Project Name

Ref No:
ACTIVITY – MECHANICAL MAINTENANCE RISK ASSESSMENT Rev.No:0
Page 1 of 11
Serial Sub-Activities Hazards Identified Risks Involved Risk Rating Control Measures Residual
No. Risk
(Generic & Task) (People & Property) Severity Probability Initial Risk
· TBT/DSTI shall be conducted by the foreman/
safety officer prior to work commencement.
· Unauthorized, untrained · Cuts · Task specific safety training to be provided. Low
1. Prepare work area workers · Abrasions 2 A L · Authorized personnel to undertake the job. (ALARP)
· Daily safety inspection should be carried out
and eliminate the hazard.

· Any lifting tasks shall be carried out by

· Incorrect lifting of loads
· Sharp edges.
2. Manual Handling · Placing the object while
fingers underneath.
• Slip/trip/fall ( same level )
• Unsafe posture
persons those physically capable to do so
· Back Injuries •No employee should be asked to carry loads
· Cut to finger above his capacity and in any case no load
· Strain shall exceed 30kg per man. Low
• Musculoskeletal 3 C M • Mass of the load is more then to be equally (ALARP)
Injuries shared
· Deploy enough number of personnel for lifting
depending upon the type of load to be lifted.
·Use mechanical aids such as trolley etc.
• Load not to be lifted above your shoulder
height
• Keep your fingers away from pinch point
while placing the load.
• Materials shall not be carried through
Pedestrian access.
• Area shall be illuminated with adequate
lighting.
· Appropriate personal protective equipment’s
shall be used while manual handling of
materials and loads.

Serial Sub-Activities Hazards Identified Risks Involved Risk Rating Control Measures Residual

ACTIVITY – MECHANICAL MAINTENANCE RISK ASSESSMENT
No. (Generic & Task)
• Unauthorized, Untrained
Workers
• Lifting failure.
Unloading , shifting of • Unsafe lifting.
water expansion tanks • Swinging of material
3. and pressurization • Damaged sling/wire rope or
units a chain
• Poor maintenance of vehicle
• Speedy operation
• Over turn
• Over load
• Poor communication
• Poor lighting
Serial Sub-Activities Hazards Identified
Project Name
Ref No:
Rev.No:0
Page 2 of 11
(People & Property) Severity Probability Initial Risk Risk
•Pre check to be carried out by the operator prior to
start the work to ensure that no hydraulic leaks, or
other visible damages seen.
• Ensure the crane and forklift engaged is tested
• Fatality and having valid license and the operators has
• Fractures valid license and approved 3rd party certificate.
• Property damage 4 C H • Engage trained and third party certified riggers shall M
• Injury to personal be provided. (ALARP)
• Sprain and strain • Barrication and warning signs shall be provided for
• Crush the area where lifting operation is carried out to
• Cuts restrict the entry.
• Check list shall be maintained for the vehicles prior
to start any work
• Use tagline for control of swing and alignment.
• All lifting equipment’s and gears shall have valid third
party certificate.
• The crane must be stopped when the wind
speed exceeds 38km/hr.
• Never exceed the SWL marked on the crane.
• All loads shall be secured prior to lifting.
• The crane and trucks inspection shall be conducted
periodically and record maintained.
·Vehicle not to be left unattended at site (ie,to be
switch off mode if required and keys removed)
• Operators and rigger must wear reflecting vest and
adequate PPE ( Shoe, helmet, leather gloves,
goggles, over all )
·Vehicle routes kept free of obstructions (with
spillages being cleaned up promptly)
• Operator and rigger shall be known on the
rigging procedure.
• Adequate lighting shall be provided for the work
location.
Risks Involved Risk Rating Control Measures Residual

