NEBOSH International General Certificate in

Occupational Safety and Health

Unit IGC2

Element 3: Musculoskeletal
Hazards and Risk Control

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Learning Outcomes
On completion of this element, you should be able to demonstrate
understanding of the content through the application of knowledge to
familiar and unfamiliar situations. In particular you should be able to:
• Explain work processes and practices which may give rise to
work-related upper limb disorders and appropriate control
measures
• Explain the hazards and control measures which should be
considered when assessing risks from manual handling
activities
• Explain the hazards, precautions and procedures to reduce
the risk in the use of lifting and moving
equipment…manual…
• Explain the hazards and the precautions and procedures to
reduce the risk in the use of lifting and moving
equipment…mechanical..
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Unit IGC 2
Element 3.1

Work-Related Upper Limb Disorders

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 Musculoskeletal Disorders (MSDs)
Back injuries
• Back muscle strain
• Ligament damage
• Disc injury

Work-related Upper Limb Disorders (WRULDs)

• Carpal tunnel syndrome
• Tenosynovitis

Hand-Arm Vibration Syndrome (HAVS)

• Vibration white finger
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MSD Risk Factors

• Task
− Repetition
− Force
− Posture
− Twisting
− Rest
• Environment
− Lighting
− Other environmental parameters
• Equipment
− Equipment design
− Equipment adjustability

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MSD Control Measures

• Adapt workplace to the worker
− Not the worker to the workplace!

• Adapt
− The task – avoid or do it differently
− The tools/equipment
− The workplace environment

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 Display Screen Equipment
Risks:
• WRULDs
• Eye strain
• Back pain
• Fatigue and stress

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DSE Control Measures

• Work station risk assessment
• Provide basic DSE workstation
equipment to minimum
standards
• Plan work routine
• Provide (free) eyesight tests
and spectacles if required
• Provide information and
training on:
− Risks
− Preventative measures

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DSE Standards

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 DSE Standards
1. Adjustable height and angle to seat back.
2. Good lumbar support.
3. Adjustable height seat to bring the hands to a comfortable position on the
keyboard. Seat also has a stable 5-star base.
4. Correct seat height adjustment and keeping the feet supported prevents
excess pressure on underside of thighs and backs of knees.
5. Foot support if user cannot get their feet on the floor.
6. Space for postural change, no obstacles under desk; this allows the user to
fidget and change position as they work.
7. Forearms approximately horizontal when hands are on keyboard.
8. Minimal extension, flexion or deviation of wrists; wrists should be straight
and flat when on the keyboard indicating proper seat height adjustment.
9. Screen height and tilt should be adjustable so as to allow comfortable head
position.
10. Space in front of keyboard to support hands/wrists during pauses in keying;
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a wrist-rest can provide further support if required.

DSE
Additional Points
• Desk layout
• Document holder
• Footrest
• Telephone headset

Specific measures for laptops:

• Short duration work only
• Docking station/separate keyboard and mouse
• Breaks
• Eye test
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Factory Assembly Line

Risks
• WURLDS – handling small components
• Eye strain – temporary fatigue
• Back Pain – sitting or standing in a fixed
position
• Fatigue and stress – due to infrequent rests
and a demanding work schedule

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 Group Discussion Point
What control measures could you suggest
to reduce the risk of ergonomic injuries
on a factory assembly line?

- Identify the general controls and more

specific controls needed

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Factory Assembly Line

General Control measures
• Carry out an ergonomic assessment
• Adjust workstation to the worker
• Plan work to allow rest breaks
• Training

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Factory Assembly Line

Specific Control measures
• Automate
• Re-layout the workstation
• Seating
• Comfortable shoes and floor mats
• Short, frequent breaks or job rotation
• Appropriate lighting
• Ergonomically designed hand tools

