Risk Assessment

Task Inventory for Industrial Express

Company Name Industrial Express
Departments

Branch Name Industrial Express

Date 2023-09-01
Prepared by Sam Wessels
Name of person approving Thandeka Khathi

List Scoring Total Score Rating Consideration

Consequence ( Severity)
1-3 = Low Risk 4-

Exposure ( probability)
People - Tasks, Equipment - Plant and Equipment,
Material Chemicals, Substances, Raw Material, Energy 11=Possible Risk 12-
TRA Document No.

14= Substantial Risk

Industrial Express

Electricity, Gas, Steam, wind etc. and the Environment

15-24=High Risk

Risk Score
Ground, Water, Air and waste.

Environmental
25=Critical
Task Rev No.
Workshop

Health

Safety

Fire
1 1 Operating a Forklift 4 4 16 High Risk
2 1 Using Hand Tools 4 4 16 High Risk
3 1 Loading or Offloading a Truck Using a Forklift 4 4 16 High Risk
4 1 Conducting Repairs and Maintenance on a Forklift 4 3 12 High Risk
5 1 Conducting Maintenance and Repairs on an Overhead Crane 4 3 12 High Risk
6 1 Operating an Overhead Crane 3 3 9 High Risk
7 1 Conducting Administrative Duties in a Office 3 2 6 High Risk

Name Signature

Customized By Sam Wessels

Approved By Thandeka Khathi

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 Risk Assessment

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 Risk Assessment

RISK ASSESSMENT and RATING FORM

Activity: Doc No. Rev No. Prepared By

Sam Wessels

Operating a Forklift 2 1

Risk Assessment Team

Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-11 Thandeka Khathi

2 Heather Mchunu

Risk Assessment Methodology Calculator

A. Severity B. Probability
Weighting Impact Effect Weighting Impact Effect
Minor cuts and bruises, small loss of containment, small/minor
perforations, punctures, lacerations, illness, sprains, strains, Has never happened in years of exposure but
1 Noticeable 1 Conceivable
muscle fatigue, cuts, dehydration, shock, 1st degree burns, is possible (Eg : 1 in 1000)
headaches, sinusitis, skin irritation
Administration of first aid care and / or equipment and / or off
site emission but no damage, minor/noticeable cuts, sprains,
Remotely
2 Important strains, electric shock, 2nd degree burns, headaches, illness, 2 A less possible coincidence (Eg : 1 in 100)
Possible
respiratory distress, property damage over R100 000, minor
environmental impact
Administration of first aid care and / or equipment and / or off
site emission but no damage, noticeable cuts, sprains, strains,
3 Serious electric shock, 2nd degree burns, respiratory distress. Loss of 3 Unusual but A more possible occurrence (Eg : 1 in 10)
time (3 days and more) Non-permanent Chronic back and possible
neck injuries, minor fractures,adverse effect on environmentor
property damage over R500 000.
Single fatality, Permanent disability / ill health , non-permanent
damage to environment, loss of limb, permanent noise
4 Very induced hearing loss, loss of sight, multiple fractures, 4 Likely Not unusual , perhaps 50/50 chance of
Serious permanent pelvic/neck/back injuries, 3rd degree burns, occurrence
permanent chronic health conditions, loss of time (14 days
and more) property damage over R1000 000
Multiple fatalities permanent local damage to environment and
eco-system, multiple severe injuries to multiple persons (3rd
5 Disaster degree burns, permanent loss of sight, hearing loss, multiple 5 Almost certain The most likely outcome if the event occurs
fractures, permanent chronic health effects, loss of limb) loss
of time (14 days and more)and property over R10 000 000

Risk Categories
Risk Category Risk Rating Remedial Activities
Critical 25 Intolerable, Implement and Monitor Control Measures, Change method and or transfer risk.
High Risk 15 - 24 Implement and Monitor Control Measures, Change Method and or Mitigate
Substantial 12 - 14 Implement and Monitor Control Measures, Change Method and or Mitigate
Risk
Possible Risk 4 - 11 Implement and Monitor Control Measures
Low Risk 1-3 Monitor

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 Risk Assessment
Assessment of the Risk Assessment of the
before Controls Risk after Controls
A B C A B C

Consequence (Severity)

Consequence (Severity)
What is the Hazards and / or

Exposure (Probability)

Exposure (Probability)
What is the Risk?
Aspect?
Risk Ass ID

Risk Score

Risk Score
Rating Rating
Electrical Hazard: Person
1 exposed to electrical wires on Person makes contact with exposed electrical wires on forklift charger 4 4 16 High Risk 4 1 4 Possible
forklift charger while operating resulting in electrical shock, 1st or 2nd degree burns, possible fatality Risk
a forklift
Biological Hazard: Person
A person exposed to a biological virus when operating a forklift resulting Substantial Possible
2 exposed to a biological virus in fever, cough, shortness of breath and possible fatality. 4 3 12 Risk 4 1 4 Risk
when operating a forklift.
Person exposed to adverse
weather conditions such as Forklift skids due to wet conditions causing forklift to cause accident Substantial Possible
3 rainy or cold conditions resulting in property damage up to R1 000 000, bumps, bruises, 4 3 12 4 1 4
Risk Risk
resulting in lung irritation, cold fractures, fatality
sores
Fire Hazard: Spilled diesel Spilled diesel, while operating a forklift, comes into contact with an Substantial Possible
4 exposed to an ignition source ignition source, causing an uncontrolled fire, resulting in property 4 3 12 4 1 4
Risk Risk
while operating a forklift damage up to R1,000,000, 1st, 2nd or 3rd degree burns
Fire Hazard: Spilled battery Spilled battery acid, while operating a forklift, comes into contact with
Substantial Possible
5 acid exposed to an ignition ignition source causing an uncontrolled fire, resulting in property 4 3 12 Risk 4 1 4 Risk
source while operating a forklift damage up to R1,000,000, 1st, 2nd or 3rd degree burns
Fire Hazard: Overheating of Forklift engine overheats while operating a forklift, causing an
Substantial Possible
6 forklift engine while operating a uncontrolled fire, resulting in property damage up to R1,000,000, 1st, 4 3 12 Risk 4 1 4 Risk
forklift 2nd or 3rd degree burns, possible multiple fatalities
Fire Hazard: Leaking gas from Leaking gas from damaged or leaking lpg tank while operating a forklift,
makes contact with ignition source, causing an uncontrolled fire or
7 damaged or leaking lpg tank 4 3 12 Substantial 4 1 4 Possible
while operating a forklift explosion, resulting in property damage up to R1,000,000, 1st, 2nd or Risk Risk
3rd degree burns, multiple fatalities
Fire Hazard: Exposed electrical Exposed electrical wiring on forklift charger, comes into contact with
wiring comes into contact with combustible materials or flammable liquids causing an uncontrolled fire,
8 4 3 12 Substantial 4 1 4 Possible
flammables while operating a resulting in property damage up to R1,000,000, 1st, 2nd or 3rd degree Risk Risk
forklift burns, possible multiple fatalities
Environmental Hazard: Spilled Spilled or leaking hydraulic fluid from hydraulic components while
9 or leaking hydraulic fluid from operating a forklift, leaks into the environment, resulting in pollution, 4 3 12 Substantial 4 1 4 Possible
hydraulic components while Risk Risk
environmental damage, legal liability and fines up to R1,000,000
operating a forklift
Environmental Hazard: Spilled Spilled or leaking diesel from diesel tank while operating a forklift, leaks
Substantial Possible
10 or leaking diesel from diesel into the environment, resulting in pollution, environmental damage, legal 4 3 12 Risk 4 1 4 Risk
tank while operating a forklift liability and fines up to R1,000,000
Environmental Hazard: Spilled Spilled or leaking battery acid from forklift battery while operating a
or leaking battery acid from Substantial Possible
11 forklift, leaks into the environment, resulting in pollution, environmental 4 3 12 4 1 4
forklift battery while operating a damage, legal liability and fines up to R1,000,000 Risk Risk
forklift
Biological Hazard: Person Person makes contact with pinch points between a boom and boom Substantial Possible
12 exposed to biological virus drive pillar while doing access control at security gate resulting in cuts, 4 3 12 Risk 4 1 4 Risk
when operating a forklift fractures, possible loss of limb
Environmental Hazard:
Person exposed to adverse weather conditions such as rainy or cold Substantial Possible
13 Adverse weather conditions conditions resulting in lung irritation, cold sores 4 3 12 Risk 4 1 4 Risk
such as rainy or cold conditions
Physical Hazard: Uncontrolled Uncontrolled action or movement of forklift while operating a forklift,
Possible Low
14 action or movement of forklift strikes a person, resulting in bruises, cuts and lacerations, fractures, 3 3 9 Risk 3 1 3 Risk
while operating a forklift possible fatality
Psychosocial Hazard: Person Person operates forklift without authorisation or irresponsibly or in
operates forklift without ignorance, while operating a forklift, resulting in person being struck by Possible Low
15 3 3 9 3 1 3
authorisation or joyrides on forklift, resulting in cuts and lacerations, fractures, possible loss of a Risk Risk
forklift while operating a forklift limb, possible impact head injuries, possible fatality, legal liability
Slip, Trip and Fall Hazard: Person trips over poorly placed forklift forks or makes contact with
16 Person exposed to poor raised forklift forks while operating a forklift, resulting in bruises, cuts 3 3 9 Possible 3 1 3 Low
placement of forklift forks while Risk Risk
and lacerations, possible fractures, possible impact head injuries
operating a forklift
Slip, Trip and Fall Hazard: Person slips and falls while climbing on or off the forklift, while accessing
Person exposed to slippery Possible Low
17 or exiting forklift, while operating a forklift, resulting in bruises, cuts and 3 3 9 3 1 3
access steps while operating a Risk Risk
lacerations, possible fractures, possible impact head injuries
forklift
Slip, Trip and Fall Hazard: Person slips and falls on slippery surface from spilled or leaking battery
18 Spilled or leaking battery acid acid while operating a forklift, resulting in bruises, cuts and lacerations, 3 3 9 Possible 3 1 3 Low
while operating a forklift possible fractures, possible impact head injuries, possible 1st or 2nd Risk Risk
degree chemical burns
Slip, Trip and Fall Hazard: Person slips and falls on slippery surface from spilled or leaking diesel Possible Low
19 Spilled or leaking diesel while while operating a forklift, resulting in bruises, cuts and lacerations, 3 3 9 Risk 3 1 3 Risk
operating a forklift possible fractures, possible impact head injuries
Physical Hazard: Person Person makes contact with sharp or rough edges of frame while
20 exposed to sharp or rough operating a forklift, while climbing on or off the forklift, resulting in 3 3 9 Possible 3 1 3 Low
edges of frame while operating bruises, cuts and lacerations Risk Risk
a forklift

