Risk Assessment & Method Statement — Ready to use, print, and adapt
| Rating | Descriptor | Description |
|---|---|---|
| 1 | Very Unlikely | Could happen but only in exceptional circumstances |
| 2 | Unlikely | Not expected to occur but possible |
| 3 | Possible | Could occur at some time |
| 4 | Likely | Will probably occur in most circumstances |
| 5 | Very Likely | Expected to occur frequently or is ongoing |
| Rating | Descriptor | Description |
|---|---|---|
| 1 | Insignificant | No injury, negligible impact |
| 2 | Minor | First aid treatment, minor property damage |
| 3 | Moderate | Medical treatment, lost time, moderate damage |
| 4 | Major | Serious injury, hospitalisation, major damage |
| 5 | Catastrophic | Fatality, permanent disability, total destruction |
| Rating | Level | Action Required |
|---|---|---|
| 1 – 4 | LOW | Acceptable risk. Monitor and maintain controls. No additional action required. |
| 5 – 9 | MEDIUM | Tolerable with controls. Review controls regularly. Reduce further if reasonably practicable. |
| 10 – 15 | HIGH | Additional controls required before proceeding. Senior management approval needed. |
| 16 – 25 | VERY HIGH | Unacceptable. Work must not proceed. Immediate action to eliminate or significantly reduce risk. |
This RAMS covers the operation of counterbalance and reach truck forklift trucks for the purposes of loading, unloading, stacking, and transporting goods within warehouse environments and external yard areas. It applies to all PHW Services operators and those under PHW supervision during training or assessment activities. Operations include pallet handling, racking operations, vehicle loading/unloading, and general materials movement.
| Hazard | Who at Risk | L | S | Risk | Control Measures | Residual |
|---|---|---|---|---|---|---|
| Collision with pedestrians | Operators, warehouse staff, visitors | 4 | 4 | 16 | Designated pedestrian walkways with physical barriers. Blue/red spot warning lights on FLTs. Speed limits enforced (5 mph internal, 10 mph external). Mirrors at blind corners. One-way traffic systems where practicable. High-visibility clothing mandatory for all personnel. | 6 |
| Overturning of truck | Operator | 2 | 5 | 10 | Pre-use checks to verify tyre condition and hydraulics. Speed limits on turns and ramps. Loads carried low to ground (<300mm). No operation on slopes exceeding manufacturer limits. Seatbelt use mandatory. Training in stability triangle principles. No sharp turns with elevated loads. | 4 |
| Falling loads from forks/racking | Operator, nearby workers | 3 | 4 | 12 | Load secured before travel. Pallet condition checked before lifting. Racking inspections (SEMA guidelines). No walking under raised forks. Overhead guard fitted. Fork extensions used for oversized loads. Load weight checked against truck capacity. | 6 |
| Striking racking or fixed structures | Operator, nearby workers | 3 | 3 | 9 | Adequate aisle widths maintained. Racking protection (column guards, barriers). Operator familiarisation with site layout. Speed limits. Proper lighting (minimum 200 lux). Rack end protectors installed. | 4 |
| Manual handling injuries during coupling/uncoupling | Operator | 3 | 2 | 6 | Correct technique training. Ergonomic assessment of attachment changeover tasks. Mechanical aids where available. Regular breaks for repetitive tasks. | 3 |
| Exhaust fumes / poor ventilation (IC engines) | All warehouse personnel | 3 | 3 | 9 | Electric trucks used indoors where possible. Adequate ventilation in enclosed areas. CO monitoring if IC trucks used indoors. Engine maintained to manufacturer specifications. Doors opened during intensive IC truck use. | 4 |
| Unsafe loading/unloading from HGVs | Operator, delivery drivers | 3 | 4 | 12 | Vehicle restraint system or wheel chocks in use. Trailer brakes applied. Communication protocol between driver and operator. Trailer kingpin lock if applicable. Dock levellers inspected. Banksman for external manoeuvres. Drivers to remain in cab or designated safe area. | 6 |
| Battery charging hazards (electric FLTs) | Operator, maintenance staff | 2 | 3 | 6 | Designated charging area with ventilation. No smoking/naked flames signage. Eye wash station available. PPE (acid-resistant gloves, goggles) for battery maintenance. Trained personnel only. Spill kit accessible. | 3 |
