Date: 04/03/15 Revision No.

: 00
Issued by: VS Page No.: Page 1 of 7
Work Instruction Material Handling ( Manual & Mechanical ) Ref No.:

Work Instruction on
Material Handling ( Manual & Mechanical)
1.0 Purpose:
The purpose of this Work Instruction is to provide a safe process of manual and mechanical
material handling including the identifying and controlling of risk associated with these activities
at Construction Sites and associated offices, stores, etc. This work instruction will help to
ensure that all manual and mechanical material handling activities should be carried out in safe
manner to prevent any incident occurrence at site and to provide a safe & healthy work
environment at all time.

2.0 Scope:
The scope of this work instruction covers the guideline and requirement for manual and
mechanical material handling, includes safety tips / techniques for manual handling,
mechanical handling, storage of material and site housekeeping.

Before commencing this activity site execution team is recommended to evaluate the
foreseeable risk by conducting risk assessment of the particular activity so as to prevent any
harm to the engaged team

3.0 Roles & Responsibility:

GPL Project Manager is responsible for adherence to the work instructions through PMC &
responsible contractors. And the respective Contractor is responsible to transmit this work
instruction to their sub-contractors and ensure that the contents are clearly understood by them.
In case of not adherence to work instructions and non-performance by Contractor, the GPL
Project Manager has the right to get this done by other contractor and back charge the same to
defaulting contractors.

4.0 Definitions/Abbreviations:

Manual Handling: An activity requiring the use of force exerted by a person to lift, lower, push,
carry or otherwise move, hold or restrain an object.

Abbreviations:
 BOCW: The Building & Other Construction Workers (Regulation of Emp & Conditions of
Service) Act, 1996 and Rules 1998.
 HIRA: Hazard Identification & Risk Assessment
 PMC: Project Management Consultant
 PPE: Personal protective equipment

5.0 Legal:
 The Building & Other Construction Workers (Regulation of Emp& Conditions of Service)
Act, 1996
 The Building & Other Construction Workers (Regulation of Emp& Conditions of Service)
Central Rules, 1998.

Prepared by: RM Reviewed by: VS Approved by: JP

 Date: 04/03/15 Revision No.: 00
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Work Instruction Material Handling ( Manual & Mechanical ) Ref No.:

6.0 Guideline for Manual and mechanical material handling: Manual materials handling
involves the handling, moving, lifting, and carrying of materials without the use of mechanical
equipment. Minimizing injuries that occur from materials handling requires planning about
these tasks. Following points must be taken into consideration while doing the manual and
mechanical material handling work,
i. Ensure that the workers engaged for manual material handling operation must be trained for
manual material handling techniques and should be carried out under experienced
supervision.
ii. Ensure that the lifting, carrying or moving of material, articles or things does not endanger
the safety of nearby and other workers.
iii. Before lifting or shifting, size up the load first. If it is too big in size, ask for help of others.
iv. Take a round, inspect and look of work / nearest area before lifting and check whether it is
slippery, has oil spillage, anything that can cause loss of balance.
v. Provide and ensure use of correct type of hand gloves (Scratch Proof Hand Gloves /
Leather Hand Gloves) as per requirement. Also ensure safety shoes, goggles (white glass)
and safety helmet with chin strip.
vi. Basic tips for manual material handling :
o Position the feet correctly while lifting the load. Space the legs apart from the hip with
one foot by the side of load & ahead of other foot in the direction of movement.
o The back needs to keep straight, not necessary vertical. It may at the same time be
inclined from hip as lifting posture may need.
o Arm should be closed to body. Grip the load correctly using roots of fingers & palm.
o Head should be slightly raised before lifting.
o Raise the body with leg muscles, the movement should not be jerky.
o While keeping load down, follow same procedure.
o While keeping load down, ensure that hand & fingers will not get pinched.
vii. Do not allow to stack material at high level, failure to this causes fatigue & serious strain.
Always use platform to stand on it to stack material at high level and ensure that material
should be stack only up to chest height.
viii. Do not carry load in such a manner that it obstruct the vision.
ix. Do not stand by holding heavy load in hand, if it is not avoidable, put down on the bench /
platform of suitable height. If bench is not / platform is not there, put it down on the ground
by using right method.
x. While moving load from one table / platform to other, do not twist the body but turn it
completely.
xi. While carry out material handling by using lifting machine, ensure that all banksman /
slingers should be trained.
xii. Check physical condition of all lifting tackles (chain sling, D shackles, nylon sling, and wire
rope sling) before use. All lifting tackles must be get tested by authorized competent person
in Form No. 11 once in a 6 month as per GPL guideline. Keep record of it.
xiii. All lifting machine whether it is own or hired from third party, shall be check for its physical
condition before use & ensure that testing of same shall be done by authorized competent
person. Test certificate must available in the lifting machine with operator.