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 Risk Assessment
Physical Hazard: Person Person is struck by rotating wheel while operating a forklift, resulting in 3 3 9 Possible 3 1 3 Low
exposed to rotating wheel bruises, cuts and lacerations, possible fractures, possible loss of limb Risk Risk
movement while operating a
forklift
Physical Hazard: Person Person is struck by rotating mast, resulting in bruises, cuts and
22 exposed to rotating mast lacerations, possible fractures, possible impact head injuries, possible 3 3 9 Possible 3 1 3 Low
movement while operating a Risk Risk
loss of limb
forklift
Physical Hazard: Person Persons head makes contact with forklift frame when entering or exiting Possible Low
23 exposed to possible head from forklift while operating a forklift, resulting in bruises, cuts and 3 3 9 Risk 3 1 3 Risk
injuries while operating a forklift lacerations, possible concussion
Environmental Hazard: Dust Person exposed to dust while driving forklift resulting in eye irritation, Possible Low
24 exposure during driving of 3 3 9 3 1 3
lung irritation Risk Risk
forklift
Environmental Hazard: Person Person exposed to direct sun for long periods while operating a forklift, Possible Low
25 exposed to excessive sun resulting in dehydration, heatstroke, heat exhaustion 3 3 9 Risk 3 1 3 Risk
while operating a forklift
Environmental Hazard: Person
Person struck by lightning while operating a forklift, resulting in Possible Low
26 exposed to lightning while electrocution, 2nd or 3rd degree burns, possible fatality 3 3 9 Risk 3 1 3 Risk
operating a forklift
Fire Hazard: Heat build up from Built up heat from exhaust of forklift while paper or other combustible Possible Low
27 material makes contact causing fire, resulting in 1st, 2nd, 3rd degree 3 3 9 3 1 3
exhaust of forklift Risk Risk
burns
Slip, Trip and Fall Hazard: Person slips and falls on slippery surface from spilled or leaking Possible Low
28 Spilled or leaking hydraulic hydraulic fluids while operating a forklift, resulting in bruises, cuts and 3 3 9 Risk 3 1 3 Risk
fluid while operating a forklift lacerations, possible fractures, possible impact head injuries
Physical Hazard: Movement of Unsecured stock being moved by forklift shifts and falls onto person,
29 unsecured stock items or during motion of forklift, causing person to be struck, resulting in bruises, 4 2 8 Possible 4 1 4 Possible
objects while operating a forklift cuts and lacerations, possible fractures, possible impact head injuries, Risk Risk
possible fatality
Low
Total over-all rating before and after controls 16 High Risk 3
Risk
Risk Assessment Team
Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-11 Thandeka Khathi

2 Heather Mchunu

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 Risk Assessment

Control Measures for Operating a Forklift

D) Engineering Control Load Limiting device
D) Engineering Control - Equipment Rotating Lights
E) Isolation Control - Barriers Machine Guarding
E) Isolation Control - Barriers Covers
F) Administrative Control - Appointment Letters Section 8
F) Administrative Control - Appointment Letters Lifting Machine Operator
F) Administrative Control - Appointment Letters Lifting Machine Inspector
F) Administrative Control - Appointment Letters Competent Forklift Operator
F) Administrative Control - Certificates Load Test Certificate
F) Administrative Control - Hygiene Survey Noise Survey
F) Administrative Control - Inspections Forklift Pre-use Inspection Checklist
F) Administrative Control - Medicals Hearing tests
F) Administrative Control - Medicals Drivers Medical Examination
F) Administrative Control - Safety Signs Warning - WW20 - Beware of Forklifts
F) Administrative Control - Safety Signs Speed Limit Sign
F) Administrative Control - Safety Signs Prohibitory - PV29 - Lifting on Forklifts Prohibited
F) Administrative Control - Safety Signs Mandatory - MV3 - Head Protection Shall be Worn
F) Administrative Control - Training General Health and Safety - Induction Training
F) Administrative Control - Training Forklift - Certification
F) Administrative Control - Training Task Analysis and SOPs
F) Administrative Control Safe Operating Procedure Operating a Forklift
G) Behavior Control - Communication Awareness General Health and Safety
H) PPE Control - Hearing Protection Ear Plugs - Disposable
H) PPE Control - Overalls Two-Piece Continental Suits 100% Cotton
H) PPE Control - Shoes Safety Shoe PU Sole
Name Signature

Customized By Sam Wessels

Approved By Thandeka Khathi

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 Risk Assessment

RISK ASSESSMENT and RATING FORM

Prepared By :
Activity: Doc No. Rev No.
Sam Wessels

Using Hand Tools 3 1

Risk Assessment Team

Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-10 Thandeka Khathi

2 Heather Mchunu

Risk Assessment Methodology Calculator

A. Severity B. Probability
Weighting Impact Effect Weighting Impact Effect
Minor cuts and bruises, small loss of containment, small/minor
perforations, punctures, lacerations, illness, sprains, strains, Has never happened in years of exposure but
1 Noticeable 1 Conceivable
muscle fatigue, cuts, dehydration, shock, 1st degree burns, is possible (Eg : 1 in 1000)
headaches, sinusitis, skin irritation
Administration of first aid care and / or equipment and / or off
site emission but no damage, minor/noticeable cuts, sprains,
Remotely
2 Important strains, electric shock, 2nd degree burns, headaches, illness, 2 A less possible coincidence (Eg : 1 in 100)
Possible
respiratory distress, property damage over R100 000, minor
environmental impact
Administration of first aid care and / or equipment and / or off
site emission but no damage, noticeable cuts, sprains, strains,
3 Serious electric shock, 2nd degree burns, respiratory distress. Loss of 3 Unusual but A more possible occurrence (Eg : 1 in 10)
time (3 days and more) Non-permanent Chronic back and possible
neck injuries, minor fractures,adverse effect on environmentor
property damage over R500 000.
Single fatality, Permanent disability / ill health , non-permanent
damage to environment, loss of limb, permanent noise
4 Very induced hearing loss, loss of sight, multiple fractures, 4 Likely Not unusual , perhaps 50/50 chance of
Serious permanent pelvic/neck/back injuries, 3rd degree burns, occurrence
permanent chronic health conditions, loss of time (14 days
and more) property damage over R1000 000
Multiple fatalities permanent local damage to environment and
eco-system, multiple severe injuries to multiple persons (3rd
5 Disaster degree burns, permanent loss of sight, hearing loss, multiple 5 Almost certain The most likely outcome if the event occurs
fractures, permanent chronic health effects, loss of limb) loss
of time (14 days and more)and property over R10 000 000

Risk Categories
Risk Category Risk Rating Remedial Activities
Critical 25 Intolerable, Implement and Monitor Control Measures, Change method and or transfer risk.
High Risk 15 - 24 Implement and Monitor Control Measures, Change Method and or Mitigate
Substantial 12 - 14 Implement and Monitor Control Measures, Change Method and or Mitigate
Risk
Possible Risk 4 - 11 Implement and Monitor Control Measures
Low Risk 1-3 Monitor

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 Risk Assessment
Assessment of the Risk Assessment of the
before Controls Risk after Controls
A B C A B C

Consequence (Severity)

Consequence (Severity)
What is the Hazards

Exposure (Probability)

Exposure (Probability)
What is the Risk?
and / or Aspect?
Risk Ass ID

Risk Score

Risk Score
Rating Rating
Biological Hazard:
Person exposed to or comes into contact with Covid 19 infected persons mucus
Contact with infected or respiratory droplets resulting in person becoming infected causing Possible
1 Covid 19 persons symptomatic infection transfer (runny nose, sore throat, cough, fever, 4 4 16 High Risk 4 1 4 Risk
mucus, respiratory
pneumonia, respiratory distress, possible fatality)
droplets
Biological Hazard: Poor Person makes contact with COVID-19 contaminated surfaces, improperly
housekeeping and cleaned and disinfected to prevent the COVID-19 virus spread, causing person Possible
2 cleaning of workplace to contract the COVID-19 virus, resulting in symptomatic effects, possible runny 4 4 16 High Risk 4 1 4
Risk
allows COVID-19 virus nose, possible sore throat, possible cough, possible fever, possible pneumonia,
to spread possible respiratory distress, possible fatality
Physical Hazard: Damaged or defective hand tool used when it should not be used, causing an
Defective or damaged Substantial Possible
3 accident to occur, resulting in bruises, cuts and lacerations, stabbing wounds, 4 3 12 4 1 4
hand tool used when it possible eye injuries, possible fatality Risk Risk
should not be used
Physical Hazard: Hand Hand tool breaks or suffer catastrophic failure when using hand tools, resulting Substantial Possible
4 tool breaks or fails in bruises, cuts and lacerations, stabbing wounds, possible eye injuries, 4 3 12 Risk 4 1 4 Risk
when using hand tools possible fatality
Physical Hazard:
Person struck by falling Person struck by falling hand tools when using hand tools, resulting in bruises,
5 3 3 9 Possible 3 1 3 Low
hand tool when using lacerations, fractures, head injuries, possible fatality Risk Risk
hand tools
Physical Hazard:
Person uses a hand Person uses a hand tool incorrectly causing the hand tool to slip while using Possible Low
6 tool incorrectly causing hand tools resulting in bruises, lacerations, minor fractures, mild fractures, 3 3 9 Risk 3 1 3 Risk
the hand tool to slip aggravated fractures, puncture wounds, temporary disablement
while using hand tools
Physical Hazard: Sharp
Person makes contact with sharp points of hand tools when using hand tools, Possible Low
7 edges of hand tools 3 3 9 3 1 3 Risk
resulting in minor cuts and lacerations Risk
when using hand tools
Slip, Trip and Fall
Due to poor housekeeping, person falls over hand tools, when using hand tools,
Hazard: Poor
8 resulting in bumps, bruises, cuts and lacerations, stabbing wounds, possible 3 3 9 Possible 3 1 3 Low
housekeeping when fatality Risk Risk
using hand tools
Physical Hazard: Hand
Hand tool is used for a job to which it is not designed to be used for, causing an
9 tool used improperly for accident to occur, resulting in bruises, cuts and lacerations, stabbing wounds, 4 2 8 Possible 4 1 4 Possible
an action to which it is Risk Risk
possible eye injuries, possible fatality
not designed for
Low
Total over-all rating before and after controls 16 High Risk 3
Risk
Risk Assessment Team
Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-10 Thandeka Khathi

2 Heather Mchunu
3

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 Risk Assessment

Control Measures for Using Hand Tools

D) Engineering Control - Equipment Eye Wash Fountain / Bottle
F) Administrative Control - Appointment Letters Section 8
F) Administrative Control - Appointment Letters Hand Tool Inspector
F) Administrative Control - Inspections Hand Tools and Equipment Inspection Checklist
F) Administrative Control - Inspections Hand Tool Register
F) Administrative Control Safe Operating Procedure Using Hand Tools
G) Behavior Control - Communication Awareness Usage of Hand Tools
G) Behavior Control - Communication Awareness Hand Tool Accidents
G) Behavior Control - Communication Awareness General Health and Safety
H) PPE Control - Eye Protection Safety Eye Wear
H) PPE Control - Eye Protection Budget Sport Spec Clear
H) PPE Control - Overalls Two-Piece Continental Suits 100% Cotton
Name Signature

Customized By Sam Wessels

Approved By Thandeka Khathi

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 Risk Assessment

RISK ASSESSMENT and RATING FORM

Prepared By :
Activity: Doc No. Rev No.
Sam Wessels

Loading or Offloading a Truck Using a Forklift 5 1

Risk Assessment Team

Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-11 Thandeka Khathi

2 Heather Mchunu

Risk Assessment Methodology Calculator

A. Severity B. Probability
Weighting Impact Effect Weighting Impact Effect
Minor cuts and bruises, small loss of containment, small/minor
perforations, punctures, lacerations, illness, sprains, strains, Has never happened in years of exposure but
1 Noticeable 1 Conceivable
muscle fatigue, cuts, dehydration, shock, 1st degree burns, is possible (Eg : 1 in 1000)
headaches, sinusitis, skin irritation
Administration of first aid care and / or equipment and / or off
site emission but no damage, minor/noticeable cuts, sprains,
Remotely
2 Important strains, electric shock, 2nd degree burns, headaches, illness, 2 A less possible coincidence (Eg : 1 in 100)
Possible
respiratory distress, property damage over R100 000, minor
environmental impact
Administration of first aid care and / or equipment and / or off
site emission but no damage, noticeable cuts, sprains, strains,
electric shock, 2nd degree burns, respiratory distress. Loss of Unusual but
3 Serious 3 A more possible occurrence (Eg : 1 in 10)
time (3 days and more) Non-permanent Chronic back and possible
neck injuries, minor fractures,adverse effect on environmentor
property damage over R500 000.
Single fatality, Permanent disability / ill health , non-permanent
damage to environment, loss of limb, permanent noise
4 Very induced hearing loss, loss of sight, multiple fractures, 4 Likely Not unusual , perhaps 50/50 chance of
Serious permanent pelvic/neck/back injuries, 3rd degree burns, occurrence
permanent chronic health conditions, loss of time (14 days
and more) property damage over R1000 000
Multiple fatalities permanent local damage to environment and
eco-system, multiple severe injuries to multiple persons (3rd
5 Disaster degree burns, permanent loss of sight, hearing loss, multiple 5 Almost certain The most likely outcome if the event occurs
fractures, permanent chronic health effects, loss of limb) loss
of time (14 days and more)and property over R10 000 000