| Noise exposure | Operator, nearby workers | 3 | 2 | 6 | Noise assessment conducted. Hearing protection available in designated zones (above 80 dB). Engine/motor maintenance. Quiet hours policy for residential-adjacent sites. | 3 |
| Poor visibility / blind spots | Operator, pedestrians | 3 | 4 | 12 | Mirrors and cameras fitted. Reversing alarms operational. Blue spot lights. Travel in reverse with bulky loads. Spotter/banksman for restricted visibility areas. Adequate lighting maintained throughout workspace. | 6 |
Emergency contacts: Site First Aider / Site Manager / Emergency Services: 999
This RAMS covers the delivery of plant and forklift truck operator training and assessment at client premises by PHW Services instructors. Activities include classroom-based theory sessions, practical operator training, competence assessments, and refresher courses. Equipment may be client-owned or PHW-supplied. Venues range from warehouses and distribution centres to construction sites and manufacturing facilities.
| Hazard | Who at Risk | L | S | Risk | Control Measures | Residual |
|---|---|---|---|---|---|---|
| Unfamiliar site layout / hazards | Instructor, candidates | 3 | 3 | 9 | Pre-visit site survey or questionnaire completed. Site induction attended on arrival. Emergency exits, assembly points, and first aid locations identified. Site-specific risk assessment reviewed with host. Training area boundaries clearly defined. | 4 |
| Interaction with site traffic and operations | Instructor, candidates, site staff | 3 | 4 | 12 | Segregated training area agreed with client. Barriers/cones to demarcate zone. Banksman available where training area adjoins live operations. Site traffic management plan obtained and briefed. Training paused if segregation is compromised. | 6 |
| Candidates lacking basic skills / nerves | Candidates, instructor, bystanders | 3 | 3 | 9 | Theory and safety briefing completed before any practical exercises. Gradual skill build-up from basic to complex manoeuvres. Instructor maintains direct line-of-sight and ability to intervene. Emergency stop procedures briefed. Candidate fitness declaration obtained. | 4 |
| Defective client-supplied equipment | Instructor, candidates | 3 | 4 | 12 | Pre-use inspection of all equipment by instructor before training commences. Current LOLER Thorough Examination certificate requested for all lifting equipment. Defective equipment rejected — training postponed or alternative equipment sourced. Written defect report provided to client. | 5 |
| Slips, trips, and falls in training area | All personnel | 3 | 2 | 6 | Training area inspected for trip hazards, spillages, uneven surfaces. Housekeeping maintained throughout training. Appropriate footwear mandatory. Area swept/cleaned if required. Temporary hazards marked with signage. | 3 |
| Lone working (instructor travelling alone) | Instructor | 2 | 3 | 6 | Instructor checks in with PHW office at start and end of each training day. Journey plan shared. Mobile phone carried and charged. Vehicle breakdown cover in place. Personal safety briefing given for isolated/remote sites. | 3 |
| Adverse weather (outdoor training areas) | Instructor, candidates | 3 | 3 | 9 | Weather forecast checked before travel. Training suspended in high winds (above 30 mph for FLTs), heavy rain affecting visibility, ice/frost on surfaces. Candidates briefed on wet/cold conditions. Welfare facilities confirmed with client (warm room, toilets, drinking water). | 4 |
| Manual handling of training equipment/materials | Instructor | 3 | 2 | 6 | Trolley/wheeled case used for heavy items. Loads split into manageable weights. Correct lifting technique applied. Client asked to assist with heavy items where possible. | 2 |
| Inadequate welfare facilities | Instructor, candidates | 2 | 2 | 4 | Welfare provision confirmed in pre-visit questionnaire (toilets, hand washing, rest area, drinking water). If facilities inadequate, training may be rescheduled. Instructor carries own water and first aid kit. | 2 |
PHW Office: [Insert Number] | Emergency Services: 999
This RAMS covers the operation of 360-degree hydraulic excavators (tracked and wheeled) on construction and civil engineering sites. Activities include general excavation, trenching, loading vehicles, grading, demolition support, drainage works, and material handling. Machine sizes range from micro/mini excavators (below 1 tonne) to large machines (above 10 tonnes). All operations are subject to site-specific conditions and the principal contractor's site rules.
