Loading and Unloading Plant and Machinery Risk Assessment

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This risk assessment covers the loading, unloading, positioning, securing, and movement of plant and machinery during delivery, collection, transfer within site, and placement for use or storage. It includes the use of lifting equipment, slings, attachments, forklifts, telehandlers, cranes, winches, ramps, and manual handling associated with these activities. The assessment applies to employees, contractors, delivery drivers, banksmen/signallers, lifting equipment operators, and any other persons who may be affected by the operation. It includes traffic management, exclusion zones, stability of loads and plant, operator competence, PPE selection, and emergency arrangements. Exclusions: routine operation of the plant once installed, maintenance activities not directly associated with loading/unloading, and specialist lifting plans for abnormal or complex lifts unless separately authorised. [4] [3]

2. Risk Assessment Methodology

A task-based risk assessment approach has been used, supported by a 5x5 risk matrix and the hierarchy of controls. The work has been broken into key stages: arrival and site entry, preparation of the unloading area, lifting and transfer, positioning and securing, and departure/housekeeping. Hazards were identified for each stage, initial risk was rated using consistent likelihood and severity scales, and controls were selected in order of preference: elimination, substitution, engineering controls, administrative controls, and PPE. Residual risk was then reassessed after controls were applied. This approach aligns with the principle that hazards should be controlled first by engineering, work practice, and administrative measures before relying on PPE, and that PPE must be selected based on a documented hazard assessment. [5] [2] [7]

3. Risk Matrix Reference

The following matrix is used to evaluate risk levels based on likelihood and severity:

		Likelihood
Rare	Unlikely	Possible	Likely	Almost Certain
Severity	Catastrophic	Low	Low	Low	Low	Medium
Major	Low	Low	Medium	Medium	High
Moderate	Low	Medium	Medium	High	High
Minor	Medium	Medium	High	High	Extreme
Negligible	Medium	High	High	Extreme	Extreme

4. Hazard Identification and Risk Evaluation

1. Struck-by or crushed-by incidents during vehicle arrival, reversing, unloading, and plant movement in shared work areas.

Potential Consequences: Serious injury or fatality from being struck by moving vehicles or trapped between plant, structures, and pedestrians. Damage to equipment and disruption to operations may also occur. [5] [8]

Affected Persons: Operators, banksmen, delivery drivers, site workers, visitors, and any pedestrians in the vicinity.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate pedestrian and vehicle interface where practicable by using a segregated unloading area away from general traffic routes.
• Use engineering controls such as physical barriers, cones, gates, wheel stops, and marked one-way traffic routes to separate vehicles from pedestrians.
• Use a trained banksman/signaller to control reversing and manoeuvring, with clear radio or hand-signal communication.
• Implement a traffic management plan covering arrival times, speed limits, reversing controls, and designated exclusion areas.
• Require high-visibility PPE and safety footwear for all persons entering the unloading zone.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Catastrophic	High

2. Failure of lifting equipment, lifting accessories, or attachments during lifting operations.

Potential Consequences: Dropped loads, collapse of lifting gear, severe crush injuries, amputations, or fatality. Secondary damage may occur to nearby structures, vehicles, and plant. [7] [2]

Affected Persons: Lifting equipment operators, slingers/signallers, nearby workers, delivery personnel, and anyone within the lift radius.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Use only suitable lifting equipment and accessories that are selected for the load, inspected, and maintained in serviceable condition.
• Ensure lifting operations are planned by a competent person and carried out in accordance with an approved lift plan where required.
• Verify safe working load, load centre, attachment points, and lifting angles before the lift begins.
• Remove defective equipment from service immediately and quarantine it to prevent reuse.
• Establish and enforce an exclusion zone beneath and around suspended loads.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Catastrophic	High

3. Instability or overturning of plant, machinery, or loads during unloading, positioning, or on ramps and uneven ground.

Potential Consequences: Plant may tip, slide, or roll, causing crush injuries, impact injuries, structural damage, and loss of control of the load.

Affected Persons: Operators, banksmen, riggers, nearby workers, and members of the public if the site is not secured.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Prepare a level, firm, and adequately compacted unloading surface before operations begin.
• Use chocks, stabilisers, outriggers, and securing devices as required by the equipment and manufacturer instructions.
• Assess ground bearing capacity, slope, weather effects, and the suitability of ramps before moving plant.
• Follow manufacturer guidance and safe operating limits for gradients, centre of gravity, and tie-down points.
• Stop work if stability cannot be assured and seek an alternative method or location.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

4. Contact with overhead services, structures, or obstructions during lifting or movement of tall plant and machinery.

Potential Consequences: Electrocution, collision damage, falling loads, structural impact, and serious injury or fatality.