Risk Categories
Risk Category Risk Rating Remedial Activities
Critical 25 Intolerable, Implement and Monitor Control Measures, Change method and or transfer risk.
High Risk 15 - 24 Implement and Monitor Control Measures, Change Method and or Mitigate
Substantial 12 - 14 Implement and Monitor Control Measures, Change Method and or Mitigate
Risk
Possible Risk 4 - 11 Implement and Monitor Control Measures
Low Risk 1-3 Monitor

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 Risk Assessment
Assessment of the Risk Assessment of the
before Controls Risk after Controls
A B C A B C

Consequence (Severity)

Consequence (Severity)
What is the Hazards and / or

Exposure (Probability)

Exposure (Probability)
What is the Risk?
Aspect?
Risk Ass ID

Risk Score

Risk Score
Rating Rating
Physical Hazard: Person exposed Person struck by moving forklift or other mobile equipment moving
1 to mobile vehicles or equipment loads in the area while loading or offloading a truck using a forklift, 4 4 16 High Risk 4 1 4 Possible
while loading or offloading a truck resulting in bruises, cuts and lacerations, fractures, possible Risk
using a forklift puncturing or impact head injuries, possible fatality
Driver of forklift indulges in horseplay while loading or offloading a
Psychosocial Hazard: Driver of
forklift indulges in horseplay while truck using a forklift causing the vehicle to operate uncontrolled and Possible
2 loading or offloading a truck using a be involved in an accident, resulting in property loss of up to R 4 4 16 High Risk 4 1 4 Risk
1,000,000, bruises, cuts and lacerations, possible fractures,
forklift
possible loss of limbs, possible multiple fatalities
Physical Hazard: Person exposed Forklift load exceeds maximum forklift lifting weight while loading or
to equipment failure as load offloading a truck using a forklift, causing loading device to fail and Possible
3 drop load, causing an accident, resulting in bruises, cuts and 4 4 16 High Risk 4 1 4
capacity is exceeded while loading Risk
or offloading a truck using a forklift lacerations, possible fractures, possible impact head injuries,
possible multiple fatalities
Physical Hazard: Poor maintenance Poor maintenance of forklift while loading or offloading a truck using
4 of forklift while loading or offloading a forklift, causes lifting mechanism to fail and load carried to be 4 4 16 High Risk 4 1 4 Possible
dropped, resulting in bruises, cut and lacerations, fractures, impact Risk
a truck using a forklift
head injuries, possible multiple fatalities
Physical Hazard: Person exposed Person traps fingers or hand in pinch points between forks and load
5 to pinch point between forks and of the forklift while loading or offloading a truck using a forklift, 4 3 12 Substantial 4 1 4 Possible
cables of forklift while loading or Risk Risk
resulting in bruises, cuts and lacerations, possible fractures
offloading a truck using a forklift
Physical Hazard: Person exposed Person traps fingers or hand in pinch points between packed
to pinch points between packed
6 containers of load while loading or offloading a truck using a forklift, 4 3 12 Substantial 4 1 4 Possible
containers of load while loading or resulting in bruises, cuts and lacerations, possible fractures Risk Risk
offloading a truck using a forklift
Physical Hazard: Person exposed Person traps fingers or hand in pinch points on control levers while
to pinch points on control levers
7 loading or offloading a truck using a forklift, resulting in bruises, cuts 4 3 12 Substantial 4 1 4 Possible
while loading or offloading a truck and lacerations, possible fractures Risk Risk
using a forklift
Physical Hazard: Person exposed Person makes contact with sharp edges of forklift controls while
to sharp edges of forklift controls
8 loading or offloading a truck using a forklift, resulting in bruises, cuts 4 3 12 Substantial 4 1 4 Possible
while loading or offloading a truck and lacerations Risk Risk
using a forklift
Physical Hazard: Person exposed Person makes contact with sharp edges of suspended load while
9 to sharp edges of suspended load loading or offloading a truck using a forklift, resulting in bruises, cuts 4 3 12 Substantial 4 1 4 Possible
while loading or offloading a truck and lacerations Risk Risk
using a forklift
Physical Hazard: Person exposed Person makes contact with sharp edges of truck or forklift structure
10 to sharp edges of truck or forklift while loading or offloading a truck using a forklift, resulting in 4 3 12 Substantial 4 1 4 Possible
structure while loading or offloading bruises, cuts and lacerations Risk Risk
a truck using a forklift
Person struck by suspended moving forklift loads as it transfers load
Physical Hazard: Person exposed
11 to suspended loads while loading or while loading or offloading a truck using a forklift, resulting in 4 3 12 Substantial 4 1 4 Possible
offloading a truck using a forklift bruises, cuts and lacerations, possible fractures, possible impact Risk Risk
head injuries, possible fatality
Unstable or improper stacking of load while loading or offloading a
Physical Hazard: Unstable load due truck using a forklift, causes load to shift and fall during forklift Substantial Possible
12 to poor stacking while loading or motion, causing a person or persons to be struck, resulting in 4 3 12 Risk 4 1 4 Risk
offloading a truck using a forklift bruises, cuts and lacerations, fractures, possible impact head
injuries, possible multiple fatalities
Physical Hazard: Person exposed Person traps fingers or hand nip points while attaching slings to load
13 to nip points while attaching slings while loading or offloading a truck using a forklift, resulting in 4 3 12 Substantial 4 1 4 Possible
to load while loading or offloading a bruises, cuts and lacerations, possible fractures Risk Risk
truck using a forklift
Unauthorised person uses forklift while loading or offloading a truck
Psychosocial Hazard: Unauthorised
14 person uses forklift while loading or using a forklift, causing an accident, resulting in property damage up 4 3 12 Substantial 4 1 4 Possible
offloading a truck using a forklift to R1,000,000, bruises, cuts and lacerations, fractures, possible Risk Risk
loss of limbs, possible multiple fatalities
Forklift exposed to strong winds while loading or offloading a truck
Environmental Hazard: Person
using a forklift, causing forklift to tip off-balance and overturn,
exposed to adverse windy Substantial Possible
15 resulting in property damage up to R1,000 000, cuts and 4 3 12 4 1 4
conditions while loading or Risk Risk
offloading a truck using a forklift lacerations, fractures, possible impact or puncturing head injuries,
possible multiple fatalities
Ergonomical Hazard: Incorrect Person adopts incorrect body posture for long periods of time sitting
Substantial Possible
16 body posture adopted while loading and using forklift while loading or offloading a truck using a forklift, 4 3 12 4 1 4
Risk Risk
or offloading a truck using a forklift resulting in neck or back strains, possible musculoskeletal damage
Built up heat from exhaust of forklift while paper or other
Fire Hazard: Heat build up from Substantial Possible
17 combustible material makes contact causing fire, resulting in 1st, 4 3 12 4 1 4
exhaust of forklift Risk Risk
2nd, 3rd degree burns
18 Fire Hazard: Shorting or fusing of Shorting or fusing of forklift electrical components while loading or 4 3 12 Substantial 4 1 4 Possible
forklift electrical components while offloading a truck using a forklift, causes an uncontrolled fire, Risk Risk

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 Risk Assessment
loading or offloading a truck using a resulting in property damage up to R1,000 000, 1st, 2nd or 3rd
forklift degree burns, multiple fatalities
Person exposed to adverse
Forklift skids due to wet conditions causing forklift to cause accident
19 weather conditions such as rainy or resulting in property damage up to R1 000 000, bumps, bruises, 4 3 12 Substantial 4 1 4 Possible
cold conditions resulting in lung fractures, fatality Risk Risk
irritation, cold sores
Physical Hazard: Obscured vision Forklift strikes person due to obscured vision while loading or Substantial Possible
20 while loading or offloading a truck offloading a truck using a forklift, resulting in bruises, cuts and 4 3 12 4 1 4
Risk Risk
using a forklift lacerations, fractures, possible impact head injuries, possible fatality
Environmental Hazard: Person Person exposed to direct sun for long periods while loading or
21 exposed to adverse hot weather offloading a truck using a forklift, resulting in dehydration, 3 3 9 Possible 3 1 3 Low
conditions while loading or Risk Risk
heatstroke, heat exhaustion
offloading a truck using a forklift
Environmental Hazard: Person Person exposed to constant rain and strong winds while loading or
22 exposed to adverse cold weather offloading a truck using a forklift, resulting in cold numbness, cold 3 3 9 Possible 3 1 3 Low
conditions while loading or Risk Risk
exposure, hypothermia
offloading a truck using a forklift
Environmental Hazard: Dust Person exposed to dust while driving forklift resulting in eye Possible Low
23 3 3 9 3 1 3
exposure during driving of forklift irritation, lung irritation Risk Risk
Environmental Hazard: Adverse
Person exposed to adverse weather conditions such as rainy or Possible Low
24 weather conditions such as rainy or cold conditions resulting in lung irritation, cold sores 3 3 9 Risk 3 1 3 Risk
cold conditions
Electrical Hazard: Person exposed Person makes contact with live electrical wires, leads or
to live exposed electrical wires,
connections on forklift control panel while loading or offloading a Possible Low
25 leads or connections of forklift truck using a forklift, resulting in electrical shock, 1st, 2nd degree 3 3 9 Risk 3 1 3 Risk
control panel while loading or burns, possible fatality
offloading a truck using a forklift
Low
Total over-all rating before and after controls 16 High Risk 3
Risk
Risk Assessment Team
Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-11 Thandeka Khathi

2 Heather Mchunu

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 Risk Assessment

Control Measures for Loading or Offloading a Truck Using a Forklift

F) Administrative Control - Appointment Letters Competent Forklift Operator
F) Administrative Control - Inspections Forklift Pre-use Inspection Checklist
F) Administrative Control - Training General Health and Safety - Induction Training
F) Administrative Control - Training Forklift - Certification
F) Administrative Control - Training Task Analysis and SOPs
F) Administrative Control Safe Operating Procedure Operating a Forklift
H) PPE Control - Clothing Rain Suits (When Rainy)
H) PPE Control - Eye Protection Safety Glasses (When Dusty)
H) PPE Control - Overalls Overall
Name Signature