| Hazard | Who at Risk | L | S | Risk | Control Measures | Residual |
|---|---|---|---|---|---|---|
| Striking underground services (gas, electric, water, telecoms) | Operator, ground workers | 3 | 5 | 15 | Service drawings obtained and reviewed (record search from utility providers). CAT and Genny scan before any excavation. Trial holes hand-dug to confirm service location. Safe digging practice per HSG47. No mechanical excavation within 500 mm of confirmed services. Banksman/spotter on standby. | 6 |
| Excavation collapse / trench failure | Ground workers, operator | 3 | 5 | 15 | Trench support (shoring/battering/stepping) designed by competent person for excavations over 1.2 m deep. Daily inspections by competent person before entry. Spoil heaps kept at least 1 m from edge. No vehicles within 2 m of unsupported edge. Barriers and edge protection installed. Rescue plan in place before entry. | 6 |
| Contact with overhead power lines | Operator, all site personnel | 2 | 5 | 10 | HSE guidance GS6 followed. Minimum clearance distances maintained (consult DNO for specific voltages). Goal posts or height restrictors where applicable. Overhead line route marked on site plan. Operator briefed on safe approach distances. Machine fitted with height limiter where available. | 4 |
| Machine overturn on unstable ground | Operator | 2 | 5 | 10 | Ground conditions assessed before positioning machine. Outriggers/stabilisers deployed on flat, firm ground. Timber mats used on soft ground. Machine not operated on slopes exceeding manufacturer limits. No slewing loads downhill. Seatbelt worn at all times. | 4 |
| Struck by swinging bucket/boom | Ground workers, pedestrians | 3 | 4 | 12 | Exclusion zone equal to the machine's maximum reach established. Banksman controls personnel access. No personnel within the slew radius during operation. Operator checks 360 degrees before slewing. Reversing cameras and proximity alarms fitted where available. | 5 |
| Objects falling into excavation onto workers | Ground workers in excavation | 3 | 4 | 12 | Toe boards installed at edges. Materials stored away from edge. Stop blocks for vehicles. All loose material cleared from edges before entry. Hard hats mandatory in excavation area. | 6 |
| Noise and vibration exposure | Operator, nearby workers | 4 | 3 | 12 | Machine fitted with low-vibration seat. Operator exposure limited per daily EAV/ELV calculations. Hearing protection mandatory within 10 m of operating machines. Regular maintenance of exhaust and silencer. Operator rotation to limit exposure duration. | 6 |
| Dust generation (silica, general) | Operator, ground workers, public | 3 | 3 | 9 | Water suppression for dusty materials. RPE (FFP3) provided where dust levels exceed WEL. Cab windows kept closed. Regular air filter maintenance. Dust monitoring if prolonged work in high-silica materials. | 4 |
| Unauthorised access to machine | Public, trespassers, children | 2 | 5 | 10 | Machine isolated and locked when unattended. Keys removed and secured. Bucket lowered to ground. Site security fencing and signage. CCTV where appropriate. Immobiliser fitted. | 3 |
| Contaminated land / hazardous materials | Operator, ground workers | 2 | 4 | 8 | Desktop study and site investigation reviewed before works. Contamination survey results obtained from client. RPE, chemical-resistant gloves, and overalls available if contamination suspected. Stop work and report immediately if unexpected contamination encountered (discoloured soil, odour, containers). | 4 |
Emergency Services: 999 | National Gas Emergency: 0800 111 999 | Power Network: 105
This RAMS covers the operation of Mobile Elevating Work Platforms (MEWPs) including scissor lifts, articulated boom lifts, and telescopic boom lifts for working at height. Activities include maintenance and installation tasks, inspection work, construction activities, and any task requiring a temporary elevated work position. This applies to both indoor (warehouse, factory) and outdoor (construction site, street works) environments.
