenever possible build the pipe-work 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 done in the safest possible way
    • any machinery should be used in accordance to the manufacturers instructions.

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 cleanups should be scheduled as part of the workday. Working on a tidy, well-maintained site makes the job easier, safer and more productive.

Team lifting

Training must be provided for all plumbers involved in team lifting. The lift needs to be coordinated by a “leader”. Remember team lifting should not be considered an adequate long-term control. Team lifting in inherently dangerous and alternative solutions should be considered.

6. Further information

Code of practice - Manual tasks 2010

Related information