Appendix 1C Risk Assessment and Risk Control Form for Manual Tasks

This is a Risk Assessment and Control Form for Manual Tasks that helps in assessing and controlling risks from manual tasks. It follows the National Code of Practice for the Prevention of Musculoskeletal Disorders from Performing Manual Tasks at Work (2007). The form includes questions related to repetitive or sustained postures, movements or forces, long duration, and high force. It also provides control options to eliminate or reduce the risk of injury.

Appendix 1C Risk Assessment and Risk Control Form (ASSESSING & CONTROLLING RISKS FROM MANUAL TASKS)
Date of assessment: Work area management rep:
Description of manual task:
Work area H&S rep:
Location of task: Others (employees, consultants):
Reason for identification
Existing task Change in task, object or tool Report of musculoskeletal disorder (MSD)
New task New information Change in the workplace/work environment
The National Standard for Manual Tasks (2007) requires duty holders to assess the risk of any hazardous manual tasks found in the workplace and put effective m
prevent injury by eliminating the risk
where elimination is not reasonably practicable, reduce the risk of injury as much as is reasonably practicable
How to use this worksheet
Follow the worksheet step by step and refer to the National Code of Practice for the Prevention of Musculoskeletal Disorders from Performing Manual Tasks at Wo
as indicated on the worksheet to:
assess tasks in the workplace involving hazardous manual tasks and determine the sources of risk – Refer COP Sections 6.3
list appropriate risk control measures – Refer COP Sections 6.4
implement those measures – Refer COP Sections 6.4
You are required to consult with the relevant health and safety representatives and, where possible, also involve the employees who do the tas
and introducing risk controls.
This worksheet and the Code of Practice can be downloaded from the ASCC website at www.ascc.gov.au
>
>
>
>
>
Record your assessment! – It is recommended that you retain your risk assessment if it shows a risk of injury.
Control any risk! – This worksheet provides general guidelines only. Some workers may still be at risk of injury because manual handling occurs in a variety of
tasks and workplace situations, and injury may be caused by a number of factors. It is important, as far as is reasonably practicable, to control any risk you find.
Assessment details Persons doing assessment
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
Question 1 – Does the task involve repetitive or sustained postures, movements or forces?
Tick yes if the task requires any of the following actions to be done:
repetitively (done more than twice a minute) OR
sustained (done for more than 30 seconds at a time)
>
>
Postures and Movements Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Bending the back
forwards or sideways
more than 20 degrees
20˚
20˚
41
Twisting the back
more than 20 degrees
41
Any visible
backward bending
41
Bending the head
forwards or sideways
more than 20 degrees
20˚ 20˚ 41
Eliminate the manual task
Automate or mechanise the task, especially
repetitive functions
Modify operation or production method
Use bulk handling methods
Alter the design and layout of the workplac
Ensure the equipment accounts for
differences in worker size, shape
and physical ability – i.e. adjustable
or fixed to suit all workers
Ensure working heights are matched to the
task and the worker
Ensure items are within reaching distance
Place items where the person can
be in a comfortable symmetrical
posture when handling
Provide seating that matches the needs
of the task and the worker – i.e. adjustable
seating for multiple workers
Reposition items that workers are required
to look at
>
>
>
>
>
>
>
>
>
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Any visible bending of
the head backwards
41
Twisting the neck more than
20 degrees
41
Working with one or both
hands above shoulder height
41
Reaching forward or sideways
more than 30cm from the
body
41
Reaching behind the body 41
Squatting, kneeling, crawling,
lying, semi-lying or jumping
41
Postures and Movements Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Use fixtures/jigs to orientate the item
worked on by the worker
Provide arm supports for precision work
Alter the nature of the load handled (p 64)
Alter the size or shape of the load
Alter the items used (p 70)
Use power tools
Ensure tools are suitable for the task
Ensure tools orient the arm, hand and
wrist in a power grip position
Alter the working environment (p 72)
Ensure visual requirements are not
too demanding by providing breaks,
better lighting
Provide visual aids
Ensure lighting is suitable to task
demands – i.e. task lighting for fine,
manipulative work
Alter the work organisation (p 74)
Relocate equipment or items
Restructure task to minimize multiple
handling
Remove machine or other pacing
Remove or monitor piecework schemes
Select the best working position for the
type of work being undertaken
>
>
>
>
>
>
>
>
>
>
>
>
>
>
* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Postures and Movements Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Standing with most of the
body’s weight on one leg
41
Twisting, turning, grabbing,
picking or wringing actions with
the fingers, hands or arms
41
Working with the fingers
close together or wide apart
41
Very fast movements 41
Bending of the wrist beyond
the angles indicated on page
40 of the Code of Practice
41
* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Forces Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Lifting, lowering or carrying 43
Carrying with one hand
or one side of the body
43
Exerting force with one hand
or one side of the body
43
Pushing, pulling or dragging 43
Gripping with the fingers
pinched together or held
wide apart
43
Eliminate the manual task
Automate or mechanise the task, especially
tasks that are repetitive
Modify operation or production method
Use bulk handling methods
Alter the design and layout of the workplac
Provide a means for attaching mechanical
aids for lifting to the load
Use jigs to hold or support the items
Alter the workplace so mechanical aids
can be used and are accessible
Alter the load handled (p 64)
Reduce weight and dimensions of the load
Reduce the number of items handled at
one time
Provide handles, handholds or cut-outs
to improve grip
Reduce amount of manipulation required
(use mechanical aids)
Modify the load so mechanical aids can
be used
Alter the items used (p 70)
Use power tools
Ensure tools are suitable for the task
Use lightweight tools where possible
Use tool counterbalances
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
Forces Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Using a finger grip, pinch
grip, or an open handed grip
to handle a load
43
Exerting force while in
an awkward posture, for
example, supporting items
while arms or shoulders are
in an awkward posture, or
moving items while legs are
in an awkward posture
43
Holding, supporting or
restraining any object,
person, animal or tool
43
Ensure tool handles fit workers comfortably
Maintain tools and equipment
Alter the work organisation (p 74)
Alter the method used to perform the
task – i.e. push rather than pull and
slide rather than lift
If gloves are used, ensure that they fit and
are suited to the task
Provide rest or recovery breaks to prevent
the onset of fatigue
Restructure task to minimize
multiple handling
>
>
>
>
>
>
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Question 2 – Does the task involve long duration?
Tick yes if the task is done for:
Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
More than 2 hours
over a whole shift,
OR
Continually for more than
60 minutes at a time
43 Alter work organisation (p 74)
Increase variety of tasks over the whole day
Provide rest or recovery breaks to prevent
the onset of fatigue
Implement task rotation
>
>
>
Question 3 – Does the task involve high force?
Tick yes if the task involves any of the following actions:
High Force Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Lifting, lowering or
carrying heavy loads
45
Pushing or pulling objects
that are hard to move or are
hard to stop (e.g. a trolley)
45
Using a finger-grip,
a pinch-grip or an open-
handed grip to handle
a heavy or large load
45
Eliminate the manual task
Automate or mechanise the task, especially
repetitive functions
Modify operation or production method
Use bulk handling methods
Alter the design and layout of the workplac
Use foot pedals
Provide a means for attaching mechanical
aids for lifting to the load
Use jigs to hold items
Modify the workplace layout to ensure
the movements of workers handling
people are not constrained
Alter the load handled (p 64)
>
>
>
>
>
>
>
* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