| Hazard | Who at Risk | L | S | Risk | Control Measures | Residual |
|---|---|---|---|---|---|---|
| Fall from the platform / basket | Operator, passengers | 2 | 5 | 10 | Full body harness with short lanyard attached to designated anchor point (boom lifts). Guard rails checked for security before elevation. No standing on mid-rails or climbing over guard rails. Platform gate closed and secured. Maximum number of persons not exceeded. No leaning over the edge. | 4 |
| Machine overturn / tip-over | Operator, ground personnel | 2 | 5 | 10 | Ground conditions assessed — firm, level surface required. Outriggers fully deployed and on pads (boom lifts). Slope limits observed per manufacturer data plate. Wind speed monitored — cease operations above manufacturer limits (typically 28 mph / 12.5 m/s). Machine not driven at height (scissor lifts: only at low speeds on level ground as per manufacturer). | 4 |
| Entrapment / crushing against structures | Operator | 2 | 5 | 10 | Operator trained in crush-avoidance. Secondary guarding (pressure-sensitive bars/panels) fitted where available. Overhead obstructions identified before elevation. Spotter on ground for proximity to structures. Slow, controlled movements near fixed structures. Emergency lowering procedure demonstrated to all occupants. | 4 |
| Contact with overhead power lines / live electrical | Operator, passengers | 2 | 5 | 10 | Overhead survey before positioning. Safe clearance distances maintained per GS6. Permit to work if within exclusion zone. Insulated platform not a substitute for safe clearance. DNO contacted if working near high-voltage lines. | 3 |
| Objects falling from platform onto persons below | Ground personnel, public | 3 | 4 | 12 | Exclusion zone at ground level below the work platform. Toe boards fitted. Tool lanyards used. No loose items in the basket. Hard hats mandatory in the exclusion zone. Debris netting if over public areas. | 5 |
| Collision with pedestrians / vehicles during travel | Pedestrians, operators, drivers | 3 | 3 | 9 | Banksman/spotter for site travel. Flashing beacon operational. Travel only in stowed position for boom lifts. Speed limit observed for scissor lifts travelling at low height. Reversing alarm operational. Route planned to avoid pedestrian areas. | 4 |
| Mechanical failure / hydraulic leak at height | Operator, passengers | 2 | 4 | 8 | Pre-use inspection completed before each shift. Current LOLER Thorough Examination certificate (6-monthly). Emergency lowering procedure tested at ground level before elevation. Ground controller trained in emergency lower. Operator carries mobile phone. Manufacturer's servicing schedule followed. | 3 |
| Electrocution from working near live systems | Operator, passengers | 2 | 5 | 10 | Permit to work / isolation certificate obtained before working near electrical installations. Lock-out/tag-out procedures followed. Voltage tester used to confirm dead. Insulated tools and gloves where appropriate. Electrically competent person on site. | 4 |
| Wind loading / adverse weather | Operator, passengers | 3 | 4 | 12 | Anemometer used to monitor wind speed. Operations cease at manufacturer's stated maximum wind speed. Weather forecast checked daily. Platform lowered and machine secured in high winds. Extra caution with large surface-area items (boards, sheeting) acting as sails. | 5 |
| Platform overloading | Operator, passengers | 2 | 4 | 8 | Safe Working Load (SWL) displayed on data plate and known by all occupants. Materials and tools accounted for in load calculation. Number of persons limited to manufacturer rating. Overload cut-out functional (tested at pre-use). | 3 |
Emergency Services: 999 | PHW Office: [Insert Number]
This RAMS covers the operation of forward-tipping and swivel-skip site dumpers on construction and civil engineering sites. Activities include the transport of excavated materials, aggregates, concrete, and general construction materials around site. Dumper types range from 1-tonne high-tip to 9-tonne forward-tipping machines. All operations are subject to the principal contractor's site rules, traffic management plan, and permit systems.
