annual reports and accounts 2004/05 · smre, ohl and oml merge to form hse’s research and...

1 | Annual Report & Accounts | Health and Safety Laboratory | 2004-2005 www.hsl.gov.uk

Health

& Safety Laboratory | A

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ual Report &

Accounts | 2004-2005

Design_www.purplecircle.co.uk

Room to moveRoom to experiment

Health & Safety LaboratoryHarpur HillBuxtonDerbyshire SK17 9JNUnited Kingdom

Tel 01298 218000Fax 01298 218590Email [email protected]

www.hsl.gov.uk

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2004-2005 ANNUAL REPORT & ACCOUNTS HEALTH AND SAFETY LABORATORY

An Agency of the Health & Safety Executive

Sixth Sense! Interesting findings in our latest set of case studies

www.hsl.gov.uk 2004-2005 | Health and Safety Laboratory | Annual Report & Accounts | 45

18. Intra-government balancesDebtors: Debtors: Creditors: Creditors:

amounts falling amounts falling amounts falling amounts fallingdue within due after more due within due after more

one year than one year one year than one year

2004/05 £’000 £’000 £’000 £’000

Balances with other central government bodies 78 0 39 0

Balances with local authorities 124 0 247 0

Balances with NHS Trusts 9 0 33 0

Balances with public corporations and trading funds 71 0 0 0

Balances with bodies external to government 1,128 4,550 2,100 57,607

At 31 March 2005 1,410 4,550 2,419 57,607

Comparative figures were not provided for 2003/04 in the Published Accounts.

1. Target To recover full economic costs on an accruals basis, taking one year with another, after making dueallowance for transitional costs related to the PFI deal in a manner agreed with HSE.

Actual performance Achieved. HSL is required to cover its full economic costs for the services it provides to HSE andother public and private sector customers. During the period HSL generated sales of £26,956,000(2003/04: £25,469,000) against net costs of £26,120,000 (2003/04: £22,861,000), to achieve anoperating surplus of £836,000 (2003/04: £2,608,000). After interest payable & similar charges, butbefore transitional funding, HSL made a deficit for the financial year of £1,812,000 (2003/04:surplus of £2,241,000). As agreed previously with HSE, HSL utilised an equal amount out of apreviously accumulated surplus in order to produce neither a surplus nor a deficit within the year.

2. Target To meet the agreed net administration costs financial control position.

Actual performance Achieved. HSL is required to generate receipts to cover at least the administration cost element(being staff costs and general administration expenses) of its total expenditure each year. To assess performance against this target, receipts are applied to running costs on a basis agreed annually with HSE (see Note 2).

3. Target To achieve 20% of turnover from non-HSE customers by 2006/07 with an interim target of£3,600,000 in 2004/05 (2003/04: £2,750,000).

Actual performance Achieved. Science and Technology income in 2004/05 from non-HSE customers was £3,680,000(2003/04: £3,103,000).

4. Target To take occupancy of the new laboratory in Buxton at a lost opportunity cost of less than £3,000,000.

Actual performance Achieved. Lost opportunity cost of £2,421,000.

17. Annual performance agreement measures (cont.)

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Opening new doors to a brighter future

Health & Safety Laboratory Tel 01298 218000 Harpur Hill Fax 01298 218590 Buxton Email [email protected] Derbyshire SK17 9JN United Kingdom

www.hsl.gov.uk

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2004-2005

ON THE COVER About HSL We explore the new laboratory, starts page 6 Sixth Sense, starts page 10 HSL is an Agency of the Health

and Safety Executive (HSE).

We are Britain’s leading Occupational Health and Safety Laboratory.

We are commercially independent and have a reputation for objective and impartial research and advice.

We employ about 350 people, the majority of them scientists and technicians.

We are a customer-focused organisation committed to training and developing our staff.

HSL Vision

HSL must be a world class health and safety laboratory operating as a successful commercial entity with a diverse portfolio of work and customer base, offering an attractive career for all employees.

Early stages of the new building at Buxton p6

NEWS CASE STUDIES FIGURES HSL Mission ABOUT HSL INTRODUCTION Operating & financial review 24 To generate, interpret and A brief introduction to who we are and We report some interesting findings provide scientific information FOREWORD TO THE ACCOUNTS relevant to the control of risks to what we are all about 1 in our latest set of case studies 10 An introduction to this people’s health and safety from ACHIEVEMENTS CASE STUDY 1 year’s accounts 25work activities.