Customized By Sam Wessels

Approved By Thandeka Khathi

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 Risk Assessment

RISK ASSESSMENT and RATING FORM

Prepared By :
Activity: Doc No. Rev No.
Sam Wessels

Conducting Repairs and Maintenance on a Forklift 12 1

Risk Assessment Team

Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-11 Thandeka Khathi

2 Heather Mchunu
3

Risk Assessment Methodology Calculator

A. Severity B. Probability
Weighting Impact Effect Weighting Impact Effect
Minor cuts and bruises, small loss of containment, small/minor
perforations, punctures, lacerations, illness, sprains, strains, Has never happened in years of exposure but
1 Noticeable 1 Conceivable
muscle fatigue, cuts, dehydration, shock, 1st degree burns, is possible (Eg : 1 in 1000)
headaches, sinusitis, skin irritation
Administration of first aid care and / or equipment and / or off
site emission but no damage, minor/noticeable cuts, sprains,
Remotely
2 Important strains, electric shock, 2nd degree burns, headaches, illness, 2 A less possible coincidence (Eg : 1 in 100)
Possible
respiratory distress, property damage over R100 000, minor
environmental impact
Administration of first aid care and / or equipment and / or off
site emission but no damage, noticeable cuts, sprains, strains,
3 Serious electric shock, 2nd degree burns, respiratory distress. Loss of 3 Unusual but A more possible occurrence (Eg : 1 in 10)
time (3 days and more) Non-permanent Chronic back and possible
neck injuries, minor fractures,adverse effect on environmentor
property damage over R500 000.
Single fatality, Permanent disability / ill health , non-permanent
damage to environment, loss of limb, permanent noise
4 Very induced hearing loss, loss of sight, multiple fractures, 4 Likely Not unusual , perhaps 50/50 chance of
Serious permanent pelvic/neck/back injuries, 3rd degree burns, occurrence
permanent chronic health conditions, loss of time (14 days
and more) property damage over R1000 000
Multiple fatalities permanent local damage to environment and
eco-system, multiple severe injuries to multiple persons (3rd
5 Disaster degree burns, permanent loss of sight, hearing loss, multiple 5 Almost certain The most likely outcome if the event occurs
fractures, permanent chronic health effects, loss of limb) loss
of time (14 days and more)and property over R10 000 000

Risk Categories
Risk Category Risk Rating Remedial Activities
Critical 25 Intolerable, Implement and Monitor Control Measures, Change method and or transfer risk.
High Risk 15 - 24 Implement and Monitor Control Measures, Change Method and or Mitigate
Substantial
12 - 14 Implement and Monitor Control Measures, Change Method and or Mitigate
Risk
Possible Risk 4 - 11 Implement and Monitor Control Measures
Low Risk 1-3 Monitor

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 Risk Assessment
Assessment of the Risk Assessment of the
before Controls Risk after Controls
A B C A B C

Consequence (Severity)

Consequence (Severity)
Exposure (Probability)

Exposure (Probability)
What is the Hazards and / or Aspect? What is the Risk?
Risk Ass ID

Risk Score

Risk Score
Rating Rating
Person traps fingers or hand between nip points on lifting
Physical Hazard: Person exposed to nip
chain while conducting repairs and maintenance on a forklift, Substantial Possible
1 points on lifting chains while conducting 4 3 12 4 1 4
repairs and maintenance on a forklift resulting in bruises, cuts and lacerations, possible fractures, Risk Risk
possible loss of limb
Slip, Trip and Fall Hazard Hazard: Person trips and falls over obstacles or obstructions in work
Obstacles and obstructions in work area are while conducting repairs and maintenance on a forklift, Substantial Possible
2 4 3 12 4 1 4
while conducting repairs and maintenance resulting in bruises, cuts and lacerations, possible fractures, Risk Risk
on a forklift possible impact head injuries
Physical Hazard: Person traps fingers or
hand between nip points between wheel Person traps fingers or hand between nip points between
3 and wheel arch while conducting repairs wheel and wheel arch while conducting repairs and 4 3 12 Substantial 4 1 4 Possible
and maintenance on a forklift, resulting in maintenance on a forklift, resulting in bruises, cuts and Risk Risk
bruises, cuts and lacerations, possible lacerations, possible fractures, possible loss of limb
fractures
Physical Hazard: Person exposed to
Person makes contact with sharp edges of forklift structure
sharp edges of forklift structure while
4 while conducting repairs and maintenance on a forklift, 4 3 12 Substantial 4 1 4 Possible
conducting repairs and maintenance on a resulting in cuts and lacerations Risk Risk
forklift
Physical Hazard: Person exposed to Persons head makes contact with forklift frame or engine
Substantial Possible
5 possible head injuries while conducting hood while conducting repairs and maintenance on a forklift, 4 3 12 Risk 4 1 4 Risk
repairs and maintenance on a forklift resulting in bruises, cuts and lacerations, possible fractures
Person traps fingers or hand between nip points on load
Physical Hazard: Person exposed to nip
6 points on load backrest while conducting backrest while conducting repairs and maintenance on a 4 3 12 Substantial 4 1 4 Possible
repairs and maintenance on a forklift forklift, resulting in bruises, cuts and lacerations, possible Risk Risk
fractures, possible loss of limb
Physical Hazard: Person exposed to nip Person traps fingers or hand between nip points on lifting
mast while conducting repairs and maintenance on a forklift,
7 points on lifting mast while conducting 4 3 12 Substantial 4 1 4 Possible
resulting in bruises, cuts and lacerations, possible fractures, Risk Risk
repairs and maintenance on a forklift
possible loss of limb
Spilled diesel from forklift comes into contact with ignition
Fire Hazard: Spilled diesel igniting while source while conducting repairs and maintenance on a
Substantial Possible
8 conducting repairs and maintenance on a forklift, causing an uncontrolled fire, resulting in property 4 3 12 Risk 4 1 4 Risk
forklift damage up to R500 000, 1st degree, 2nd degree, 3rd
degree burns, possible multiple fatalities
Spilled battery acid from forklift comes into contact with
Fire Hazard: Spilled battery acid igniting ignition source while conducting repairs and maintenance on
Substantial Possible
9 while conducting repairs and maintenance a forklift, causing an uncontrolled fire, resulting in property 4 3 12 Risk 4 1 4 Risk
on a forklift damage up to R500 000, 1st degree, 2nd degree, 3rd
degree burns, possible multiple fatalities
Leaking lpg gas from gas tank makes contact with an ignition
Fire Hazard: Person exposed to source while conducting repairs and maintenance on a
Substantial Possible
10 flammable gas while conducting repairs forklift, causing an uncontrolled fire, resulting in property 4 3 12 Risk 4 1 4 Risk
and maintenance on a forklift damage up to R500 000, 1st d, 2nd, 3rd degree burns,
possible multiple fatalities
Exposed electrical wires on forklift charger come into contact
Fire Hazard: Exposed electrical wires with combustible materials or flammable liquids while
11 from forklift charger while conducting conducting repairs and maintenance on a forklift, causing an 4 3 12 Substantial 4 1 4 Possible
repairs and maintenance on a forklift uncontrolled fire resulting in property damage up to R500 Risk Risk
000 1st degree, 2nd degree, 3rd degree burns, possible
multiple fatalities
Slip, Trip and Fall Hazard Hazard: Poor Person trips and falls over work tools or work items in work
12 housekeeping in work area while are while conducting repairs and maintenance on a forklift, 4 3 12 Substantial 4 1 4 Possible
conducting repairs and maintenance on a resulting in bruises, cuts and lacerations, possible fractures, Risk Risk
forklift possible impact head injuries
Environmental Hazard: Spilled or leaking Spilled or leaking battery acid from forklift leaks into the
13 battery acid while conducting repairs and environment while conducting repairs and maintenance on a 3 3 9 Possible 3 1 3 Low
maintenance on a forklift forklift, resulting in pollution, environmental damage, legal Risk Risk
liability and fines
Environmental Hazard: Spilled or leaking Spilled or leaking hydraulic fluid from forklift leaks into the
environment while conducting repairs and maintenance on a
14 hydraulic fluid while conducting repairs 4 2 8 Possible 4 1 4 Possible
and maintenance on a forklift forklift, resulting in pollution, environmental damage, legal Risk Risk
liability and fines
Spilled or leaking diesel fuel from forklift leaks into the
Environmental Hazard: Spilled or leaking
environment while conducting repairs and maintenance on a Possible Possible
15 diesel fuel while conducting repairs and 4 2 8 4 1 4
maintenance on a forklift forklift, resulting in pollution, environmental damage, legal Risk Risk
liability and fines
Ergonomic Hazard: Person exposed to Person overexerts due to repetitive stretches and strains
repetitive stretches and strains when
from straining to reach awkward areas of forklift while Possible Possible
16 extending or straining to reach awkward conducting repairs and maintenance on a forklift, resulting in 4 2 8 Risk 4 1 4 Risk
areas of forklift while conducting repairs neck, shoulder or back strains, musculoskeletal damage
and maintenance on a forklift
17 Slip, Trip and Fall Hazard: Person Person slips and falls due to spilled or leaking battery acid 3 2 6 Possible 3 1 3 Low
exposed to wet or slippery floors from while conducting repairs and maintenance on a forklift, Risk Risk
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8/11/22, 12:28 AM Risk Assessment
spilled or leaking battery acid while resulting in bruises, cuts and lacerations, possible fractures,
conducting repairs and maintenance on a possible impact head injuries, possible chemical burns
forklift
Slip, Trip and Fall Hazard: Person Person slips and falls due to spilled or leaking diesel fuel
exposed to wet or slippery floors from while conducting repairs and maintenance on a forklift, Possible Low
18 spilled or leaking diesel fuel while resulting in bruises, cuts and lacerations, possible fractures, 3 2 6 Risk 3 1 3 Risk
conducting repairs and maintenance on a
possible impact head injuries
forklift
Slip, Trip and Fall Hazard: Person Person slips and falls due to spilled or leaking hydraulic
exposed to wet or slippery floors from fluids while conducting repairs and maintenance on a forklift, Possible Low
19 spilled or leaking hydraulic fluids while 3 2 6 3 1 3
resulting in bruises, cuts and lacerations, possible fractures, Risk Risk
conducting repairs and maintenance on a
possible impact head injuries
forklift
Thermal Hazard: Person exposed to hot Person makes contact with hot engine surfaces and
20 engine surfaces and components while components while conducting repairs and maintenance on a 3 2 6 Possible 3 1 3 Low
conducting repairs and maintenance on a Risk Risk
forklift resulting in 1st or 2nd degree burns
forklift
Chemical Hazard: Person exposed to Person makes contact with or ingests battery acid while
21 corrosive or acidic chemicals while conducting repairs and maintenance on a forklift, resulting in 3 2 6 Possible 3 1 3 Low
conducting repairs and maintenance on a skin irritation, 1st or 2nd degree chemical burns, possible Risk Risk
forklift eye damage, internal chemical burns,
Electrical Hazard: Exposed electrical wire Person makes contact with exposed electrical wires on
22 on forklift charger while conducting forklift charger while conducting repairs and maintenance on 3 2 6 Possible 3 1 3 Low
a forklift, resulting in 1st degree, 2nd degree burns, electrical Risk Risk
repairs and maintenance on a forklift
shock, cardiac arrest, possible fatality
Chemical Hazard: Person exposed to lpg Person makes inhales lpg gas fumes or vapours while
Possible Low
23 gas fumes or vapours while conducting conducting repairs and maintenance on a forklift, resulting in 3 2 6 3 1 3
Risk Risk
repairs and maintenance on a forklift nausea and vomiting
Chemical Hazard: Person exposed to Person inhales battery acid fumes or vapours while
24 corrosive or acidic fumes or vapours while conducting repairs and maintenance on a forklift, resulting in 3 2 6 Possible 3 1 3 Low
conducting repairs and maintenance on a Risk Risk
nausea and vomiting, internal chemical burns,
forklift
Thermal Hazard: Person exposed to hot Person makes contact with hot exhaust components while
Possible Low
25 exhaust components while conducting conducting repairs and maintenance on a forklift resulting in 3 2 6 Risk 3 1 3 Risk
repairs and maintenance on a forklift 1st or 2nd degree burns
Total over-all rating before and after controls 12 Substantial 3 Low
Risk Risk
Risk Assessment Team
Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-11 Thandeka Khathi