| Hazard | Who at Risk | L | S | Risk | Control Measures | Residual |
|---|---|---|---|---|---|---|
| Dumper overturn on slopes / soft ground | Operator | 3 | 5 | 15 | Route planned to avoid excessive gradients. Travel up and down slopes — never across. Load carried uphill on forward-tip dumpers. Speed reduced on inclines. Ground conditions assessed before travel — avoid waterlogged/rutted areas. ROPS fitted and seatbelt worn at all times. Skip not raised during travel. | 6 |
| Collision with pedestrians / other plant | Pedestrians, operators of other machines | 3 | 4 | 12 | Site traffic management plan followed. Designated haul routes. Banksman where visibility is restricted. Reversing alarm and flashing beacon operational. Speed limits enforced (typically 10 mph on site). No passengers at any time. One-way systems where practicable. Mirrors clean and adjusted. | 5 |
| Falling into excavation during tipping | Operator | 2 | 5 | 10 | Stop blocks positioned at excavation edges before dumper approaches. Banksman to guide dumper to tipping point. Minimum 2 m setback from unsupported edges. Ground conditions at tip edge inspected. Operator to remain in cab during tipping. Never reverse towards an unprotected edge. | 4 |
| Load shifting during travel | Operator, nearby workers | 3 | 3 | 9 | Load not heaped above skip sides. Wet materials loaded to a lower level. Speed reduced on uneven ground. Avoid sharp turns with loaded skip. Secure loose items on the load (pipes, timber). | 4 |
| Contact with overhead power lines / structures | Operator | 2 | 5 | 10 | Skip lowered during travel and under low structures. Overhead obstructions marked on site plan. Height barriers installed on routes near overhead lines. Safe clearance distances per GS6 maintained. Goal posts where necessary. | 3 |
| Operator thrown from cab (no seatbelt) | Operator | 3 | 5 | 15 | Seatbelt mandatory — checked at pre-use. ROPS/FOPS frame fitted and undamaged. Zero-tolerance policy on seatbelt non-use. Supervisors conduct spot-checks. Disciplinary action for non-compliance. | 5 |
| Struck by excavator bucket during loading | Operator | 3 | 4 | 12 | Operator to remain in cab during loading. FOPS overhead protection fitted. Never stand between excavator and dumper. Clear communication (radio or hand signals) between excavator and dumper operators. Approach from a visible angle — never from behind. | 5 |
| Hydraulic failure during tipping | Operator, nearby workers | 2 | 4 | 8 | Pre-use check of hydraulic rams, hoses, and connections. Never work under a raised skip without mechanical prop. Tipping only on level ground. Area cleared below tipping zone. Regular maintenance per manufacturer schedule. | 3 |
| Noise and whole-body vibration | Operator | 4 | 3 | 12 | Vibration-dampened seat maintained in good condition. Operator exposure monitored against EAV/ELV. Haul routes maintained to reduce jolting (potholes filled). Operator rotation. Hearing protection provided where needed. Speed limits reduce vibration on rough ground. | 6 |
| Fuel spillage / fire | Operator, environment | 2 | 3 | 6 | Refuelling in designated area only, engine off. Spill kit available. No smoking near fuel. Fire extinguisher in cab, serviced and accessible. Drip tray under machine overnight if on sensitive ground. | 3 |
Emergency Services: 999 | PHW Office: [Insert Number]