A summary of what we have Raising awareness of asthma risks ACCOUNTS HSL Shared Values achieved in the past year 2 in motor vehicle repair 12 All the figures for the 2004/05 • We take pride in our work MILESTONES CASE STUDY 2 financial year 30and in HSL

A look back at how we began and a Raising the profile of occupational • We value, respect, support and NOTES TO THE ACCOUNTS encourage all HSL colleagues few of the things that have shaped us health 14 Providing all the detailed information

• We enhance and promote the along the way 3 CASE STUDY 3 to the accounts 33reputation and capabilities of HSL

FOREWORD Handling baggage at airports 16 • We value diversity and we

Reporting on the past year support equal opportunities. CASE STUDY 4 and what lies ahead for HSL, Preventing asbestos disease in building

HSL Brand Image Dr David Buchanan 4 maintenance staff 18 • HSL is easy to deal with,

values its customers and CASE STUDY 5 meets their needs FEATURE

NEW BUILDING SPECIAL Evaluation of safety nets by modelling

• HSL is an independent provider and experiment 20of information and solutions to

We explore the new laboratory at health and safety problems CASE STUDY 6 Buxton and discover the benefits this • HSL takes pride in its corporate Mechanical ignition of explosive gas

knowledge and quality science brings to HSL 6 and dust atmospheres 22 • HSL provides value for money

• HSL is a consistent, professional organisation capable of rapid response and a multi-disciplinary approach.

Trying out the new facilities p6

“These achievements have been gained as a result of dedicated hard work by HSL staff, and my thanks go to all staff” The Health and Safety

Laboratory would like to thank New Scientist for permission to Dr David Buchanan commenting on the achievements of all base the design of this report HSL staff in the Foreword, page 4 on their magazine.



HSL news and exclusives

News

utilised an equal amount out of

a previously accumulated

surplus in order to produce

from non-HSE customers by 2006/07 with an interim target of £3.6m in 2004/05.

An analytical laboratory in the new Buxton building

Achievements To demonstrate to the satisfaction of HSE’s Science and Innovation Strategy Committee HSL’s positive contribution to HSE’s Public Service Agreement targets.

A joint HSE/HSL paper reporting HSL’s positive contribution to HSE’s PSA targets was submitted to, and agreed by, HSE’s Chief Scientist (chair of HSE’s Science and Innovation Strategy Committee).

To implement by March 2005 the accepted recommendations resulting from the Scientific Audit carried out in 2004.

Action has been taken in respect of all accepted recommendations.

To avoid RIDDOR events.

HSL reported six events under the Reporting of Industrial

Diseases and Dangerous Occurrences Regulations (RIDDOR).

To recover full economic costs on an accruals basis, taking one year with another, after making due allowance for transitional costs related to the PFI deal in a manner agreed with HSE.

Achieved

HSL is required to recover its full economic costs for the services it provides to HSE and other public and private sector customers. During the period HSL generated sales of £26,956,000 against net costs of £26,120,000, to achieve an operating surplus of £836,000. After interest payable and similar charges, but before transitional funding, HSL made a deficit for the financial year of £1,812,000. As agreed previously with HSE, HSL

neither a surplus nor a deficit

within the year.

To meet the agreed net administration costs financial control position.

Achieved

In 2004/05 HSL met the agreed

net administration costs

financial control position.

To achieve 20% of turnover

Achieved

Science and technology income in 2004/05 from non-HSE customers was £3,680,000.

To take occupancy of the new laboratory in Buxton at a lost opportunity cost of less than £3m.

Achieved

Lost opportunity cost of £2,421,000.

Sound tests being carried out in the new anechoic chamber



In this section • Achievements • Milestones • Foreword

Milestones

Early tests at SMRE

1911

Government agrees to fund an experimental station at Eskmeals in Cumberland for the investigation of explosions in coal mines.

1921

The establishment of the Safety in Mines Research Board.

1924

Acquisition of the Harpur Hill Buxton site for mining safety work on a large scale.

1928

Opening of central laboratories in Portobello Street, Sheffield.