2 Heather Mchunu

https://system.ohsonline.co.za/admin/risk_task_report.php?table= &id= 6762&reports%5B%5D= 2&reports%5B%5D= 3&docs%5B%5D= 1&docs… 16/29

 Risk Assessment

Control Measures for Conducting Repairs and Maintenance on a Forklift

D) Engineering Control - Equipment Eye Wash Fountain / Bottle
E) Isolation Control - Barriers Safety Lock Device
E) Isolation Control - Barriers Electrical Cover
E) Isolation Control - Barriers Designated Enclosed Working Area
E) Isolation Control - Barriers Machine Guarding
E) Isolation Control - Barriers Covers
E) Isolation Control - Barriers Emergency Switch
F) Administrative Control - Appointment Letters Competent Forklift Operator
F) Administrative Control - Appointment Letters Section 8
F) Administrative Control - Certificates Load Test Certificate
F) Administrative Control - Certificates Regular service intervals
F) Administrative Control - Inspections Forklift Pre-use Inspection Checklist
F) Administrative Control - Inspections Maintenance Management System
F) Administrative Control - Medicals Annual - Full medical examination
F) Administrative Control - Permits Valid drivers licence
F) Administrative Control - Safety Signs Warning - WW20 - Beware of Forklifts
F) Administrative Control - Safety Signs Speed Limit Sign
F) Administrative Control - Safety Signs Prohibitory - PV12 - Loose Clothing, Ties, Jewellery and Unconfined Long Hair Prohibited
F) Administrative Control - Safety Signs No Unauthorized Entry Sign
F) Administrative Control - Safety Signs Mandatory - MV7 - Foot Protection Against Crushing Shall be Worn
F) Administrative Control - Safety Signs Mandatory - MV20 - Overalls Shall be Worn
F) Administrative Control - Safety Signs Beware of Mobile Equipment
F) Administrative Control - Safety Signs Authorized Persons Only
F) Administrative Control - Safety Signs Prohibitory - PV2 - Fire and Open Flames Prohibited
F) Administrative Control - Safety Signs Prohibitory - PV1 - Smoking Prohibited
F) Administrative Control - Safety Signs Warning - WW7 - Beware of Electric Shock
F) Administrative Control - Training Forklift - Re-Certification
F) Administrative Control - Training Forklift - Certification
F) Administrative Control - Training General Health and Safety - Induction Training
F) Administrative Control - Training Task Analysis and SOPs
F) Administrative Control Safe Operating Procedure Repairing and Maintaining Vehicles / Forklifts / Excavators / Machinery
F) Administrative Control Safe Operating Procedure Operating a Forklift
F) Administrative Control Safe Operating Procedure Charging Forklift Batteries
G) Behavior Control - Communication Awareness Working with Mobile Lifting Equipment
G) Behavior Control - Communication Awareness General Safety Awareness
G) Behavior Control - Communication Awareness Ergonomical Stresses
H) PPE Control - Eye Protection Safety Eye Wear
H) PPE Control - Gloves Gloves
H) PPE Control - Hearing Protection Ear Plugs - Disposable
H) PPE Control - Overalls Two-Piece Continental Suits 100% Cotton
H) PPE Control - Shoes Safety Boot PU Shoe
H) PPE Control - Shoes Safety Shoe PU Sole
Name Signature

Customized By Sam Wessels

Approved By Thandeka Khathi

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 Risk Assessment

RISK ASSESSMENT and RATING FORM

Activity: Doc No. Rev No. Prepared By :

Sam Wessels

Conducting Maintenance and Repairs on an Overhead Crane 22 1

Risk Assessment Team

Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-11 Thandeka Khathi

2 Heather Mchunu
3

Risk Assessment Methodology Calculator

A. Severity B. Probability
Weighting Impact Effect Weighting Impact Effect
Minor cuts and bruises, small loss of containment, small/minor
perforations, punctures, lacerations, illness, sprains, strains, Has never happened in years of exposure but
1 Noticeable 1 Conceivable
muscle fatigue, cuts, dehydration, shock, 1st degree burns, is possible (Eg : 1 in 1000)
headaches, sinusitis, skin irritation
Administration of first aid care and / or equipment and / or off
site emission but no damage, minor/noticeable cuts, sprains, Remotely
2 Important strains, electric shock, 2nd degree burns, headaches, illness, 2 A less possible coincidence (Eg : 1 in 100)
Possible
respiratory distress, property damage over R100 000, minor
environmental impact
Administration of first aid care and / or equipment and / or off
site emission but no damage, noticeable cuts, sprains, strains,
electric shock, 2nd degree burns, respiratory distress. Loss of Unusual but
3 Serious 3 A more possible occurrence (Eg : 1 in 10)
time (3 days and more) Non-permanent Chronic back and possible
neck injuries, minor fractures,adverse effect on environmentor
property damage over R500 000.
Single fatality, Permanent disability / ill health , non-permanent
damage to environment, loss of limb, permanent noise
4 Very induced hearing loss, loss of sight, multiple fractures, 4 Likely Not unusual , perhaps 50/50 chance of
Serious permanent pelvic/neck/back injuries, 3rd degree burns, occurrence
permanent chronic health conditions, loss of time (14 days
and more) property damage over R1000 000
Multiple fatalities permanent local damage to environment and
eco-system, multiple severe injuries to multiple persons (3rd
5 Disaster degree burns, permanent loss of sight, hearing loss, multiple 5 Almost certain The most likely outcome if the event occurs
fractures, permanent chronic health effects, loss of limb) loss
of time (14 days and more)and property over R10 000 000

Risk Categories
Risk Category Risk Rating Remedial Activities
Critical 25 Intolerable, Implement and Monitor Control Measures, Change method and or transfer risk.
High Risk 15 - 24 Implement and Monitor Control Measures, Change Method and or Mitigate
Substantial
12 - 14 Implement and Monitor Control Measures, Change Method and or Mitigate
Risk
Possible Risk 4 - 11 Implement and Monitor Control Measures
Low Risk 1-3 Monitor

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 Risk Assessment
Assessment of the Risk Assessment of the Risk
before Controls after Controls
A B C A B C

Consequence (Severity)

Consequence (Severity)
What is the Hazards and / or

Exposure (Probability)

Exposure (Probability)
What is the Risk?
Aspect?
Risk Ass ID

Risk Score

Risk Score
Rating Rating
Fire Hazard: Short circuit on db board Short circuit on db board of on overhead crane while conducting Substantial Possible
1 of overhead crane while conducting maintenance on overhead crane resulting in fire, property 4 3 12 Risk 4 1 4 Risk
maintenance on overhead crane damage up to R100 000
Person makes contact with exposed electrical wires of
Electrical Hazard: Exposed electrical overhead crane while conducting maintenance on overhead Possible Possible
2 4 2 8 4 1 4
wires while conducting maintenance crane resulting in 1st, 2nd or 3rd degree burns, Risk Risk
unconsciousness, fatality
Physical Hazard: Siren on overhead Accidental lowering of hook block of overhead crane while Possible Possible
3 crane defective while conducting conducting maintenance on overhead crane onto person 4 2 8 Risk 4 1 4 Risk
maintenance on overhead crane resulting possible fractures, head injury, neck injury, fatality
Physical Hazard: Short circuit on db
Short circuit on db board of overhead crane while conducting
4 board of overhead crane while maintenance on overhead crane resulting in 1st, 2nd, 3rd 4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead degree burns, possible fatality Risk Risk
crane
Physical Hazard: Sharp edges on on Person makes contact with a sharp point on the pendant control
Possible Possible
5 pendant control while conducting of overhead crane while conducting maintenance on overhead 4 2 8 Risk 4 1 4 Risk
maintenance on overhead crane crane resulting in minor cuts, lacerations
Physical Hazard: Safe work load on Person overloading overhead crane while conducting
6 overhead crane not identified while
maintenance on overhead crane causing lifted material to fall
4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead onto person resulting possible fractures, head injury, neck Risk Risk
crane injury, fatality
Physical Hazard: Safe work load on Person overloading overhead crane hook block while
7 hook block of overhead crane not
conducting maintenance on overhead crane causing lifted
4 2 8 Possible 4 1 4 Possible
identified while conducting material to fall onto person resulting possible fractures, head Risk Risk
maintenance on overhead crane injury, neck injury, fatality
Physical Hazard: Overstrained hoist Overstrained hoist motor of overhead crane while conducting
8 motor of overhead crane while
maintenance on overhead crane during lift causing lifted
4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead material to fall resulting in serious head injury, neck injury, Risk Risk
crane fatality
Physical Hazard: Missing bolts on
Missing bolts on girder of overhead crane while conducting
9 girder of overhead crane while maintenance on overhead crane causing structure to fall 4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead resulting in property damage up to R100 000, possible fatality Risk Risk
crane
Physical Hazard: Structural damage Structural damage of gantry causing overhead crane while
10 of gantry of overhead crane while conducting maintenance on overhead crane structure to fall 4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead resulting in property damage up to R1 000 000, possible Risk Risk
crane multiple fatalities
Structural damage on end carriage of overhead crane while
Physical Hazard: Structural damage
11 on end carriage while conducting conducting maintenance on overhead crane causing structure 4 2 8 Possible 4 1 4 Possible
maintenance on overhead crane to fall resulting in property damage up to R1 000 000, possible Risk Risk
multiple fatalities
Structural damage on girder of overhead crane while
Physical Hazard: Structural damage
12 on girder while conducting conducting maintenance on overhead crane causing structure 4 2 8 Possible 4 1 4 Possible
maintenance on overhead crane to fall resulting in property damage up to R1 000 000, possible Risk Risk
multiple fatalities
Physical Hazard: Structural damage
Structural damage on hoist hook while conducting maintenance
13 on hoist hook of overhead crane while on overhead crane causing hoist hook to fall resulting in serious 4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead head injury, neck injury, possible fatality Risk Risk
crane
Physical Hazard: Structural damage Structural damage on wheels of hoist block of overhead crane
on wheels of hoist block of overhead while conducting maintenance on overhead crane causing hoist Possible Possible
14 4 2 8 4 1 4
crane while conducting maintenance block to fall resulting in property damage up to R100 000, Risk Risk
on overhead crane possible fatality
Physical Hazard: Swinging pendant Person hit by pendant control of overhead crane while
Possible Possible
15 control while conducting maintenance conducting maintenance on overhead crane resulting in minor 4 2 8 4 1 4
Risk Risk
on overhead crane cuts, lacerations, bruising
Physical Hazard: Uncontrolled Person gets struck by uncontrolled movement of load while load Possible Possible
16 movement of load while load testing testing an overhead crane resulting in bruises, cuts, lacerations, 4 2 8 4 1 4
Risk Risk
overhead crane fractures, fatality
Thermal Hazard: Overheated cross Overheating of cross travel motor of while conducting
17 travel motor of overhead crane while maintenance on overhead crane overhead crane during lift 4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead causing lifted material to fall resulting in serious head injury, Risk Risk
crane neck injury, fatality
Thermal Hazard: Overheated hoist Overheating of hoist motor of overhead crane while conducting
18 motor of overhead crane while maintenance on overhead crane during lift causing lifted 4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead material to fall resulting in serious head injury, neck injury, Risk Risk
crane fatality
Physical Hazard: Falling from height Person falls from height while conducting maintenance on Possible Possible
19 while conducting maintenance on overhead crane resulting in fractures, head injuries, fatality 4 2 8 Risk 4 1 4 Risk
overhead crane
Physical Hazard: Failure of Person gets struck by material falling while load testing on an Possible Possible
20 components while load testing overhead crane fails resulting in bruises, cuts, lacerations, 4 2 8 Risk 4 1 4 Risk
overhead crane fractures, fatality
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 Risk Assessment
Ergonomical Hazard: Continuous use Person continuously uses pendant control of overhead crane Possible Possible
21 of pendant control while conducting for a long period while conducting maintenance on overhead 4 2 8 Risk 4 1 4 Risk
maintenance on overhead crane crane resulting in ergonomical stress, joint pain
Fire Hazard: Electrical short on hoist
Short circuit on hoist motor of overhead crane while conducting
22 motor of overhead crane while maintenance on overhead crane resulting in fire, property 4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead damage up to R100 000 Risk Risk
crane
Fire Hazard: Short circuit on electrical Short circuit on electrical control box on overhead crane while Possible Possible
23 control box while conducting conducting maintenance on overhead crane resulting in fire with 4 2 8 4 1 4
Risk Risk
maintenance on overhead crane property damage up to R100 000, 1st, 2nd, 3rd degree burns
Physical Hazard: Broken emergency Broken emergency stop control while conducting maintenance
24 stop control of overhead crane while on overhead crane during a uncontrolled load of overhead 4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead crane resulting in serious head injury, neck injury, possible Risk Risk
crane fatality
Physical Hazard: Broken pendant Broken control pendant control of overhead crane while
25 control of overhead crane while conducting maintenance on overhead crane causing 4 2 8 Possible 4 1 4 Possible
conducting maintenance overhead uncontrolled load resulting in cuts and bruises, deep Risk Risk
crane lacerations, possible fractures
Physical Hazard: Broken sheath hook Sheave hook block of overhead crane breaking during lift while
26 block of overhead crane while conducting maintenance on overhead crane causing lifted 4 2 8 Possible 4 1 4 Possible
conducting maintenance overhead material to fall resulting in serious head injury, neck injury, Risk Risk
crane fatality
Physical Hazard: Broken stop blocks
Broken stop blocks on girder of overhead crane while
27 on girder of overhead crane while conducting maintenance on overhead crane resulting in 4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead property damage up to R100 000, possible fatality Risk Risk
crane
Physical Hazard: Damage on cable Damage on cable at dead end on hoist block while conducting
28 joining at dead end on hoist block of maintenance on overhead crane causing hoist rope of overhead
4 2 8 Possible 4 1 4 Possible
overhead crane while conducting crane to fall uncontrolled resulting in cuts and bruises, deep Risk Risk
maintenance on overhead crane lacerations, possible fractures
Physical Hazard: Damage on hoist Damage on hoist rope of overhead crane while conducting
29 rope of overhead crane while maintenance on overhead crane causing lifted material to fall 4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead uncontrolled resulting in serious head injury, neck injury Risk Risk
crane possible fatality
Physical Hazard: Damaged centre Damaged centre pulley on cross travel of overhead crane while
30 pulley on cross travel of overhead conducting maintenance on overhead crane causing load to fall 4 2 8 Possible 4 1 4 Possible
crane while conducting maintenance Risk Risk
resulting in serious head injury, neck injury, possible fatality
on overhead crane
Physical Hazard: Damaged or broken Winch drum of overhead crane breaking during lift while
31 winch drum of overhead crane while
conducting maintenance on overhead crane causing lifted
4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead material to fall resulting in serious head injury, neck injury, Risk Risk
crane fatality
Physical Hazard: Damaged or worn Brake failure on overhead crane while conducting maintenance
on overhead crane causing girder to run into stop blocks
32 brakes while conducting maintenance 4 2 8 Possible 4 1 4 Possible
resulting in property damage up to R500 000, bumps, bruises, Risk Risk
on overhead crane
lacerations, fractures, possible multiple fatalities
Physical Hazard: Damaged rails of Damaged rails of overhead crane while conducting
Possible Possible
33 overhead crane while conducting maintenance on overhead crane causing structure to fall 4 2 8 Risk 4 1 4 Risk
maintenance on overhead crane resulting in property damage up to R100 000, possible fatality
Physical Hazard: Damaged sheathes Damaged sheaves on hook block of overhead crane while
34 on hook block of overhead crane
conducting maintenance on overhead crane causing hoist rope
4 2 8 Possible 4 1 4 Possible
while conducting maintenance on to break resulting in serious head injury, neck injury, possible Risk Risk
overhead crane fatality
Physical Hazard: Damaged swivel on Damaged swivel on hook block of overhead crane while
35 hook block of overhead crane while
conducting maintenance on overhead crane causing lifted
4 2 8 Possible 4 1 4 Possible
conducting maintenance on overhead material to fall resulting in serious head injury, neck injury, Risk Risk
crane fatality
Physical Hazard: Defective safety
Defective safety latch on hook of overhead crane while
latch on hook of overhead crane while Possible Possible
36 conducting maintenance on overhead crane causing load to fall 4 2 8 4 1 4
conducting maintenance on overhead Risk Risk
resulting in serious head injury, neck injury, possible fatality
crane
Thermal Hazard: Overheated long Overheating of long travel motor of overhead crane while
travel motor of overhead crane while conducting maintenance on overhead crane during lift causing Possible Possible
37 4 2 8 4 1 4
conducting maintenance on overhead lifted material to fall resulting in serious head injury, neck injury, Risk Risk
crane fatality
Total over-all rating before and after controls 12 Substantial 4 Possible
Risk Risk
Risk Assessment Team
Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-11 Thandeka Khathi