Affected Persons: Operators, banksmen, riggers, delivery drivers, and nearby workers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Catastrophic	High

Control Measures

• Survey the route and unloading area in advance to identify overhead power lines, building projections, lighting columns, and other obstructions.
• Use exclusion distances and physical markers to prevent plant entering unsafe areas.
• Where necessary, isolate or reroute services before work starts, or use an alternative unloading method.
• Appoint a competent banksman to maintain clearance and stop the operation if safe separation is lost.
• Use height-limiting devices or route controls where appropriate.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Catastrophic	High

5. Manual handling of chains, slings, dunnage, securing devices, and smaller components during loading and unloading.

Potential Consequences: Sprains, strains, back injuries, hand injuries, and dropped objects causing foot injuries or impact injuries.

Affected Persons: Operators, riggers, slingers, delivery drivers, and site workers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Eliminate unnecessary manual handling by using mechanical aids such as forklifts, hoists, pallet trucks, or lifting beams.
• Break down loads where practicable and use team lifts for awkward or heavy items.
• Store lifting accessories close to the point of use to reduce carrying distance.
• Provide manual handling instruction on posture, grip, load assessment, and communication.
• Require suitable gloves and safety footwear when handling sharp, heavy, or awkward items.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

6. Pinch points, entanglement, and crush hazards when attaching, detaching, or adjusting lifting gear and securing devices.

Potential Consequences: Finger injuries, hand crush injuries, lacerations, and entrapment between moving or settling components.

Affected Persons: Slingers, operators, fitters, and anyone assisting with the lift.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Use tools and positioning aids to keep hands clear of pinch points wherever possible.
• Apply a clear communication system so the operator does not move the load until all personnel are clear.
• Use purpose-designed lifting points and attachments to reduce the need for manual adjustment.
• Train workers to keep hands out of line of fire and to never place body parts under suspended or unstable loads.
• Wear suitable gloves that provide grip and limited protection without creating entanglement risk.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

7. Poor operator competence, inadequate supervision, or unsafe communication during lifting and transport activities.

Potential Consequences: Incorrect lifting, collision, dropped loads, equipment damage, and serious injury to workers or bystanders.

Affected Persons: Operators, banksmen, supervisors, delivery drivers, and nearby workers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Allow only competent, authorised personnel to operate lifting and transport equipment.
• Verify training, familiarisation, and any required certification before work starts.
• Use a single designated person to direct the lift and ensure all signals are understood.
• Conduct a pre-task briefing covering roles, sequence, hazards, emergency stop arrangements, and exclusion zones.
• Stop the task if communication is unclear or if an unsafe instruction is given.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

8. Slips, trips, and falls caused by poor housekeeping, uneven surfaces, debris, spilled fluids, or poor lighting.

Potential Consequences: Sprains, fractures, impact injuries, and secondary incidents such as dropped loads or loss of balance near moving plant.

Affected Persons: All personnel in the loading/unloading area, including visitors and drivers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Keep the unloading area clear of debris, packaging, loose straps, and spillages.
• Provide adequate lighting for early morning, evening, or indoor operations.
• Maintain level walking routes and repair or isolate damaged surfaces.
• Use designated pedestrian routes and keep them separate from vehicle paths.
• Require slip-resistant safety footwear.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

9. Adverse weather conditions affecting lifting, visibility, ground conditions, and load control.

Potential Consequences: Loss of control of suspended loads, reduced braking and traction, instability, and increased risk of collision or overturning.

Affected Persons: Operators, banksmen, drivers, and nearby workers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Suspend or modify operations during high winds, heavy rain, ice, lightning, or poor visibility where safe control cannot be maintained.
• Inspect ground conditions before work and after significant weather changes.
• Use weather thresholds and stop-work criteria for lifting operations.
• Provide weather-appropriate PPE and ensure visibility aids remain effective in wet or dark conditions.
• Reassess the task if conditions change during the operation.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

5. General Control Measures

• Implement a documented safe system of work for all loading and unloading activities.

The safe system should define the sequence of work, roles and responsibilities, communication methods, exclusion zones, stop-work authority, and the controls required before any lift or movement begins.

• Maintain a site-specific traffic management plan.

Separate pedestrians and vehicles, control reversing, define delivery routes, and use signage, barriers, and banksmen where needed to manage interaction between plant, machinery, and people.

• Ensure all lifting equipment, accessories, and plant are suitable, inspected, and maintained.

Use pre-use checks, periodic inspections, and removal-from-service procedures for defective items. Confirm that equipment is appropriate for the load and task before use.

• Establish and enforce exclusion zones around lifting and unloading operations.

No person should stand under suspended loads or enter the lift radius unless specifically authorised and protected by the task plan.

• Provide and enforce suitable PPE based on the hazard assessment.

PPE should supplement, not replace, higher-level controls. Typical PPE may include safety footwear, high-visibility clothing, gloves, eye protection, and head protection where required by the task and site conditions. [6] [9]

6. Emergency Preparedness

• Stop-work and emergency stop procedures must be understood by all personnel before the task begins. Any person may call a stop if a load becomes unstable, communication fails, or an unauthorised person enters the exclusion zone.
• If a load is dropped, shifted, or a lifting accessory fails, the area must be evacuated immediately and the lift suspended until the equipment and scene are made safe and investigated by a competent person.
• A rescue and first aid response must be available for crush injuries, entrapment, and impact injuries. Emergency access routes must remain clear for ambulances and site responders.
• If contact with overhead electrical services is suspected, the operator must remain in the cab if safe to do so, warn others to keep clear, and contact the utility provider and emergency services immediately.
• Spill response arrangements must be in place for hydraulic oil, fuel, or coolant leaks so that slip hazards and environmental contamination are controlled promptly.