ACTIVITY – MECHANICAL MAINTENANCE RISK ASSESSMENT
No. (Generic & Task)
∙ Unauthorized, untrained
workers
· Material fall from height
4. Stacking and Storing • Improper stacking
• Collapse of materials
• Untrained, unauthorized
Installation of water Workers
5. expansion tanks and • Sharp edges
pressurization unit • Unsafe posture
• Slip, trip and fall
Serial Sub-Activities
No. Hazards Identified
(Generic & Task)
Project Name
Ref No:
Rev.No:0
Page 3 of 11
(People & Property) Severity Probability Initial Risk Risk
·Any reversing that is necessary should be
overseen by a trained flagman / Banks man and
reverse beeper to be fitted to all equipment’s to alert
the people around the vicinity.
· Operator should follow the site speed limit
and obey the traffic rules.
• Colour coded system to be implemented to all
lifting equipment’s as per the month.
• Close supervision to be done at all times.
• Crush · All materials shall be stored below 2 meters
· Cut and abrasion height. Low
· Damage to 3 B M · If the material is too heavy, use hydraulic (ALARP)
property trolley to shift the material.
• No materials shall be stored at work place, only
required quantity to be taken for the job.
• Personnel protective equipment must be worn at all
time during the activity. (Helmet, shoe, vest, coverall,
gloves, goggles, mask.)
· Authorized personnel to undertake the job
∙Work location shall be inspected by
concerned supervisor / foreman.
• Cut and abrasion • Close supervision to be done at all times
• Back Injuries • Materials shall not be kept in walkways and to Low
• Fatigue 3 C M the edges. (ALARP)
• Musculoskeletal · Deploy enough number of personnel for
Injuries material lifting shall be appointed to the task
depending upon the distance.
Risk Rating
Risks Involved Residual
Control Measures
(People & Property) Severity Probability Initial Risk Risk
 Project Name

Ref No:
ACTIVITY – MECHANICAL MAINTENANCE RISK ASSESSMENT Rev.No:0
Page 4 of 11
• Proper communication to be maintained
between the workers while doing the
installation
• Maintain a good housekeeping to prevent from slip,
trip, and fall hazards.
• Emergency procedure shall be briefed to all
personnel prior to start the activity.
• Emergency evacuation plan shall be readily
available according to site condition and briefed to the
workforce prior to start.
• Trained first aider, fire warden and emergency
vehicle to be available at the site during the activity.
• Emergency contact numbers shall be displayed at
work location for easy communication
• PPE to be worn at all times( Gloves, goggles,
mask, helmet, shoe, vest, overall)
• Defective tools should not be issued or used
to perform the task, to be checked by store
keeper
• Slip, trip and fall • Don’t extend the spanner by using a pipe as
Use of Hand tools ( Hack • Damaged / worn out hand • Fatigue an extension bar Low
6. saw, torch wrench, tools • Trigger finger 3 C M •Hand tools shall be free from oil, grease & etc. (ALARP)
hammer ) • Flying objects • Cuts and abrasions • Chisel’s head shall have safety cap to avoid
∙ Mushroom Heads finger injury.
• Using incorrect type • Never use a file as a lever
• Never use a screw driver as a chisel
• Use eye/ face protection when there is flying
materials hazard, wear gloves while required to
protect the hands
• Use right tools for the job

Serial Sub-Activities Risks Involved Risk Rating

No. Hazards Identified Residual
(People & Property) Control Measures
(Generic & Task) Severity Probability Initial Risk Risk

ACTIVITY – MECHANICAL MAINTENANCE RISK ASSESSMENT
• Defective equipment
 Electricity
7. Use of power tools  Improper use of equipment
(Grinder, Pipe cutter, drill  Poor maintenance
)  Untrained workers
 Flying object
 Noise and vibration
 Fire
 Dust
Serial Sub-Activities
No. Hazards Identified
(Generic & Task)
Project Name
Ref No:
Rev.No:0
Page 5 of 11
 Hearing losses
 Eye injury • PTW shall be applied and obtained prior to start, If
 Crushing spark producing activity is performed
 Back injury · Defective tools should not be issued or used to M
 Burns 3 C M perform a task. (ALARP)
 Electrocution • Operators must be having their training card.
• Monthly inspection should be carried out by the
 Ringing in the
electrician and record to be kept at the store
ear / Deafness
· All portable power tools should be fitted with
adequate fuse protection either in the tool body or in
its electrical plug.
· The weight, size and type of tool should be selected
to suit the job being carried out.
• Don’t lay the cables around the access way, it
should be routed properly.
• Industrial distribution board and socket only shall be
used at site.
• No joints shall be made in electrical cable.
• Cable hangers shall be used to avoid the
direct contact of power tools cable with the
scaffolding members.
• Electrical connection shall be routed through
ELCB only ( Eg. 30ma )
· Tools should be stored and maintained in good
working condition.
· Appropriate PPE Should be use ( Goggles, Mask,
Ear plug, Gloves, Shoe, Helmet, Overall, Vest )
Risk Rating
Risks Involved Residual
Control Measures
(People & Property) Severity Probability Initial Risk Risk
 Project Name