2 Heather Mchunu
3

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 Risk Assessment

Control Measures for Conducting Maintenance and Repairs on an Overhead Crane

D) Engineering Control - Equipment Alarm / Audible Warning Device
D) Engineering Control - Equipment Cones and Hazard triangles
D) Engineering Control - Equipment Safety Harnesses
D) Engineering Control - Equipment Eye Wash Fountain / Bottle
E) Isolation Control - Barriers Barricade Area
E) Isolation Control - Barriers Machine Guarding
E) Isolation Control - Barriers Covers
E) Isolation Control - Barriers Emergency Switch
F) Administrative Control - Appointment Letters Section 37.2 Contractors Agreement
F) Administrative Control - Appointment Letters Section 8
F) Administrative Control - Certificates Electrical Compliance Certificate
F) Administrative Control - Hygiene Survey Noise Survey
F) Administrative Control - Inspections Overhead Crane Inspection Checklist
F) Administrative Control - Inspections Maintenance Management System
F) Administrative Control - Medicals Annual - Full medical examination
F) Administrative Control - Permits Working at Heights
F) Administrative Control - Safety Signs Authorized Persons Only
F) Administrative Control - Safety Signs Warning - WW14 - Beware of Workers Overhead
F) Administrative Control - Safety Signs Mandatory - MV3 - Head Protection Shall be Worn
F) Administrative Control - Safety Signs Warning - WW7 - Beware of Electric Shock
F) Administrative Control - Training Overhead Cranes Certification
F) Administrative Control - Training General Health and Safety - Induction Training
F) Administrative Control - Training Task Analysis and SOPs
F) Administrative Control Safe Operating Procedure Working at Heights
F) Administrative Control Safe Operating Procedure Conducting Maintenance on Overhead Crane
H) PPE Control - Eye Protection Safety Eye Wear
H) PPE Control - Gloves Cut Resistant Gloves
H) PPE Control - Head Protection Hard Hat
H) PPE Control - Overalls Two-Piece Continental Suits 100% Cotton
H) PPE Control - Reflective Bibs and Jackets Cross Over Reflective
H) PPE Control - Shoes Safety Shoe PU Sole
Name Signature

Customized By Sam Wessels

Approved By Thandeka Khathi

https://system.ohsonline.co.za/admin/risk_task_report.php?table= &id= 6762&reports%5B%5D= 2&reports%5B%5D= 3&docs%5B%5D= 1&docs… 21/29

 Risk Assessment

RISK ASSESSMENT and RATING FORM

Activity: Doc No. Rev No. Prepared By :

Sam Wessels

Operating an Overhead Crane 26 1

Risk Assessment Team

Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-11 Thandeka Khathi

2 Heather Mchunu
3

Risk Assessment Methodology Calculator

A. Severity B. Probability
Weighting Impact Effect Weighting Impact Effect
Minor cuts and bruises, small loss of containment, small/minor
perforations, punctures, lacerations, illness, sprains, strains, Has never happened in years of exposure but
1 Noticeable 1 Conceivable
muscle fatigue, cuts, dehydration, shock, 1st degree burns, is possible (Eg : 1 in 1000)
headaches, sinusitis, skin irritation
Administration of first aid care and / or equipment and / or off
site emission but no damage, minor/noticeable cuts, sprains, Remotely
2 Important strains, electric shock, 2nd degree burns, headaches, illness, 2 A less possible coincidence (Eg : 1 in 100)
Possible
respiratory distress, property damage over R100 000, minor
environmental impact
Administration of first aid care and / or equipment and / or off
site emission but no damage, noticeable cuts, sprains, strains,
electric shock, 2nd degree burns, respiratory distress. Loss of Unusual but
3 Serious 3 A more possible occurrence (Eg : 1 in 10)
time (3 days and more) Non-permanent Chronic back and possible
neck injuries, minor fractures,adverse effect on environmentor
property damage over R500 000.
Single fatality, Permanent disability / ill health , non-permanent
damage to environment, loss of limb, permanent noise
4 Very induced hearing loss, loss of sight, multiple fractures, 4 Likely Not unusual , perhaps 50/50 chance of
Serious permanent pelvic/neck/back injuries, 3rd degree burns, occurrence
permanent chronic health conditions, loss of time (14 days
and more) property damage over R1000 000
Multiple fatalities permanent local damage to environment and
eco-system, multiple severe injuries to multiple persons (3rd
5 Disaster degree burns, permanent loss of sight, hearing loss, multiple 5 Almost certain The most likely outcome if the event occurs
fractures, permanent chronic health effects, loss of limb) loss
of time (14 days and more)and property over R10 000 000

Risk Categories
Risk Category Risk Rating Remedial Activities
Critical 25 Intolerable, Implement and Monitor Control Measures, Change method and or transfer risk.
High Risk 15 - 24 Implement and Monitor Control Measures, Change Method and or Mitigate
Substantial 12 - 14 Implement and Monitor Control Measures, Change Method and or Mitigate
Risk
Possible Risk 4 - 11 Implement and Monitor Control Measures
Low Risk 1-3 Monitor

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 Risk Assessment
Assessment of the Risk Assessment of the
before Controls Risk after Controls
A B C A B C

Consequence (Severity)

Consequence (Severity)
What is the Hazards and / or

Exposure (Probability)