7. Training Requirements

• Operator Competence and Authorisation: All operators of forklifts, telehandlers, cranes, winches, and other lifting or transport equipment must be trained, assessed as competent, and authorised for the specific equipment and task. Refresher training should be provided when equipment, methods, or site conditions change. [9] [7]
  • Task-specific familiarisation before first use.
  • Verification of competence for banksmen and slingers/signallers.
  • Supervision for inexperienced workers until competence is demonstrated.
• Lifting Operations and Slinging/Signalling Training: Personnel involved in lifting operations must understand load weights, centre of gravity, attachment points, sling angles, exclusion zones, communication signals, and the limits of lifting accessories. Training should emphasise the consequences of standing under suspended loads and the need to stop work when conditions are unsafe.
  • Pre-use inspection of lifting accessories.
  • Correct selection and use of slings, shackles, and attachments.
  • Clear hand signals or radio communication protocols.
• Traffic Management and Vehicle-Pedestrian Segregation: Workers must be trained in site traffic routes, reversing controls, pedestrian segregation, speed limits, and the role of the banksman. Training should also cover safe approach distances and how to respond to moving plant in shared areas.
  • Reversing and manoeuvring rules.
  • Pedestrian exclusion zones.
  • Delivery vehicle arrival and waiting procedures.
• Manual Handling and Load Stability Awareness: Employees who handle chains, slings, dunnage, securing devices, or smaller components must be trained to assess load weight, use mechanical aids, and recognise unstable or awkward loads. Training should include safe lifting posture and team-lift communication.
  • Use of mechanical aids where available.
  • Recognising pinch points and crush zones.
  • Reporting unstable loads or damaged packaging.
• Emergency Response and Stop-Work Authority: All relevant personnel must know the emergency stop procedure, incident reporting requirements, first aid arrangements, and evacuation routes. Workers should be empowered to stop the task immediately if a hazard escalates or controls fail.
  • Who to contact in an emergency.
  • How to isolate the area after an incident.
  • Preserving the scene for investigation where safe to do so.

8. Monitoring and Review

Review Frequency: Annually and after any incident, near miss, change in equipment, change in process, or significant change in site conditions.

Monitoring Type	Frequency	Responsible Party	Description
Pre-Use Inspection	Before each shift and before each lift	Equipment operator and lifting supervisor	Inspect lifting equipment, attachments, vehicle condition, tyres, brakes, lights, warning devices, and securing points. Remove defective equipment from service immediately and report defects before use.
Work Area Inspection	Daily and before unloading begins	Supervisor or appointed competent person	Check ground conditions, route obstructions, lighting, weather impacts, exclusion zone integrity, and housekeeping. Confirm that the unloading area remains suitable throughout the task.
Traffic Management Compliance Check	Weekly and after any layout change	Site supervisor or safety representative	Verify that pedestrian routes, barriers, signage, reversing controls, and delivery arrangements remain effective and are being followed by drivers and workers.
Lifting Operation Audit	Monthly or after any significant lift	Lifting supervisor or competent manager	Review lift plans, competence records, communication arrangements, and adherence to exclusion zones. Confirm that lessons learned from near misses and incidents are incorporated into future work.
PPE Condition and Use Check	Routine observation and monthly formal review	Supervisor	Confirm that required PPE is worn correctly, fits the user, and remains in good condition. Replace damaged or unsuitable PPE and reinforce correct use where deficiencies are observed. [1] [1]

9. Special Circumstances

• Night work or low-light operations increase the likelihood of vehicle conflicts, miscommunication, and slips or trips. Additional lighting, reflective PPE, and stricter supervision are required.
• Adverse weather such as high winds, rain, ice, snow, or lightning can significantly increase instability, visibility problems, and ground failure risk. Work should be paused or rescheduled when safe control cannot be maintained.
• Lone working is not suitable for high-risk lifting or unloading tasks. Where lone work cannot be avoided for low-risk support activities, communication checks and emergency arrangements must be in place.
• Public interface or shared-site operations require additional segregation, signage, and access control to prevent unauthorised entry into the work area.
• Abnormal loads, awkward plant geometry, or damaged equipment may require a separate lift plan, additional supervision, or specialist lifting resources before work proceeds.

Approval and Sign-off

This risk assessment has been reviewed and approved by:

Assessor: _________________________ Date: __________

Manager/Supervisor: _________________________ Date: __________

Safety Representative: _________________________ Date: __________

This risk assessment must be reviewed annually and after any incident, near miss, change in equipment, change in process, or significant change in site conditions. or when significant changes occur.

Safety powered by SALUS