Ref No:
ACTIVITY – MECHANICAL MAINTENANCE RISK ASSESSMENT Rev.No:0
Page 6 of 11
·Defective Machine
·Improper use of Machine • Cuts • Polythene sheets shall be laid and drip trays to be
·Poor maintenance • Crush placed below the machine to prevent spillages. M
·Untrained, Unauthorized • Skin Effect 3 C M • Defective machine should not be used to (ALARP)
Operating with Thread
8. Workers • Entanglement perform the task.
Machine • Slip, trip and fall • Eye, finger injury • Only those persons who have been adequately
• Spillage • Fracture trained and experienced in the use of the
machine should be allowed to use the same.
• Machine should be maintained in good working
condition.
• All spillages must be cleaned immediately
• Waste oil should be disposed in an approved
manner.
• Operator should check the machine condition
prior to start the work.
• Adequate lighting and ventilation shall be
provided.
• Fire extinguisher shall be provided
• Area shall be barricaded and provide signage.
· Appropriate PPE Should be use ( Goggles, Mask,
Ear plug, Gloves, Shoe, Helmet, Overall, Vest )
• PTW to be applied and obtained prior to start,
If spark producing activity is performed
• Fire •Electric Shock • Certified person only undertake the welding job
• Untrained, Unauthorized •Burns • All Flammable /combustible materials should Low
9. Welding/ brazing work Worker •Skin Effect 4 C H be removed from the area where welding & gas (ALARP)
• Improper lighting •Eye Injury cutting operations are carried out.
• Inadequate ventilation •Property damage • Fire blankets should be used to contain sparks
and molten metal’s within the floor and should
not be allowed to fall from height.

Serial Sub-Activities Risk Rating

No. Hazards Identified Risks Involved Residual
Control Measures
(Generic & Task) (People & Property) Severity Probability Initial Risk Risk
 Project Name

Ref No:
ACTIVITY – MECHANICAL MAINTENANCE RISK ASSESSMENT Rev.No:0
Page 7 of 11
• Warning signs and boards should be provided
And area to be well barricaded
• Adequate lighting and ventilation to be
Provided.
• Close supervision to be done at all times.
•Flash back arrestor to be installed for the cylinder
•Empty cylinder to be identified and stored separately.
•Fire extinguishers to be made available.
• Gauges of cylinders to be functional to ensure the
pressure variation inside the cylinder.
• Hoses should be of approved type and should
be free and hose checklist to be maintained.
∙Area to be restricted to unauthorized personnel.
• Calibrated gauges only to be used.
·Appropriate PPE Should use ( Face shield, Dust
mask, Goggles, Gloves, Shoe, Helmet, Overall,
Vest )

• The ladder should extend minimum one meter

from the top for safe movement
• Do not erect in slippery, uneven surface
• Person/ material falling from • Sprain and strain • Should be set up with a 4 vertical to 1 Low
height • Fracture 3 C M horizontal slope ( 4:1 ) (ALARP)
10. Use of ladder • Over reaching • Injury to the • Inspection and maintenance shall be carried out
• Over loading person and recorded by the store keeper
• Obstructing the access way • Step ladder must fully open and lock the
• Slippery or uneven surface devices as per manufacturer recommendations.
• Defective ladder should not be used and report
it immediately.

Serial Sub-Activities Risk Rating

No. Hazards Identified Risks Involved Residual
Control Measures
(Generic & Task) (People & Property) Severity Probability Initial Risk Risk
 Project Name