Exposure (Probability)
What is the Risk?
Aspect?
Risk Ass ID

Risk Score

Risk Score
Rating Rating
1 Thermal Hazard: Overheated long Overheating of long travel motor of overhead crane during lift causing 3 3 9 Possible 3 1 3 Low
travel motor of overhead crane lifted material to fall resulting in serious head injury, neck injury, fatality Risk Risk
Physical Hazard: Safe work load Person overloading overhead crane hook block causing lifted material Possible Low
2 on hook block of overhead crane to fall onto person resulting possible fractures, head injury, neck injury, 3 3 9 Risk 3 1 3 Risk
not identified fatality
Physical Hazard: Safe work load Person overloading overhead crane causing lifted material to fall onto Possible Low
3 3 3 9 3 1 3
on overhead crane not identified person resulting possible fractures, head injury, neck injury, fatality Risk Risk
Physical Hazard: Sharp edges on
Person makes contact with a sharp point on the pendant control of Possible Low
4 on pendant control of overhead overhead crane resulting in minor cuts, lacerations 3 3 9 Risk 3 1 3 Risk
crane
5 Physical Hazard: Short circuit on Short circuit on db board of overhead crane resulting in 1st, 2nd, 3rd 3 3 9 Possible 3 1 3 Low
db board of overhead crane degree burns, possible fatality Risk Risk
Physical Hazard: Siren on Accidental lowering of hook block of overhead crane onto person Possible Low
6 3 3 9 3 1 3
overhead crane defective resulting possible fractures, head injury, neck injury, fatality Risk Risk
Physical Hazard: Structural Structural damage of gantry causing overhead crane structure to fall Possible Low
7 damage of gantry of overhead resulting in property damage up to R1 000 000, possible multiple 3 3 9 Risk 3 1 3 Risk
crane fatalities
Physical Hazard: Structural Structural damage on end carriage of overhead crane causing
Possible Low
8 damage on end carriage of structure to fall resulting in property damage up to R1 000 000, 3 3 9 Risk 3 1 3 Risk
overhead crane possible multiple fatalities
Physical Hazard: Structural Structural damage on girder of overhead crane causing structure to fall
Possible Low
9 damage on girder of overhead resulting in property damage up to R1 000 000, possible multiple 3 3 9 Risk 3 1 3 Risk
crane fatalities
Physical Hazard: Structural Structural damage on hoist hoist hook causing hoist hook to fall Possible Low
10 damage on hoist hook of overhead resulting in serious head injury, neck injury, possible fatality 3 3 9 Risk 3 1 3 Risk
crane
Physical Hazard: Structural Structural damage on wheels of hoist block of overhead crane causing Possible Low
11 damage on wheels of hoist block hoist block to fall resulting in property damage up to R100 000, 3 3 9 Risk 3 1 3 Risk
of overhead crane possible fatality
12 Physical Hazard: Swinging Person hit by pendant control of overhead crane resulting in minor 3 3 9 Possible 3 1 3 Low
pendant control of overhead crane cuts, lacerations, bruising Risk Risk
Thermal Hazard: Overheated
Overheating of cross travel motor of overhead crane during lift causing Possible Low
13 cross travel motor of overhead 3 3 9 Risk 3 1 3 Risk
lifted material to fall resulting in serious head injury, neck injury, fatality
crane
Thermal Hazard: Overheated hoist Overheating of hoist motor of overhead crane during lift causing lifted
14 3 3 9 Possible 3 1 3 Low
motor of overhead crane material to fall resulting in serious head injury, neck injury, fatality Risk Risk
15 Physical Hazard: Overstrained Overstrained hoist motor of overhead crane during lift causing lifted 4 2 8 Possible 4 1 4 Possible
hoist motor of overhead crane material to fall resulting in serious head injury, neck injury, fatality Risk Risk
16 Physical Hazard: Missing bolts on Missing bolts on girder of overhead crane causing structure to fall 4 2 8 Possible 4 1 4 Possible
girder of overhead crane resulting in property damage up to R100 000, possible fatality Risk Risk
Physical Hazard: Defective safety Defective safety latch on hook of overhead crane causing load to fall Possible Possible
17 4 2 8 4 1 4
latch on hook of overhead crane resulting in serious head injury, neck injury, possible fatality Risk Risk
Physical Hazard: Damaged swivel Damaged swivel on hook block of overhead crane causing lifted Possible Possible
18 4 2 8 4 1 4
on hook block of overhead crane material to fall resulting in serious head injury, neck injury, fatality Risk Risk
Ergonomical Hazard: Continuous Person continuously uses pendant control of overhead crane for a long Possible Possible
19 use of pendant control on period resulting in ergonomical stress, joint pain 4 2 8 Risk 4 1 4 Risk
overhead crane
20 Fire Hazard: Electrical short on Short circuit on hoist motor of overhead crane resulting in fire, property 4 2 8 Possible 4 1 4 Possible
hoist motor of overhead crane damage up to R100 000 Risk Risk
21 Fire Hazard: Short circuit on db Short circuit on db board of on overhead crane resulting in fire, 4 2 8 Possible 4 1 4 Possible
board of overhead crane property damage up to R100 000 Risk Risk
Fire Hazard: Short circuit on Short circuit on electrical control box on overhead crane resulting in fire Possible Possible
22 electrical control box on overhead 4 2 8 4 1 4
with property damage up to R100 000, 1st, 2nd, 3rd degree burns Risk Risk
crane
Physical Hazard: Broken Broken emergency stop control during an uncontrolled load of Possible Possible
23 emergency stop control of overhead crane resulting in serious head injury, neck injury, possible 4 2 8 Risk 4 1 4 Risk
overhead crane fatality
24 Physical Hazard: Broken pendant Broken control pendant control of overhead crane causing uncontrolled 4 2 8 Possible 4 1 4 Possible
control of overhead crane load resulting in cuts and bruises, deep lacerations, possible fractures Risk Risk
Physical Hazard: Broken sheath Sheave hook block of overhead crane breaking during lift causing lifted Possible
25 4 2 8 4 1 4 Possible
hook block of overhead crane material to fall resulting in serious head injury, neck injury, fatality Risk Risk
26 Physical Hazard: Broken stop Broken stop blocks on girder of overhead crane resulting in property 4 2 8 Possible 4 1 4 Possible
blocks on girder of overhead crane damage up to R100 000, possible fatality Risk Risk
Physical Hazard: Damage on Damage on cable at dead end on hoist block causing hoist rope of Possible Possible
27 cable joining at dead end on hoist overhead crane to fall uncontrolled resulting in cuts and bruises, deep 4 2 8 Risk 4 1 4 Risk
block of overhead crane lacerations, possible fractures
Damage on hoist rope of overhead crane causing lifted material to fall
Physical Hazard: Damage on hoist Possible Possible
28 rope of overhead crane uncontrolled resulting in serious head injury, neck injury possible 4 2 8 Risk 4 1 4 Risk
fatality
Physical Hazard: Damaged centre
Damaged centre pulley on cross travel of overhead crane causing load Possible Possible
29 pulley on cross travel of overhead 4 2 8 4 1 4
to fall resulting in serious head injury, neck injury, possible fatality Risk Risk
crane
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 Risk Assessment
30 Physical Hazard: Damaged or Winch drum of overhead crane breaking during lift causing lifted 4 2 8 Possible 4 1 4 Possible
broken winch drum of overhead material to fall resulting in serious head injury, neck injury, fatality Risk Risk
crane
Physical Hazard: Damaged or Brake failure on overhead crane causing girder to run into stop blocks Possible Possible
31 worn brakes on overhead crane resulting in property damage up to R500 000, bumps, bruises, 4 2 8 Risk 4 1 4 Risk
lacerations, fractures, possible multiple fatalities
32 Physical Hazard: Damaged rails of Damaged rails of overhead crane causing structure to fall resulting in 4 2 8 Possible 4 1 4 Possible
overhead crane property damage up to R100 000, possible fatality Risk Risk
Physical Hazard: Damaged Damaged sheaves on hook block of overhead crane causing hoist
Possible Possible
33 sheathes on hook block of rope to break resulting in serious head injury, neck injury, possible 4 2 8 Risk 4 1 4 Risk
overhead crane fatality
34 Electrical Hazard: Exposed Person makes contact with exposed electrical wires of overhead crane 4 2 8 Possible 4 1 4 Possible
electrical wires on overhead crane resulting in 1st, 2nd or 3rd degree burns, unconsciousness, fatality Risk Risk
Total over-all rating before and after controls 9 Possible 3 Low
Risk Risk
Risk Assessment Team
Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-11 Thandeka Khathi

2 Heather Mchunu
3

https://system.ohsonline.co.za/admin/risk_task_report.php?table= &id= 6762&reports%5B%5D= 2&reports%5B%5D= 3&docs%5B%5D= 1&docs… 24/29

 Risk Assessment

Control Measures for Operating an Overhead Crane

D) Engineering Control Load Limiting device
D) Engineering Control - Equipment Overhead Crane Pendant Control Hook
D) Engineering Control - Equipment Safety Harnesses
D) Engineering Control - Equipment Eye Wash Fountain / Bottle
E) Isolation Control - Barriers Demarcated Walkways
E) Isolation Control - Barriers Electrical Cover
E) Isolation Control - Barriers Lock-Out Device
E) Isolation Control - Barriers Access Controllable Doors - Buzz in System
E) Isolation Control - Barriers Machine Guarding
E) Isolation Control - Barriers Covers
E) Isolation Control - Barriers Emergency Switch
E) Isolation Control - Barriers Emergency Stop Controls
F) Administrative Control - Appointment Letters Competent Crane Operator
F) Administrative Control - Appointment Letters Section 8
F) Administrative Control - Certificates Load Test Certificate
F) Administrative Control - Certificates Electrical Compliance Certificate
F) Administrative Control - Inspections Overhead Crane Inspection Checklist
F) Administrative Control - Medicals Annual - Full medical examination
F) Administrative Control - Safety Signs Warning - WW7 - Beware of Electric Shock
F) Administrative Control - Safety Signs Mandatory - MV3 - Head Protection Shall be Worn
F) Administrative Control - Safety Signs Mandatory (DO) - MV1 - Eye Protection Shall be Worn
F) Administrative Control - Training Overhead Cranes Certification
F) Administrative Control - Training Rigging and Slinging Training
F) Administrative Control - Training General Health and Safety - Induction Training
F) Administrative Control - Training Task Analysis and SOPs
F) Administrative Control Safe Operating Procedure Conducting Maintenance on Overhead Crane
F) Administrative Control Safe Operating Procedure Operating an Overhead Crane
G) Behavior Control - Communication Awareness Ergonomical Stresses
G) Behavior Control - Communication Awareness Ergonomics in the Workplace
G) Behavior Control - Communication Awareness General Safety Awareness
G) Behavior Control - Communication Awareness Lifting Safety
H) PPE Control - Eye Protection Safety Eye Wear
H) PPE Control - Gloves Leather Gloves
H) PPE Control - Head Protection Hard Hat
H) PPE Control - Hearing Protection Ear Plugs - Disposable
H) PPE Control - Overalls Two-Piece Continental Suits 100% Cotton
H) PPE Control - Reflective Bibs and Jackets Cross Over Reflective
H) PPE Control - Shoes Safety Boot PU Shoe
H) PPE Control - Shoes Safety Shoe PU Sole
Name Signature

Customized By Sam Wessels

Approved By Thandeka Khathi

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 Risk Assessment

RISK ASSESSMENT and RATING FORM

Prepared By :
Activity: Doc No. Rev No.
Sam Wessels

Conducting Administrative Duties in a Office 34 1

Risk Assessment Team

Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-10 Thandeka Khathi

2 Heather Mchunu
3

Risk Assessment Methodology Calculator

A. Severity B. Probability
Weighting Impact Effect Weighting Impact Effect
Minor cuts and bruises, small loss of containment, small/minor
perforations, punctures, lacerations, illness, sprains, strains, Has never happened in years of exposure but
1 Noticeable 1 Conceivable
muscle fatigue, cuts, dehydration, shock, 1st degree burns, is possible (Eg : 1 in 1000)
headaches, sinusitis, skin irritation
Administration of first aid care and / or equipment and / or off
site emission but no damage, minor/noticeable cuts, sprains, Remotely
2 Important strains, electric shock, 2nd degree burns, headaches, illness, 2 A less possible coincidence (Eg : 1 in 100)
Possible
respiratory distress, property damage over R100 000, minor
environmental impact
Administration of first aid care and / or equipment and / or off
site emission but no damage, noticeable cuts, sprains, strains,
electric shock, 2nd degree burns, respiratory distress. Loss of Unusual but
3 Serious 3 A more possible occurrence (Eg : 1 in 10)
time (3 days and more) Non-permanent Chronic back and possible
neck injuries, minor fractures,adverse effect on environmentor
property damage over R500 000.
Single fatality, Permanent disability / ill health , non-permanent
damage to environment, loss of limb, permanent noise
4 Very induced hearing loss, loss of sight, multiple fractures, 4 Likely Not unusual , perhaps 50/50 chance of
Serious permanent pelvic/neck/back injuries, 3rd degree burns, occurrence
permanent chronic health conditions, loss of time (14 days
and more) property damage over R1000 000
Multiple fatalities permanent local damage to environment and
eco-system, multiple severe injuries to multiple persons (3rd
5 Disaster degree burns, permanent loss of sight, hearing loss, multiple 5 Almost certain The most likely outcome if the event occurs
fractures, permanent chronic health effects, loss of limb) loss
of time (14 days and more)and property over R10 000 000