1947

Formation of the Safety in Mines Research Establishment (SMRE) as part of the Ministry of Fuel and Power, bringing together the work at Sheffield and Buxton.

1957

Opening of a new laboratory in Red Hill, Sheffield, to house engineering and metallurgical work.

1959

Formation of the Occupational Medicine Laboratory (OML), located in central London.

1965

Opening of second laboratory in Red Hill, Sheffield, with provision for breathing apparatus studies, general laboratories, library and conference facilities.

1966

Formation of the Occupational Hygiene Laboratory (OHL) by the Factory Inspectorate, located in central London.

1973

Relocation of the Occupational Medicine Laboratory and Occupational Hygiene Laboratory to Cricklewood, North London.

1975

Formation of the Health and Safety Executive (HSE). SMRE, OHL and OML merge to form HSE’s Research and Laboratory Services Division (RLSD) to cover work from across a wide range of industrial health and safety topics. RLSD adopts a three laboratory structure:

• The Occupational Medicine and Hygiene Laboratory (OMHL) (at Cricklewood, North London)

• The Safety Engineering Laboratory (SEL) (at Sheffield and Buxton)

• The Explosion and Flame Laboratory (EFL) (at Buxton)

1992

Transfer of OMHL from Cricklewood to the purpose built Robens Building in Sheffield.

1995

The restructuring of the three laboratories into a single integrated laboratory, the Health and Safety Laboratory (HSL) which becomes an agency of HSE.

2004

New laboratory, funded under the Private Finance Initiative, opens on the Buxton site to accommodate all Sheffield and Buxton staff.

A laboratory at SMRE, Sheffield



News

David Buchanan Chief Executive

Dr David Buchanan FREng

ForewordI am pleased to report another construction of a new building nil. The physical move of staff building snagging problems successful year for HSL. under the PFI process. and equipment was emerged, but they have been

In addition to the core At the end of October 2004, meticulously planned and largely addressed. business of delivering science HSL’s PFI partners, Investors in carried out over four successive Since the move, staff have and technology to our the Community (Buxton) Ltd, weekends. A key test was settled in well and reactions customers, the major challenge (ICB), made the building whether the IT system would of staff and visitors have of the year was the move to the available to HSL for occupancy. work correctly on day one been extremely positive. new laboratory at Buxton. This met the agreed schedule. – and it did. By the end of The programme of demolition

In previous Annual Reports Construction costs were tightly November all staff and of the remaining unwanted I have given details of HSL’s controlled and, although a equipment had successfully buildings and the associated estates rationalisation number of building variations moved and the Sheffield site landscaping has been programme. This involves the were agreed, their net cost was was vacated. Inevitably, some completed. The sale of the

HSL’s move to a new, state-of-the-art laboratory in Buxton has now been successfully completed



Sheffield site and premises, ultimately to the University of Sheffield, was completed on schedule.

HSL now has a state-of-the -art laboratory and can look forward to working with ICB over the coming years to deliver even better services. In May 2005, the laboratory will be formally opened by Lord May of Oxford, President of the Royal Society.

During the difficult period of the move, HSL staff continued to produce high quality work for customers. Revenue was greater than budget and costs were less, with the overall result that the transitional funding required from HSE was £1.8m rather than the budgeted amount of £5.1m. This funding was required to cover the anticipated deficit resulting from the move to the new laboratory. From an accounting point of view it was met from surpluses built up over previous years. Particularly noteworthy was the fact that the lost opportunity cost of the move was restricted to £2.4m rather than the budget figure of £3m.

HSL’s non-HSE business continued to expand. The target of £3.6m was exceeded, and the outturn was 14% of the total science and technology turnover. It is particularly pleasing that HSL is now winning large contracts and this is very encouraging in view of our objective to double, at least, our non-HSE revenue over the next few years.

One disappointing note was

Clive Jackson Norman West John Verney Planning and Operations Finance Administration

Since the move, staff have settled in well and reactions of staff and visitors have been extremely positive

“HSL now has a state-of-the-art laboratory and can look forward to working with ICB over the coming years to deliver even better services”

the occurrence of six RIDDOR events. These were mainly related to manual handling of incident material and further training for relevant staff is being progressed. On the positive side, there were no RIDDORs (or indeed other accidents) associated with the move to the new building. HSL continues to put a high priority on health and safety, and a programme of improvement is being followed.