High Force Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Exerting force at the
limit of the grip span
45
Needing to use two
hands to operate a tool
designed for one hand
45
Holding, supporting or
restraining a person,
animal or heavy object
45
Exerting force with the
non-preferred hand
45
Two or more people need
to be assigned to handle a
heavy or bulky load
45
During the application of
high force, the body is in
a bent, twisted or otherwise
awkward posture
45
Reduce weight of the load
Reduce the number of items handled
at one time
Provide handles, handholds or cutouts
to improve grip
Modify the load so mechanical aids can
be used
Move animals to a place that constrains
movement before commencing the task
Alter the items used (p 70)
Use power tools
Ensure tools are suitable for the task
Use lightweight tools where possible
Use tool counterbalances
Ensure tool handles
fit workers comfortably
Maintain tools and equipment
Alter the work organisation (p 74)
Restructure task to minimize
multiple handling
Reduce amount of manipulation
required (use mechanical aids)
Alter the method used to perform the
task – i.e. push rather than pull and
slide rather than lift
>
>
>
>
>
>
>
>
>
>
>
>
>
>
* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

High Force Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Applying force suddenly
in response to unexpected
forces (for example, when
an animal suddenly moves)
45
Hitting or kicking 45
Holding, supporting or
restraining a person or animal
likely to move unexpectedly
45
Throwing or catching 45
Jumping while loading a load 45
If gloves are used, ensure that they are
well fitted and are suited to the task
Provide adequate rest breaks to prevent
the onset of fatigue
Reduce the effort require to start
a load in motion by aligning wheels
to the direction of travel
Control unpredictable movements,
for example movements of animals
by using physical constraints
>
>
>
>
* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
Tick yes if workers report any of the following about the task
High Force Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
The task can only be
done for short periods
46
Pain or significant discomfort
during or after the task
46
Stronger workers are
assigned to do the task
46
Workers think the task
should be done by more
than one person, or seek
help to do the task
46
Workers say the task is
physically very strenuous
or difficult to do
46
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Question 4 – Is there a risk?
Does the task involve repetitive or sustained postures, movements or forces, AND long duration?
Tick yes if you ticked any boxes in Questions 1 and 2 The task is a risk. Risk control is
Does the task involve high force?
Tick yes if you ticked any box in Question 3 The task is a risk. Risk control is
Question 5 – Are aspects of the work environment or the way work is organised increasing the risk?
Tick yes if the task involves:
Vibration Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Hand-arm vibration 48
Whole-body vibration 48
Eliminate the manual task
Use remote controlled processes to
isolate workers from vibration sources
Alter the design and layout of the workplac
Isolate workers from vibration
sources through the use of
damping or suspension systems.
Alter the items used (p 70)
Select alternative lower vibration equipment
Use balancers/tensioners
Use vibration damping materials
Maintain equipment
Alter work organisation (p 74)
Reduce exposure time to vibration
Eliminate the manual task
>
>
>
>
>
>
>
* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Thermal Environment Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Low temperatures (for
example, in cool rooms,
cold stores, or working
outside in cold weather)
49
Wearing thick clothing that
restricts movement while
working in cold conditions
(e.g. gloves)
49
Handling very cold or
frozen objects
49
High air temperatures
(for example, in foundries,
laundries, kitchens,
manufacturing processes
which generate heat,
or working outside in
hot weather)
49
Radiant heat (for example,
from the sun, or from
processes such as smelting
or plastics extrusion)
49
Automate or isolate processes
Alter the items used (p 70)
Insulate hot/cold items or tools
Alter the working environment (p 72)
Redirect cold exhaust air
Improve ventilation and air circulation
Provide shade
Provide thermal screens/barriers
Provide sheltered walkways/wind barriers
Provide lighting suited to the task
Alter work organisation (p 74)
Avoid working in the cold
Provide warm clothing
Avoid working in the heat
Provide a supply of drinking water
Allow workers time to acclimatise
to cold and heat
Provide rest breaks
Implement task rotation
Provide information and training
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Thermal Environment Page Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Wearing heavy protective
clothing while working in
hot conditions
49
Workers are working in hot