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 End of Section Quiz

1. What factors relating to the task

increase the risk of musculoskeletal
injuries?
2. What health effects can arise due to
the use of DSE?
3. What control measures should be
implemented to reduce the risk of DSE
injuries? (NB not the contents of a DSE
assessment)
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Answers
1- • Repetition – the need for repetitive movements
when carrying out the task (e.g. typing for several
hours).
• Force – the physical force required to perform the
task and the strain this puts on the body (e.g. closing
stiff catches on a machine).
• Posture – any requirement to adopt an awkward
posture (e.g. stooping over into a bin to pick out
contents).
• Twisting – any twisting action required by the task
(e.g. twisting the wrist when using a screwdriver).
• Rest – the potential for the worker to rest and
recover from any fatigue

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Answers

2- WURLDS, eye strain, back pain, fatigue

and stress

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 Answers
3- • Carry out a workstation assessment of the user’s
workstation to ensure that the equipment and
environment meet minimum standards and that the
workstation can be adjusted to suit the user.
• Provide basic DSE workstation equipment that meets
minimum standards in terms of good ergonomic design.
• Plan the user’s work routine so that they can take
short, frequent breaks from screen and keyboard use.
• Provide DSE users with a free eye test and, if
required, spectacles for screen use.
• Provide information and training to users on the
potential health risks of DSE use and the preventive
measures, in particular ergonomic use of the
workstation.

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Unit IGC 2
Element 3.2

Manual Handling Hazards, Risks and

Control Measures

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Group Syndicate Exercise

1. What common injuries occur when
carrying out a manual handling task?
2. Suggest the most effective ways of
preventing them

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 Common Injuries

• Back injury
• Tendon and ligament injuries
• Muscle injuries
• Hernias
• WRULDs (Work-related-upper-limb-
disorders)
• Cuts, burns, dislocations and broken
bones

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Assessing Manual Handling Risks

Four Main Factors:

T ask
I ndividual
L oad
E nvironment

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Group Syndicate Exercise

Consider what factors would need to be
considered when carrying out a manual
handling risk assessment.
Use the following headings:
• Task
• Individual
• Load
• Environment

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 The Task
• Height of load
• Repetition of movement
• High work rate
• Distance
• Awkward position
– Stooping
– Twisting
• Rest breaks
• Vertical distance
• Lifting above shoulder height
• Distance of load from body

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Load
• Weight
• Size and bulk
• Easy shape to lift?
• Stability
• Centre of gravity
• Grip points/handles?
• Is it hot, sharp, etc?

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The Environment
• Space restrictions
• Floor condition
– slippery?
– uneven?
• Changes in level
• Light levels
• Temperature
• Humidity

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 Individual Capabilities
• Unusual ability required?
• Significant risks to vulnerable people?
– pregnant workers
– workers with back pain

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Minimising the Risks

• Eliminate (Example Case Studies 1,2,3,4,5)
• Assess manual handling which remains
• Use handling aids
• Modify the:
– task
– load
– environment
• Match individual capabilities to the activity

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Elimination
• Automation
• Mechanisation
• Conveyor systems
• Forklift trucks
• Pallet trucks
• Cranes
• Hoists

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 Handling Aids

• Trolleys
• Barrel lifts
• Gin wheels
• Trucks
• Hoists and lifts

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Modify
The Task: The Environment:
• Rest breaks or job • Rearrange workspace
rotation • Level floors
• Eliminate stooping or • Additional lighting
twisting
• Table lift

The Load: The Individual:

• Smaller loads • Match individual
• Several workers capabilities to the
activity
• Stabilise loads
• Mark centre of gravity
• Attach handles
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Safe Lifting Techniques

Before lifting
• Check the load
• Plan the route of the carry
• Establish a firm grip

The lift
• Bend the knees and use the leg muscles to lift
• Keep the back upright
• Keep the load close to the body
• Avoid twisting, over-reaching, jerking

Setting down
• Use the same principles as lifting
• Maintain good balance
• Set the load down and then adjust its position
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 End of Section Quiz

1. What are the four factors which

should be considered in a manual
handling risk assessment?
2. What common injuries occur due to
inappropriate manual handling?