During the year, HSL established new capabilities in epidemiology and statistics. We recruited an excellent team of experienced staff to work on a variety of contracts. We are also in the process of establishing a team to assist HSE with the task of

spotting emerging issues, or ‘horizon scanning’.

A review of HSL’s status was carried out by HSE. A number of options were considered, in particular Trading Fund and Government-Owned Contractor Operated (GOCO) status. Eventually it was agreed that HSL should remain an Agency of HSE, but with increased emphasis on our commercial, non-HSE activities. The Review made a number of recommendations which HSL and HSE are taking forward.

On a personal note, I will retire towards the end of 2005 so this will be my last Foreword to the Annual Report. It has been my privilege and pleasure to be Chief Executive of HSL since 1995. During this period

some exciting developments have taken place: we are much more business aware; non-HSE business has grown from virtually nothing to almost 15% of turnover; we have held our share of the HSE business overall whilst managing a significant change of scientific emphasis; and of course we are now in new premises. These achievements have been gained as a result of dedicated hard work by HSL staff, and my thanks go to all staff, past and present, for their support over the last ten years. I have no doubts that HSL will continue to excel and I wish staff and my successor best wishes for the future.



“The new laboratory is superb, both in design and execution. You and your team are to be congratulated for bringing this major project to such a successful conclusion”



Cover story | New building special

Previous annual reports have recorded progress on the project to rationalise HSL’s estate by means of the Private Finance Initiative (PFI) and to construct a new laboratory on the Harpur Hill, Buxton site. The year 2004 saw the completion of this project and the successful move of virtually all our staff into the new facility. The building was finished on time and to cost, and last October staff started moving in. We look back here at the main stages of the project and present some photographs of the construction and the wide range of specialised facilities now available under one roof.

We deserve a lab of honour

The need

HSL’s accommodation at Buxton and Sheffield far exceeded our needs and maintenance was expensive. Many of the buildings on both sites were life expired or in need of major refits. Most of the accommodation lacked the flexibility of a modern laboratory. The status quo was not a viable long-term option.

The project

HSL’s aims in rationalising the estate were to:

• reduce the amount of accommodation to that required to meet foreseeable needs

• provide enhanced operational flexibility

• substantially reduce the number of separate buildings

• locate the entire laboratory on a single site

It was recognised that single site occupancy would greatly enhance HSL’s effectiveness by simplifying the supporting infrastructure, improving communications and avoiding duplication. Flexibility was also particularly important for HSL to be able to effectively support HSC/E’s evolving strategy.

The PFI deal

Following extensive negotiation of the PFI deal, a Concession Agreement was eventually signed in April 2002 with Investors in the Community (Buxton) Ltd (ICB). ICB is a special purpose vehicle (SPV) set up under the PFI to design, build, finance and operate the new laboratory for HSL. In addition, ICB assumed responsibility for disposing of HSL’s vacated site in Sheffield. This agreement will last for 30 years, after which HSL has the option of taking over the buildings and services or negotiating a further deal.

The site at Buxton

HSL, to use the modern name, has occupied the Buxton site for some 80 years. The size of the facility has changed over this time but it currently extends to some 200ha. The extent of the site enables HSL to undertake large, noisy and energetic experiments. Fortunately, these experimental areas are located away from the flat central core of the site, and it was this 30ha area that offered the most suitable location for redevelopment.



Thermal chamber capable of being controlled from -40˚c to +70˚c

Building design

Designing the new facility (of some 19,500 square metres gross internal area) was technically challenging. Individual spaces range from blast cells, isolated from the main building and capable of withstanding overpressures of 100mbar, to thermal chambers capable of being controlled from -40̊ c to +70̊ c. Additional facilities include a Category 3 laboratory, an anechoic chamber and a strong floor capable of withstanding 100 tonne forces without any deformation greater than +0.25mm.-

The central feature is a long spine, or ‘street’, with offices to one side and laboratory blocks to the other side and at the back. There are meeting rooms of various sizes, a library and a restaurant.