conditions and they are not
used to it
49
High humidity caused by
the weather or processes
such as steam cleaning
49
Windy conditions, combined
with hot or cold weather
49
Handling large objects
in windy conditions
49
Wind chill caused by
exposure to wind in
low temperatures
49
* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Work organisation and work practicesPage Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
The work rate being set by a
machine or the team and not
under the worker’s control
50
Systems of work, such as
piecework, that encourage
workers to skip breaks to
finish early, or to produce
more items in the set time
50
Levels of work demand that
workers find difficult to keep
up with (pace)
50
Sustained high levels of
attention and concentration
50
Systems of work that
offers the worker little
or no control over the
way they do their work
50
Workers frequently needing
to meet tight deadlines
50
* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
Alter work organisation (p 74)
Allow for task variation
Provide rest breaks
Allow workers some latitude to
influence the rate and pace of work
Ensure workloads and deadlines
are achievable
Ensure good communication and
reporting of problems
Give and receive feedback about work
requirements and performance
Allow workers some latitude to
influence workload, work methods
and changes in the workplace
Monitor and control overtime
and shiftwork
Provide appropriate training and
supervision to develop and maintain
skills required
Allow for a gradual build up to full
production speed
Seek advice on special requirements
>
>
>
>
>
>
>
>
>
>
>
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Work organisation and work practicesPage Comments* Describe any risk control
options you have identified
Control Options
(not exhaustive list)
Sudden changes in workload,
or seasonal changes
in volume without any
mechanisms for dealing
with the change
50
Levels of physical work
demand that workers find
difficult to maintain (effort)
50
Tick yes if workers
Feel that guidance and
resources provided by
supervisors or co-workers
should be increased so
they can perform to the
required standard
50
Feel that they have not
been given sufficient training
and information by their
employers in order to carry
out their job successfully
50
* Describe what the person is doing – e.g. hand operation of drill 10 times per minute, performed 3 hrs per day, five days a week
What are the sources of risk? Describe any aspect of the design and layout of the workplace, the nature of the load handled, the nature of the item used, the working environme
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Has there been a report of MSD associated with this task?
The report of MSD associated with the task usually means increased risk so implementing risk controls should be a high priority.
Tick yes if any reports of MSD have been made
Provide comments here. It may be helpful to sketch the task or attach a photograph, and describe the task or area more fully.
If you found any risk of MSD, you must control it as far as is reasonably practicable.
Generally, the more boxes you ticked in each section on this worksheet, the greater the risk.
If the assessment shows a risk of MSD, you should keep this record until the task is no longer done or if the task is changed and another assessment is done.
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Risk Control
How are you going to fix the problems?
You may need to use a combination of risk controls to eliminate or minimise the risk as far as reasonably practicable.
Can you stop doing the task or part of the task?
No
Can you eliminate or reduce the risk by doing
one or more of these things?
altering the design and layout of the workplace
altering the nature of the load
altering the nature of the items used
altering the working environment
altering work practices and work organisation
>
>
>
>
>
No
Yes Describe how you can eliminate the need to perform the task?
What information, instruction, training and supervision is necessary to make the new procedure work properl
Can you stop doing the task or part of the task?
What information, instruction, training and supervision is necessary to make the new procedure work properl
Can you reduce the risk with information, instruction, training and supervision? How?
Yes
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF

Implementing Risk Controls
Task: Date prepared:
When will these controls be implemented?
Short-term (immediately to within a few weeks)
Action required Person responsible Completion date Reviewed date Action completed
Medium-term (within a few weeks to a couple of months)
Action required Person responsible Completion date Reviewed date Action completed
Long-term (within several months)
Action required Person responsible Completion date Reviewed date Action completed
NATIONAL CODE OF PRACTICE FOR THE PREVENTION OF MUSCULOSKELETAL DISORDERS FROM PERF