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Unit IGC 2
Element 3.3

Manually Operated Load Handling

Equipment

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Manually Operated Load Moving

Equipment

Caged Platform Two-wheeled Sack Truck

Truck Platform Truck

Pallet Truck
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 Manually Operated Handling
Equipment
Includes trucks, trolleys and pallet trucks
Hazards:
• Manual handling risks
• Instability of the load
• Moving up, down or across slopes
• Poor parking
• Other pedestrians may be struck
• Trapped feet
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Manually Operated Handling

Equipment
Controls:
• Trained workers • Use the brakes (if
only fitted)
• Follow • Care when moving or
manufacturer’s lowering the load
recommendations
• Avoid uneven • Safe parking and
ground and slopes storage
• Use ramps over • Routine inspection
steps and maintenance
• Safe working load • Safety shoes or boots
• Secure Load

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Patient Hoists

• Used for moving people

− Can be manual or powered
− Can be mobile or fixed

• Consider the environment A ceiling mounted powered hoist

(Source:

− e.g. difficult to push http://www.hse.gov.uk/pubns/books/hsg225.htm)

on carpeting
• Inspection needed

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 Other Patient Handling Equipment
• Slidesheets
− Slide patient from trolley to bed
− Avoids lifting the person

• Wheelchairs
− Can be powered though most are pushed

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End of Section Quiz

1. What are the potential hazards arising
from the use of a manual pallet truck
to move a heavy load?

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Answer
1- • Manual handling risk associated with
pushing or pulling the truck.
• Instability of the load causing the load to fall.
• Moving up, down or across slopes causing
loss of control.
• Poor parking of the truck causing obstruction
in a traffic route.
• Other pedestrians may be struck during
manoeuvring.
• Trapped feet under the wheels or when
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lowering the load.

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 Unit IGC 2
Element 3.4

Mechanically Operated Load

Handling Equipment

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General Requirements
• Suitable for the task and appropriately
rated
• Equipment stable and secure
• Visibly marked with SWL
• Lifting operations planned and carried
out by competent persons
• Equipment for lifting persons may
require additional inspections

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Forklift Trucks

Pedestrian Pallet Pedestrian

Stacker Counterbalanced Truck

Four-directional Truck

Reach Truck Side Loading Truck

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 Group Syndicate Exercise

What accidents could occur with the use

of a forklift truck?

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Forklift Truck Hazards

• Overturn of the truck
• Fall of the load
• Striking pedestrians
• Fall or entrapment of
persons riding on forks
• Fall from a loading dock

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General FLT Precautions

• Trained operators only
• Routine visual inspections
• Routine maintenance
• Only lift people with correct working
platform
• Load secure and stable
• Don’t exceed SWL
• Speed limits followed
• Travel with forks lowered
• Clear line of vision

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 Battery-Powered Trucks
Risks:
• Explosion from hydrogen
gas whilst charging
• Corrosive acid
• Manual handling
• Arcing, shock, burns or
fire
• Environmental - battery
disposal
• Silent running
• Battery leads can
short
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Precautions:
• Charge batteries:
– in well-ventilated areas
– no ignition sources
• Use PPE when handling
acid
• Mechanise battery
handling
• Electrical safety
– insulated tools
– gloves

Diesel-Powered Trucks
Risks: Precautions:
• Dermatitis from the • Use in well-ventilated
diesel areas
• Slip hazards • Spill kits
• Environmental pollution • Use gloves when
from large spills handling diesel
• Toxic exhaust fumes
• Bulk storage of diesel

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Liquid Petroleum Gas-Powered FLTs

Risks: Precautions:
• Explosion risk from • Use in well-
Liquid Petroleum ventilated areas
Gas (LPG) • Mechanise LPG
• Toxic exhaust cylinder handling
fumes • Store spare
• Manual handling cylinders in a:
– secure
• Storage of LPG – safe
cylinders or bulk – well-ventilated
location

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 Lifts and Hoists
Hazards:
• Falling objects
• Being struck by the load
• Entanglement in moving parts
• Falls from height
• Being struck while riding on
the platform of the lift by:
– landing levels
– parts of any enclosure
– other projections

