Rank: Forum user 
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I am looking into the feasibility of my companies caretaking team replacing damaged concrete fence posts (51Kg) and gravel boards (33Kg). Currently they are replacing wooden posts and gravel boards.
While we can employ manual handling aids to assist with moving the posts and gravel boards to the workplace we are struggling to identify aids to lift the gravel boards into the slotted fence posts.
As I see it the significant risks are the manual handling aspect, lifting above head height (33Kg gravel boards up 1.8m to slot them into the fence posts), poor ground conditions, team lifting and possibility of loosing control of the load and trapping fingers. This is not a frequent task and will probably only happen 3 or 4 times a year at present. If anyone else has had this issue have you identified a manual handling aid to assist or what safe methods have you adopted to reduce the risk.
Inchoa
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Rank: Forum user 
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Hi Inchoa,
You can avoid lifting the gravel board almost completely by setting one post in place, dig the hole for the second post, lay the gravel board on the ground in the groove of the first post and then set the second post against the gravel board and so on. Leave a small gap to allow for removal and re-fitting should it be required in the future.
I think it's fair to say that unless they get damaged, concrete posts and gravel boards rarely need replacing. Trying to lift a concrete gravel board up above and then down between two posts is not the way to go.
Stu.
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Rank: Forum user
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33kg is not a HUGE weight, but the big issue would likely be the above head lifting - could you devise a safe system using something like an alloy tower on either side to eliminate the primary risk of lifting above head height and have a tandem / team lift from above using strops and lowering onto wedges? the towers effectively forming a cordon around the risk area while the load is raised / lowered?
Another alternative would be to use a small machine and guide ropes, but that depends on access etc.
Al
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Rank: Super forum user 
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stuart46 is correct. not only is that the safest way to do it's also the best way of ensuring the posts are sited accurately.
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Rank: Forum user
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In response to A Brown, what happened to keeping things simple. Whilst there may be some circumstances where this long winded and expensive method that would introduce god knows how many additional risks may be necessary, should we really be recommending towers, team lifts, strops etc when it can easily be done with no more than two people and little lifting if done thoughtfully. All this work is just not necessary. I hear the phrase OTT all too often form people outside the profession. We need to avoid it from within.
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Rank: Super forum user 
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Again i would agree with Stuart46, You need to ensure you minimise Heavy lifting not create it.
Redo your Method statement to include Stuart46's way and you'll be surprised just how easy the job will become
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Rank: Super forum user 
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I'm glad I didn't mention using a crane!
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Rank: Forum user
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My understanding from the original post was that the task was to replace components within an existing fence, which would require the panels to be dropped down into the 'H' section beams.
Certainly to build a new fence the process mentioned above eliminates the lifting clear off the ground, but it will require temporary support to be put in place until the next post is in place.
It's All about balance of risk. I'm not suggesting I know the right answer in detail, merely suggesting ONE option capable of being carried out safely using fairly basic equipment to carry out a repair
I'd also contest that sometimes keeping it simple is not enough - sometimes to cover all bases needs a bit of complexity.
But hey, what would I know? I know I wouldn't want to see anyone installing a post next to an unsupported 1.8m high panel out in the open.
This after all is a process of risk assessment - looking at various options and deciding which presents the lowest balance of risk for the task to be completed.
Al
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Rank: Super forum user
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Gravel board is only about 12" tall
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Rank: Forum user
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ah, small boards, not big panels. I was imagining the sectional garage type panels
easy job, less unwieldy!
Al
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Rank: Super forum user
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I guess if you can get 2 burly Builders to lift a 33kg Gravel board into a Fence slot then you could bring out the big guns and use a genie lift to lift the board and then into the slot, however your going to have a hard time especially on soft ground. http://www.fthhiregroup....e-material-lift-sl10.jpgI would Just get a couple of Strong Guys to do the job :-)
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Rank: Super forum user
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As an alternative to two strong men, just employ one really strong man (like Geoff Capes was some 30 years ago) who would have no problem lifting a 30kg gravel board. In the interests of equality I'd better also suggest a really strong woman as another alternative! :-)
For the benefit of any younger forum users who might not have heard of Geoff Capes, he is a Brit who won the title of 'World's Strongest Man' twice and the titles of 'Europe's Strongest Man' and 'Britain's Strongest Man' thrice respectively.
Graham B
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Rank: Super forum user
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Gravel boards are very heavy and I've had to lift many over the years in my 'sometime' position of delivery driver in the SW of England.
If possible have 2 people lift the boards and posts, one at each end.
Stress that speed is not an issue.
Heart attacks and hernias will not make the job any easier, so do it the easy way, share the lifting.
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