“HSL’s reputation, already high, will grow accordingly and I am sure the future of the lab and its excellent staff is now secured in this truly world class scientific establishment dedicated to health and safety”

As well as meeting HSL’s scientific and technical requirements, the building had to meet stringent planning issues particularly related to its visibility from the Peak National Park. The new building mirrors the topography of the site and is constructed over two and three storeys to blend into the surrounding landscape.

The building’s exterior includes eight different finishes. One of these exterior finishes is natural stone wall cladding. This was built over a twenty-week period using traditional dry stone walling techniques by two local specialist subcontractors, and used natural Mandale Derbyshire fossil limestone quarried locally

in Sheldon near Bakewell.

The central feature at the new laboratory

Construction

Twenty-six existing buildings and structures were demolished before building work could begin. Demolition was not without its challenges since much of the area had been occupied by the military during both World Wars (as a mortar proving range in World War 1 and as an RAF station in World War 2). Unexploded mortars were often uncovered during building work.

Steel erection started in November 2002. Extensive off-site manufacturing techniques were used to achieve both the 17 month services installation programme and the required high quality standards. Particularly successful was the pre-fabrication of water and gas pipework, areas especially prone to quality control problems and installation delay.

Water, gas, electricity and voice/data services were diverted during the construction period, and new provision included the installation of a 4km power cable to connect to the National Grid and a 1km connection to the public water supply. To allow all this work to proceed, staff were relocated into existing buildings. All of this happened without disrupting HSL operations.

Another challenging element was the maintenance of an operational voice/data

network throughout the entire construction period. A temporary network was designed and installed to connect all the remaining buildings on the Buxton site. This work was completed on schedule and the network change-over was accomplished over a week-end with no operational downtime.

Health, safety and environment issues

Health and safety and environment issues were important factors in both the design and construction of the project. HSL and ICB co-operated closely on safety issues throughout the period of enabling works and construction. This was particularly important given that the works occupied the core of an operational site. No major accidents occurred during construction.

The building incorporates a number of energy efficient elements. Solaglass glazing has solar reflection and insulation qualities, and the central street atrium includes a natural ventilation system whereby the widows open automatically when the temperature reaches a certain pre-set level.

Externally, excavated materials from the enabling works were recycled in a number of different ways. Soft excavated materials were retained on site and modelled into the landscaping. The hard excavated materials were stockpiled, crushed and used under roads and buildings as hardcore. All hardcore resulting from the demolition of original HSL buildings was crushed and re-used. This environmental policy had the added advantage of reducing lorries on local roads, as excavated materials were not removed off site.



The move

Availability was achieved, as scheduled, on 27 October 2004 and HSL staff moved in over the following four weekends. Because of the complex nature of the move the main removal contractor employed over 20 specialist sub-contractors whose activities all had to be dovetailed into the overall exercise. Staff packed up their own offices, vacated their old location at 12.00noon on the Friday and were at their new place of work after 8.00am on the following Monday. Many staff considered the key success factor to be whether or not the IT system worked on day one – and it did.

Staff

HSL was successful in almost all cases in re-deploying non-mobile staff to other government sector jobs in Sheffield. Although a number of support services were transferred to ICB no staff were, in the end, transferred under TUPE.

An enhanced relocation package was agreed for Sheffield-based staff with the Trade Unions to encourage as many people as possible to remain with HSL. Some staff have moved house and others are travelling daily. We are also operating daily minibuses from the Sheffield area to assist those not wishing to move house. Apart from benefits to staff, these services contribute significantly to fulfilling HSL’s Green Transport Plan.

Operation

Overall, the reaction to the new building has been very positive from staff and visitors alike. The open plan office arrangements are working well, and the ‘street’ is proving particularly popular for informal meetings with colleagues and customers. As was to be expected, a number of snagging issues were identified, but the majority of these have been satisfactorily addressed.

The following comments from a recent visitor sum up the achievement resulting from the hard work of HSL’s staff and our PFI partners over the last few years: “The new laboratory is superb, both in design and execution. You [David Buchanan] and your team are to be congratulated for bringing this major project to such a successful conclusion. HSL’s reputation, already high, will grow accordingly and I am sure the future of the lab and its excellent staff is now secured in this truly world class scientific establishment dedicated to health and safety.”