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Lifts and Hoists

Precautions:
• Suitable for its intended use
• Preventing people getting:
– underneath the lift platform
– access to an unprotected landing edge
– struck by landing and obstructions when
being carried on the platform
• Maximum safe working load
• Safety devices, e.g. brakes working
• Competent operators
• Information, instruction and training
• Routine maintenance
• Routine inspection and thorough examination

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Conveyors

Roller conveyor

Belt conveyor

Screw conveyor

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 Conveyors

Hazards:
• In-running nips
• Entanglement
• Contact with moving parts In-running nip
hazard

Entanglement hazard
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Conveyors

Precautions:
• Warnings to alert prior to moving
• Guards on moving parts
• Emergency stops
• Guards beneath overhead conveyors to catch
falling objects
• Barriers to exclude people
• Information, instruction and training
• No loose clothing/long hair/jewellery
• Inspection and maintenance
• Defect reporting system

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Cranes

Tower Crane Mobile Crane

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 Group Syndicate Exercise
What could go wrong with a crane and its
operation?
Try to explain why.

Tower Crane Mobile Crane

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Mobile Cranes
Hazards
• The crane collapsing or toppling over
• The arm (jib or boom) striking structures
• Falling load
• The load striking objects or people
• Contact with live overhead cables

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Mobile Cranes
Factors causing instability:
• Overloading
• Uneven or unstable ground
• Not using outriggers
correctly
• Use in high winds
• Extending the jib or boom
too far
• Structural failure

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 Mobile Cranes
Precautions:
• Use within the safe • Banksman
lifting capacity (signaller)
• Careful siting
• Safety devices
• Maintenance and
examination • Check weather
• Trained and • Use outriggers
competent operators correctly
• Lift to be planned
and supervised • Never lift the load
over a person
• PPE
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Lifting Accessories
• Lifting accessories need to be inspected

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Statutory Examination of Lifting

Equipment
Thorough examination:
• Before it is used for the first time
• Periodically
• After an event that may have
affected its strength and stability
Frequency of thorough examination:
• Every 12 months - where not used to carry
people
• Every 6 months - where used to carry people
• Every 6 months - lifting accessories
By a competent engineer

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 End of Section Quiz
1. What are the general precautions
which should be taken when using
forklift trucks?
2. What are the specific risks associated
with the use of an LPG powered
forklift truck?
3. What are the main hazards and
precautions associated with the use of
conveyors?
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Answers
1- The precautions for safe use of forklift trucks include:
• Restricting use to trained operators only.
• Routine visual inspection of the truck before use.
• Routine maintenance of the truck in accordance with
the manufacturer’s recommendations.
• Never using the forklift to lift people unless a proper
working platform is attached.
• Ensuring that the load on the forks is secure and
stable.
• Ensuring that the safe working load limits of the truck
are not exceeded.
• Observing site speed limits.
• Never travelling with the forks raised.

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Answers
2- – LPG is an explosive gas.
– Exhaust fumes are toxic.
– LPG cylinders are heavy and present a
manual handling risk during changing.
– Those hazards associated with the
storage of replacement cylinders or bulk
storage of LPG.

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 Answers
3- The main hazards associated with conveyors are:
• In-running nip points - where fingers might be drawn into moving parts.
• Entanglement – where loose clothing might become entangled with rotating parts.
• Falling objects – from overhead conveyor systems.

The precautions for safe use of conveyors include:

• Warning alarms or sirens to alert people that the belt is about to start moving
• Guarding of moving parts to prevent drawing in and entanglement as far as is possible.
• Ensuring that emergency stop buttons or pull-cords are fitted and available for use.
• Barriers to exclude people from the area (protects also from falling objects)
• Fitting guards underneath overhead conveyors to catch falling objects.
• Information, instruction and training for operators.
• Controlling loose clothing and long hair, e.g. by the use of overalls and hairnets in the
workplace.
• Maintenance by authorised persons only to ensure safe running
• Provision of a defect reporting system to highlight concerns

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