Wet Load-In: Manual Handling and a Tripping RCD
You are leading a three-person crew loading in for a school auditorium event. The truck is parked 15 m from the stage, but the route includes six steps, each 18 cm high, and a 1.2 m wide doorway. One flight case weighs 80 kg and contains two powered speakers; it has no wheels. The trolley is locked in the school maintenance room and the key holder is unavailable for 40 minutes. It is raining, and the ramp surface is wet. A 20 m extension cord runs from a hallway outlet to the stage; the cord crosses a wet floor area and the RCD tripped once when the crew plugged in a kettle. The event starts in 90 minutes, and the client is asking the crew to ‘just carry it.’
1. What risk assessment and manual-handling controls would you apply before moving the 80 kg case?
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Run a quick risk assessment with the crew before touching the 80 kg case. The hazards are manual handling on wet steps, slips, electrical contact, and schedule pressure. Use the hierarchy: eliminate the lift if possible by waiting for the key holder or finding a second trolley; reduce the load by removing the two speakers and carrying them separately; engineer the route with a dry mat, a temporary ramp, and a spotter; administer a team lift with gloves, clear commands, and no twisting; use PPE. An 80 kg case is not a one- or two-person lift up wet steps. If the trolley cannot be released, the safe decision is to wait, use four people with lifting straps on a dry route, or ask the school to open an accessible entrance. Do not ‘just carry it’ because the client is pressing.
2. How would you respond to the cord across the wet floor and the RCD trip?
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The RCD trip is a stop signal. A kettle plus the AV load may have overloaded the circuit, but an RCD trip can also mean a fault or moisture. Unplug the kettle, inspect the 20 m cord for damage, keep plugs and connectors off the wet floor, and use a covered distro or cable ramp. Test the RCD with its test button, then reset once. If it trips again with only the AV load, stop and have the school electrician check the circuit; do not tape the RCD or use a bypass. Use a separate circuit for the audio if available, and keep the generator outdoors if one is used.
3. What would you say to the client who wants the crew to hurry?
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Tell the client: ‘We are not refusing the job; we are refusing an unsafe lift and a repeatedly tripping circuit. We can start on time if the trolley is released in 10 minutes or if we use the accessible entrance; otherwise setup will be delayed by 30–40 minutes.’ Escalate to the school coordinator and your supervisor, document the time and the request, and offer a reduced setup that meets the start time. Safety-related delays are legitimate; a fall on wet steps or an electrical shock would cost more than the delay.