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xiv. Ensure that operator engaged for lifting operation must be trained, experienced and valid
licenses holder.
xv. Safe Working Load must be mark on the lifting tackles & lifting Machine with colour coding
as per the respective company standards.
xvi. Angle between two slings should be maintaining as per the length & weight of material to be
lifted.
xvii. While using nylon sling / chain sling, use packing material to protect from sharp points /
edges of material.
xviii. Load should be landed on the suitable sleepers (wooden boards / sleepers) to avoid
damage of lifting tackles.
xix. Never tie knot to chain sling or nylon sling to shorten them.
xx. Make sure that right pin is used in all D shackles & that they are properly screwed.
xxi. All hooks of lifting machine or lifting tackles should have safety hook latch lock to avoid
displacement of sling due to jerk or uneven movement of lifted material.
xxii. Always see that crane hook is centrally placed over the load (c. g. of the load) to prevent
swinging when load is being lifted.
xxiii. Take your hand away from chain, rope before lifting the load & stand clear to avoid pinch of
finger or hand between the sling & material.
xxiv. While giving signaling to the lifting machine, stand where you can see the load and operator
and vice - versa.
xxv. Ensure that only trained signal man shall be allowed for signaling and giving direction to the
operator.
xxvi. Use PPE like safety helmet, safety shoes, scratch proof hand gloves and safety harness.
xxvii. Hold the load after lifting by tag line (nylon rope) of sufficient length to avoid uneven
movement of material.
xxviii. When lifting machine is in operation, do not leave the area unless you have been relieved by
a trained signalman.
xxix. Do not ride on the load. Do not use lifting tackles for the other purpose like use of nylon sling
as a rope to hold the lifted material.
xxx. After completion of job, keep all lifting tackle in store with proper arrangement.
xxxi. If you found that some of the lifting tackles available at site are got damage or unsafe during
testing of it, immediately remove and make it as scrap permanently.
xxxii. Tool Box Talk must conduct before start the work

6.1 Manual Handling: Most of the operation in construction industry depends on manual material
handling, which involves lifting, shifting, or moving of material from one place to other.
Each handling task poses unique demands on the worker. However, workplaces can help
workers to perform these tasks safely and easily by implementing and adhering proper manual
handling techniques and procedures.
Following safety tips / techniques need to be considering for manual material handling.
i. As for as possible, mechanical lifting equipment shall be used in place of manual handling.
ii. No employee shall be asked to carry loads above his capacity and in any case no load shall
exceed 50kg.

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Work Instruction Material Handling ( Manual & Mechanical ) Ref No.:

iii. Lifting an object from the ground is more stressful than lifting the same object from several
inches off the ground. When possible, store objects on platforms (i.e., sleepers, shelves or
pallets) that raise them off the ground. Starting positions that are at a level between the knee and
waist are the least stressful to the back.
iv. Balance the load when possible. For example, if carrying handled containers (paint cans, etc.),
carry one in each hand. If carrying or lifting a box, try to distribute the weight of the items
evenly over the whole box (don’t allow one side to be noticeably heavier than the other). Avoid
carrying stacked items that can slip off and/or unbalance the load.
v. Ensure that the load does not obstruct your vision and that should be secure, so that it will not
shift during transport.
vi. Test the weight of the load by tipping or moving it slightly before you pick it up.
vii. Face the load squarely, keep back straight, and use legs to lift. Feet should be about shoulder
width apart to provide a stable stance. Avoid awkward body positions in picking
up/carrying/setting down items.
viii. Avoid stretching/bending while lifting.
ix. Never lift and twist. This action is hard on the back. Move your feet to reposition your direction.
x. Avoid awkward body positions in picking up/carrying/setting down items
xi. The load should be lifted and carried as close to the body as possible. When the load is not
carried closely, the body is positioned out of alignment and more strain is put on the lower back.
xii. Bring the object to the edge of the platform, shelf or pallet in preparation for the lift. Do not
reach over other objects.
xiii. If you become tired, put the load down and rest briefly. If the load begins to shift, put the load
down, reposition and secure contents, resume.
xiv. Plan the placement/delivery. Once the object reaches its final destination, be sure to set it down
in the same manner of lifting it: do not bend at the waist, keep the object close to body, and
maintain a wide posture.
xv. To prevent overemployment injuries, pay attention to pain, numbness and/or uncomfortable and
take action to prevent further strain or injury.
xvi. Change the routine: do not repeat the same activity over and over, but alternate it with other
activities. In some situations, equipment or tools are available that will reduce physical stress.
xvii. Material required to be lifted, carried or moved, shall be lifted, carried or moved in such a way
and with such precautions and safeguards that the lifting, carrying or moving of the material
does not endanger the safety of any worker and property.
xviii. Material shall be transported, placed or stored so that the material,:
a. will not tip, collapse or fall
b. can be removed or withdrawn without endangering the safety of any worker
xix. Material to be removed from a storage area, pile or rack, shall be removed in a manner that
will not endanger the safety of any worker
xx. Reduce the distance over which the load has to be moved by relocating workplace and
storage areas near to each other or vice-versa. Design work place or stations so that
workers:
a. can store and handle all material between ankle and shoulder height; waist height is
most desirable
b. can begin and end handling material at the same height
c. can face the load and handle materials as close to the body as possible
d. do not have to handle loads using awkward postures or an extended reach, and
e. do not handle loads in confined spaces that prevent them from using good body
mechanics

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xxi. The best control measure is to eliminate the need for workers to perform manual handling
tasks. Since this is not always possible, design manual handling tasks so that they are
within the workers’ capabilities. Considerations include the load itself, the design of the
workstation and work practices. Providing mechanical handling devices or aids can often
eliminate the task itself or wellbeing the demands on the worker.
xxii. Reduce the weight of the load by
decreasing the size of the object (specify
size to suppliers), weight of the container
(e.g., plastic is lighter than steel), capacity
of containers, load in the container.
xxiii. Steps to follow:
 Establish good footing;
 Place feet about shoulder width apart;
 Bend at the knees to grasp the weight;
 Keep the back straight;
 Get a firm hold;
 Lift gradually by straightening the legs;
 When the weight is too heavy or bulky to
lift comfortably, get help;
 Take small steps, keeping the load close to
your body and no more than waist high;
 Do not twist your body, move your feet to
turn; and
 When putting down, reverse this
procedure.

6.2 Mechanical Handling: Mechanical lifting and handling equipment must be selected
considered with the size of material, weight of material, capacity of lifting accessories,
distance travel and topography of the area around the site.
I. Before carrying out heavy erections such as motors, panels, chillers, AHUs etc., a detailed
method statement is prepared and a risk assessment is carried out.
II. All lifting appliances like slings, chain pulley blocks etc. brought to the site will be provided
with a test certificate from approved third party (Competent Person).
III. Ensure that the hired crane deployed is suitable to the purpose of the job and is safe to use.
IV. While transporting materials in vehicles, it will be ensured that undue projections from the
vehicles will not be allowed. If there is any projection, the person responsible for the loading
operation shall ensure that either red flag or red lamp is tied to the projections to warn the
vehicles coming behind.
V. Keep the center of gravity of the load as low as possible. Place heavy objects on the bottom
of the load. Keep feet clear of the wheels.
VI. Load should be placed in such a way that so it will not slip, shift, or fall. Load only to a
height that will allow a clear view ahead.
VII. Trained and licensed operators/drivers will only be allowed to operate lifting machinery.
VIII. All technicians will be instructed on the correct and safe way to operate lifting machinery
6.3 Storage of Material.
i. All material stored in tiers shall be stacked, racked, blocked or otherwise secured to prevent
sliding, falling or collapse. Material will not be stored direct on the ground or on concrete floors.