Risk Categories
Risk Category Risk Rating Remedial Activities
Critical 25 Intolerable, Implement and Monitor Control Measures, Change method and or transfer risk.
High Risk 15 - 24 Implement and Monitor Control Measures, Change Method and or Mitigate
Substantial 12 - 14 Implement and Monitor Control Measures, Change Method and or Mitigate
Risk
Possible Risk 4 - 11 Implement and Monitor Control Measures
Low Risk 1-3 Monitor

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 Risk Assessment
Assessment of the Risk Assessment of the
before Controls Risk after Controls
A B C A B C

Consequence (Severity)

Consequence (Severity)
Exposure (Probability)

Exposure (Probability)
What is the Hazards and / or Aspect? What is the Risk?
Risk Ass ID

Risk Score

Risk Score
Rating Rating
Biological Hazard: Communicable
Making contact with biological agents at fingerprint scanner
1 diseases, bacteria and viruses on while conducting administrative duties in a office resulting in 3 2 6 Possible 3 1 3 Low
fingerprint scanner while conducting bacterial or viral infection Risk Risk
administrative duties in a office
Physical Hazard: Severely tinted windows Colliding with oncoming person due to poor visibility while Possible Low
2 in office area while conducting conducting administrative duties in a office resulting in minor 3 2 6 Risk 3 1 3 Risk
administrative duties in a office bumps and bruises
Physical Hazard: Turning or moving Person is struck by turning or moving turnstiles while Possible Low
3 objects in turnstiles in office area while conducting administrative duties in a office resulting in minor 3 2 6 Risk 3 1 3 Risk
conducting administrative duties in a office bumps and bruises, concussion
Slip, Trip and Fall Hazard: Protruding Person slips and falls over protruding carpet edging strips Possible Low
4 carpet edging strips while conducting while conducting administrative duties in a office resulting in 3 2 6 3 1 3
Risk Risk
administrative duties in a office minor strains, sprains and fractures
Slip, Trip and Fall Hazard: Cleaning
appliances (brooms, mops, buckets, Person slips and falls over cleaning materials while conducting Possible Low
5 vacuum cleaner, cleaning cloths) left administrative duties in a office resulting in minor strains, 3 2 6 Risk 3 1 3 Risk
unattended while conducting sprains and fractures
administrative duties in a office
Slip, Trip and Fall Hazard: Cracked tiles Person trips and falls over cracked tiles and floor surfaces Possible Low
6 and floor surfaces in office area while while conducting administrative duties in a office resulting in 3 2 6 Risk 3 1 3 Risk
conducting administrative duties in a office minor strains, sprains and fractures
Slip, Trip and Fall Hazard: Electrical Person slips and falls over electrical cables while conducting Possible Low
7 cables running over carpets while administrative duties in a office resulting in minor strains, 3 2 6 Risk 3 1 3 Risk
conducting administrative duties in a office sprains and fractures
Slip, Trip and Fall Hazard: Furniture items Person trips and falls over furniture items in walkway while
Possible Low
8 in walkways while conducting conducting administrative duties in a office resulting in minor 3 2 6 Risk 3 1 3 Risk
administrative duties in a office strains, sprains and fractures
Slip, Trip and Fall Hazard: Loose carpets Person trips and falls over a loose carpets while conducting Possible Low
9 in office area while conducting administrative duties in a office resulting in minor strains, 3 2 6 Risk 3 1 3 Risk
administrative duties in a office sprains and fractures
Slip, Trip and Fall Hazard: Loose tiles on Person trips and falls over a loose tiles while conducting Possible Low
10 office area while conducting administrative administrative duties in a office resulting in minor strains, 3 2 6 Risk 3 1 3 Risk
duties in a office sprains and fractures
Slip, Trip and Fall Hazard: Lubricated or Person slips and falls over a wet lubricated floor while Possible Low
11 wet surface while conducting conducting administrative duties in a office resulting in minor 3 2 6 Risk 3 1 3 Risk
administrative duties in a office strains, sprains and fractures
Slip, Trip and Fall Hazard: Poorly placed Person trips and falls over poorly placed delivered goods while
Possible Low
12 delivered goods in walking space while conducting administrative duties in a office resulting in minor 3 2 6 3 1 3
Risk Risk
conducting administrative duties in a office strains, sprains and fractures
Slip, Trip and Fall Hazard: Sidewalk while Person trips and falls over a sidewalk while conducting Possible
13 conducting administrative duties in a office administrative duties in a office resulting in minor strains, 3 2 6 Risk 3 0 0
sprains and fractures
Slip, Trip and Fall Hazard: Slippery ramp Person slips and falls using a disabled persons ramp while Possible Low
14 for disabled persons while conducting conducting administrative duties in a office resulting in minor 3 2 6 Risk 3 1 3 Risk
administrative duties in a office strains, sprains and fractures
Slip, Trip and Fall Hazard: Stairs or steps Person trips and falls over stairs or steps while conducting Possible Low
15 while conducting administrative duties in a administrative duties in a office resulting in minor strains, 3 2 6 Risk 3 1 3 Risk
office sprains and fractures
Slip, Trip and Fall Hazard: Uneven floor Person trips and falls over an uneven floor surface while Possible Low
16 surfaces in office area while conducting conducting administrative duties in a office resulting in minor 3 2 6 Risk 3 1 3 Risk
administrative duties in a office strains, sprains and fractures
Physical Hazard: Protruding sharp edge Person makes contact with protruding sharp edges on furniture Possible Low
17 from furniture in office area while in office area while conducting administrative duties in a office 3 2 6 Risk 3 1 3 Risk
conducting administrative duties in a office resulting in minor cuts, lacerations
Physical Hazard: Protruding door latch in Person makes contact with protruding door latch in office area Possible Low
18 office area while conducting administrative while conducting administrative duties in a office resulting in 3 2 6 Risk 3 1 3 Risk
duties in a office minor cuts, lacerations
Biological Hazard: On door handles, Making contact with biological agents on door handles while
Possible Low
19 surfaces and furniture in office area while conducting administrative duties in a office resulting in 3 2 6 3 1 3
Risk Risk
conducting administrative duties in a office bacterial or viral infection
Electrical Hazard: Exposed Electrical wires Contact with exposed electrical wires at fingerprint scanner Possible Low
20 by fingerprint scanning device while while conducting administrative duties in a office resulting in 3 2 6 Risk 3 1 3 Risk
conducting administrative duties in a office 1st and 2nd degree burns
Electrical Hazard: Loose connections and Contact between loose and live electrical wires on fingerprint
wiring by fingerprint scanning and other scanner and other electrical devices while conducting Possible Low
21 administrative duties in a office resulting in uncontrolled fire, 3 2 6 3 1 3
electrical devices while conducting Risk Risk
property damage up to R100 000, 2nd or 3rd degree burns,
administrative duties in a office
electrical shock
Ergonomical Hazard: Delivered Items to Manually moving heavy loads while conducting administrative
22 be manually moved through office area duties in a office resulting in minor sprains and strains, chronic 3 2 6 Possible 3 2 6 Possible
while conducting administrative duties in a Risk Risk
back injuries
office

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 Risk Assessment
23 New Hazard for Task:2133 New Risk for Task:2133 3 2 6 Possible 3 1 3 Low
Risk Risk
Possible Low
24 New Hazard for Task:2133 New Risk for Task:2133 3 2 6 3 1 3
Risk Risk
25 New Hazard for Task:2133 New Risk for Task:2133 3 2 6 Possible 3 1 3 Low
Risk Risk
Physical Hazard: Automatic sliding doors Person is struck by automatic sliding doors while conducting Possible Low
26 in office area while conducting administrative duties in a office resulting in minor bumps and 3 2 6 Risk 3 1 3 Risk
administrative duties in a office bruises, concussion
Physical Hazard: Criminal activity such as Exposure to criminal activity such as hostage taking resulting
Possible Low
27 hostage taking while conducting in mental trauma, bumps and bruises, fractures, severe 3 2 6 Risk 3 1 3 Risk
administrative duties in a office bleeding, unconsciousness, fatality
Physical Hazard: Criminal activity such as Exposure to criminal activity such as robberies while
28 robberies while conducting administrative conducting administrative duties in a office resulting in mental 3 2 6 Possible 3 1 3 Low
trauma, bumps and bruises, fractures, severe bleeding, Risk Risk
duties in a office
unconsciousness, possible fatality
Physical Hazard: Glass with no visual Colliding with hard objects such as glass windows, doors while Possible Low
29 indicators in office area while conducting conducting administrative duties in a office resulting in minor 3 2 6 Risk 3 1 3 Risk
administrative duties in a office bumps and bruises, cuts, severe bleeding
Physical Hazard: Limited room for moving Moving in a confined area resulting in contact with hard
Possible Low
30 through and in the office area while surfaces while conducting administrative duties in a office, 3 2 6 Risk 3 1 3 Risk
conducting administrative duties in a office minor bumps and bruises
Physical Hazard: Pinch points between Person makes contact with pinch points between door and
Possible Low
31 door and door frames while conducting door frames while conducting administrative duties in a office 3 2 6 Risk 3 1 3 Risk
administrative duties in a office resulting in minor cuts, lacerations, sprains and strains
Physical Hazard: Pinch points between Person makes contact with pinch points between two sliding
Possible Low
32 two sliding doors while conducting doors while conducting administrative duties in a office 3 2 6 Risk 3 1 3 Risk
administrative duties in a office resulting in minor cuts, lacerations, sprains and strains
Physical Hazard: Pinch points within and Person makes contact with pinch points between gates or
33 between turnstile gates or doors by office turnstiles while conducting administrative duties in a office 3 2 6 Possible 3 1 3 Low
area while conducting administrative Risk Risk
resulting in minor cuts, lacerations, sprains and strains
duties in a office
Slip, Trip and Fall Hazard: Wet lubricated Person slips and falls over lubricated or slippery surfaces while Possible Low
34 floors in office area while conducting conducting administrative duties in a office resulting in head, 3 2 6 Risk 3 1 3 Risk
administrative duties in a office neck, back and pelvic injuries
Possible Low
Total over-all rating before and after controls 6 3
Risk Risk
Risk Assessment Team
Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-10 Thandeka Khathi

2 Heather Mchunu
3

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8/11/22, 12:28 AM Risk Assessment

Control Measures for Conducting Administrative Duties in a Office

F) Administrative Control - Hygiene Survey Illumination Survey
F) Administrative Control - Inspections Health and Safety Representative Inspection Checklist
F) Administrative Control - Training General Health and Safety - Induction Training
F) Administrative Control - Training Task Analysis and SOPs
G) Behavior Control - Communication Awareness Hand Safety
G) Behavior Control - Communication Awareness General Health and Safety
Risk Assessment Team
Member Name Date Approved by Approved Signature Responsible person

1 Thandeka Khathi 2023-08-10 Thandeka Khathi

2 Heather Mchunu
3

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