| Hazards | Associated Risks | Safety Precautions / Control Measures |
|---|---|---|
| High-pressure hydraulic failure or hose burst | Sudden release of pressurized oil causing injury to eyes, face, or hands | • Use only certified hoses and connectors • Inspect jack and hoses before use for cracks, leaks, or wear • Do not stand directly in line with hose connections |
| Jack or load slippage / sudden settlement | Crushing injury to feet, hands, or body | • Ensure jack is placed on firm, level, and stable ground • Use steel plates or wooden sleepers for load distribution • Keep hands and body parts away from moving load |
| Unstable test platform or improper alignment | Collapse or toppling of equipment | • Check alignment of jack, reaction frame, and load cell • Secure all components before applying load |
| Manual handling of heavy components (plates, jack, etc.) | Back strain, finger injuries, foot crush | • Use proper lifting techniques or mechanical aids • Wear safety shoes and gloves |
| Unauthorized operation or accidental load release | Sudden load drop causing injury | • Only trained personnel should operate the hydraulic jack • Do not exceed rated pressure / test load • Use pressure gauge to monitor load gradually |
| Oil spillage from hydraulic system | Slips, fire hazard, environmental contamination | • Place drip trays under hydraulic connections • Clean any spills immediately • Dispose of oil-soaked materials properly |
| Pinch points between moving components | Finger or hand injury | • Keep hands clear during loading/unloading • Communicate clearly with team members before operation |
| Noise / vibration during test | Operator distraction or fatigue | • Maintain proper positioning and avoid long-duration exposure |
Personal Protective Equipment (PPE)
- Safety Helmet
- Safety Shoes (Steel Toe)
- Hand Gloves (Oil-resistant)
- Safety Goggles / Face Shield
- High-Visibility Vest
Additional Safety Guidelines
Ensure work area is barricaded and free from unnecessary personnel
Maintain clear communication between operator and observers
Stop the test immediately if any abnormal noise, leakage, or misalignment is noticed
Follow manufacturer’s guidelines for jack operation and pressure limits