ACTIVITY – MECHANICAL MAINTENANCE RISK ASSESSMENT
• Uneven surface
• Overhead structure and cable
• Materials and worker fall
Working on mobile from height
11. scaffold • Untrained, unauthorized
Workers
• Collapse of scaffold
Ref No:
Rev.No:0
Page 8 of 11
• Do not work from the top of two rungs of step
ladders.
• Remember the 3 point contact.
• Do not work in front of the door. If work is
carried out then locked the door or blocked off
• Ladder shall be used for short duration works
Only limited to 15 min.
• Colour code system shall be implemented.
• Do not stack materials on to the scaffold.
• Visual inspection should be carried out before use
• Sprain and strain (i.e., hand rails, toe board, on the platform and any
• Fracture opening are there). Low
• Spinal cord damage 3 C M • Out rigger shall be fitted and breaks are locked (ALARP)
• Musculoskeletal on.
Injury • Only trained scaffolders shall be involved in
• Fatality erection & dismantling activities.
• No person to be on the scaffold while it is
being moved.
• Safety harness shall be used above 2mtr height and
anchored in above shoulder height at all time
• Tagging system shall be implemented ( i.e., all safe
scaffolds shall be provided with green tags and unsafe
scaffolds with red tag )
• Keep walkways free of obstacles, tools and
equipment.
• Work at height is restricted during adverse weather
condition.
• Adequate lighting shall be provided while
working at night.
• Never stand and sit on the hand rails
• Mobile scaffold height should be restricted to
3.5 to 4 times the shortest base width, If height
of scaffold exceeds raker support or it should be
tied to the structure properly.

Serial Sub-Activities Risk Rating

No. Hazards Identified Risks Involved Residual
Control Measures
(Generic & Task) (People & Property) Severity Probability Initial Risk Risk
 Project Name

Ref No:
ACTIVITY – MECHANICAL MAINTENANCE RISK ASSESSMENT Rev.No:0
Page 9 of 11
• Unauthorized/ • Openings in the roof must be securely covered
Untrained workers • Fatality or guarded.
• Slip, trip and fall • Fracture 4 B M • Keep walkways free of obstacles, tools and Low
12. Working on roofs • Material Fall from • Sprain and strain Equipment (ALARP)
height • Covering or guarding may be removed to allow
• Abnormal weather the passage of men or material, it must be
replaced immediately after that operation.
• Barricade the ground level area of work and
post warning signs.
• Wet, windy or hot weather can seriously affect
your safety during roofing works, ask if in
doubt and do not work in that abnormal
weather condition
• High visibility vest to be worn at all times
while work on roof.
· Work notification shall be applied and
obtained prior to start the night work from Low
∙ Poor illumination ∙ Fatality 3 B M main contractor. (ALARP)
13. While working at night · Slip/trip/fall • Cuts · Sufficient illumination shall be provided.
shift · Light post shall be secured to avoid fall.
· Proper cable management system shall be
followed
· All materials shall be staged in proper
manner without obstacles

· Drink plenty of water

∙ Dehydration ∙ Employees shall be trained about heat
14. Working in hot weather ∙ Heat Stress · Sunburn stress symptoms & first aid measures. Low
· Skin Cancer 2 B M · Avoid highly physical tasks during the hottest (ALARP)
time of the day.

Serial Sub-Activities Risk Rating

No. Hazards Identified Risks Involved Residual
Control Measures
(Generic & Task) (People & Property) Severity Probability Initial Risk Risk
 Project Name

Ref No:
ACTIVITY – MECHANICAL MAINTENANCE RISK ASSESSMENT Rev.No:0
Page 10 of 11
· Isotonic drinks shall be provided.
• Provide sufficient rest breaks based on the
humidity & temperature conditions.
• Heat stress management plan shall be
developed and implemented during the
activity.
· General housekeeping, Remove all surplus and
· Poor housekeeping unwanted waste materials from the work place. Low
15. Work Completion · Slip/trip/fall · Fire 2 A L · All necessary precautions will be adopted to (ALARP)
prevent fire

RISK MATRIX
Probability
 Project Name

Ref No:
ACTIVITY – MECHANICAL MAINTENANCE RISK ASSESSMENT Rev.No:0
Page 11 of 11
A B C D E
Severity

Improbable Remote Occasional

Probable Frequent
People Assets Environment Reputation 1 in 100,000 1 in 10,000 1 in 1000
1 in 100 years 1 in 10 years
Years Years years

5-Catatrophic Multiple
fatalities or Extensive
Massive effect International impact
permanent total damage
disabilities
Single
fatalities or Major
4-Severe
permanent total damage
Major effect National impact High Risk
disabilities

Major injury or Local Considerable

Medium Risk
3-critical Localised effect
health effects damage impact (ALARP)
Minor
Minor
2-Marginal injury or health Minor effect Minor impact
damage
effects
Slight injury or Slight
1-Negligble
health effects Damage
Slight effect Slight impact Low Risk

3-E
HIGH 4-C,D,E
5-B,C,D,E
1-D,E
2-B,C,D,E
3-A,B,C,D
MEDIUM 4-A,B
5-A
LOW 1-A,B,C
2A