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ii. Material delivery and storage areas should have enough space and lighting to allow for the
safe movement of the materials.
iii. The ground conditions of storage and lay down areas should be even and compacted.
iv. Ensure the work area is flat level ground, i.e. make sure the slab area has a flat, compacted
graded area around it to accommodate materials such as brick packs.
v. Ensure the materials are stored in a manner that does not present hazards to other workers
or the publics.
vi. Keep all construction and associated materials out of reach of fall zone, at least two meter
away from the edges.
vii. Aisles and passageways shall be kept clear to provide for the free and safe movement of material
handling equipment or employees such areas shall be kept in good repair.
viii. Minimum required materials will only be supplied to site and it will be temporary.
ix. Method statement will be provided if materials are stocked at site for long duration.
x. The manufacturer’s recommendations will be followed with respect to temperature and humidity
requirements, and stacking.
xi. Material stored inside buildings under construction shall not be placed within 3 meters of an
exterior wall, which does not extend above the top of the material stores. Compressed gas
cylinders will be stored upright.
xii. Stacks of cylindrical objects such as pipes and cable drums will be stabilized using chocks or
wedges.
xiii. Material stack will be limited in height to ensure stability; heights of more than 2m will be
avoided unless specifically authorized by the project Manager.
xiv.Drums and containers will be marked clearly to indicate contents.
xv. Secure storage will be provided for all hazardous substances, to prevent access by unauthorized
persons.
xvi.Stockpiles and storage areas will be inspected regularly to ensure stability and to ensure that the
above physical precautions are in place. Verbal instructions and training will be given to
operatives as necessary to ensure good housekeeping standards are maintained on site.

6.4 Site 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. Well maintained
site makes the job easier and safe. Ensure the following
i. The site must be kept in as tidy a condition as possible.
ii. Remove the broken bricks form the place as it effects their own and others safety and also
have a tendency to tripping hazards on their own and others.
iii. Tidy up all construction waste with segregation of its type into one area (neat piles) at the
end of each day.
iv. Ensure all wind-blown material to be placed and secured in the designated area / bin
provided at site.
v. Routine, regular clean-ups, housekeeping should be scheduled as part of the workday.
vi. Fallow the HK WI and checklist.

7.0 Emergency Procedures and Details of Site Features:

 A pre start job meeting shall be arranged for informing about proper communication method.
 Arrangement of first aid facilities and emergency vehicles shall be ensured.
 Contractor should inform to PMC/ GPL for commencement of work.

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 In condition as where work affecting by natural calamities like heavy rain, dusty
environment, thunderstorm, etc PMC/ GPL guidelines shall be followed.

8.0 Risk Assessment

Before commencing this activity the Safety Engineer of Contractor should evaluate the
foreseeable risk by conducting independent risk assessment in consultation with site execution
team as per site condition & topography to ensure that appropriate control measures are
established and incorporated. GPL /PMC Safety Engineer are responsible to review & approve
the same.
Use SOP on HIRA and standard HIRA record template available with HO-Safety
9.0 Checklist:

The site team is responsible to prepare a suitable checklist on “Manual & Mechanical Material
Handling” based on the above procedure and HIRA conducted at site and also keeping in view
the site location topography.

10.0 References:
i. Contract Document
ii. GPL HSE Guideline
iii. Site EHS Plan
iv. BOCW Act & Rules

Prepared by: RM Reviewed by: VS Approved by: JP