Engineering laboratory with strong floor capable of withstanding 100 tonne forces



Case Studies

Sixth 1 2 3

4 5 6



Interesting findings in our latest set of case studies

sense! 1 Raising awareness of asthma

risks in motor vehicle repair

2 Raising the profile of occupational health

3 Handling baggage at airports

4 Preventing asbestos disease in building maintenance staff

5 Evaluation of safety nets by modelling and experiment

6 Mechanical ignition of explosive gas and dust atmospheres

Scientific excellence is at the heart of HSL’s vision, but it is not an end in itself. Our science and technology activity is focused on solving health and safety problems, whether it be supporting HSE in delivering its Public Service Agreement targets or transferring knowledge through our work for non-HSE customers.

Our strength lies in the multi-disciplinary teams that we can quickly bring together to tackle a particular problem. HSL’s expertise covers a wide range of specialisms - for example, from fire and process safety to psychology, chemistry to social science, and engineering to medical sciences - and in this section of the Annual Report we present a selection of case studies that illustrate the breadth of our work.

The case study on asthma risks in the motor vehicle repair industry is a good example of our multi-disciplinary approach and also demonstrates a novel way of communicating health and safety messages to the workforce.

Partnership is an important element in knowledge transfer as several of the case studies amply illustrate. For example, the mechanical ignition of explosive gas and dust atmospheres case study describes a collaborative research project where international partners have been brought together to address a problem of common interest across Europe. The occupational health case study shows how many different partners are working together to increase awareness and share good practice in this high priority area.

The following pages give just a sense of our activities - visit our website (www.hsl.gov.uk) to read more about the many and varied problems we have helped to solve.



Case Study 1 Raising awareness of asthma risks in motor vehicle repair Ro

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Two-pack paints are used extensively in primers and lacquers for repainting vehicles in the motor

vehicle repair (MVR) trade. The properties of these paints make them ideal for vehicles but the presence of isocyanates in the paints presents risks to operators, especially during spray application. Spray mist and vapours containing isocyanates may cause or worsen existing asthma.

Larger companies use spray-painting booths designed for the purpose. These are equipped with ventilation systems to reduce

worker exposure to the paint spray. Smaller premises tend to use ventilated rooms designated as “spray spaces”. Despite these control measures and the use of respiratory protective equipment, MVR paint sprayers are eighty times more likely to become asthmatic compared with the UK working population as a whole. Once people are affected their symptoms can be triggered by very low repeat exposures. Over fifty MVR sprayers are diagnosed with occupational asthma every year and most have to leave the industry.

“Spray mist and vapours containing isocyanates may cause or worsen existing asthma”

A screen grab of ELVis this equipment helps to identify the activities causing the highest exposure to isocyanates



“MVR paint sprayers are eighty times more likely to become asthmatic compared with the UK working population as a whole”

Models demonstrate, in a very visual way, how air moves within the ventilated areas and the efficiency of removal of contaminated air

HSE asked HSL to investigate the use of two-pack isocyanate paints in MVR so that exposure routes could be better understood and more effective means of controlling exposure could be developed. The exposure of spray painters was measured during field studies and superimposed on video recordings of the tasks, thus identifying the activities causing the highest exposure to isocyanates. Working models of spray booths and spray spaces were constructed using information gathered in these surveys. These models demonstrate, in a very visual way, how air moves within the ventilated areas and the efficiency of removal of contaminated air.

An experimental spray space and robotic spraying system were then constructed at HSL to investigate a wide range of variables for comparison with field observations and measurements. This is providing a better

understanding of the behaviour of paint spray aerosols during and after application and is helping in suggesting improvements to the design and operation of spray spaces and the working practices of sprayers.

The ventilation models and video images, together with the experimental results, are being used in a programme of Safety and Health Awareness Days organised by HSE for the MVR industry. At these events, sprayers and employers are given targeted information by a range of experts about the hazards and risks associated with spraying isocyanates and how to control exposure to prevent ill-health. A video presentation of an interview with a person affected by isocyanate asthma leaves attendees in no doubt about the impact the disease has on sufferers’ lives.



Case Study 2 Raising the profile of occupational health

SOHDG organises lunchtime meetings aimed at those with a basic knowledge of occupational health

HSE has developed strategic programmes of support and intervention work to deliver public

service targets for significant reductions in the incidence of occupational illnesses by 2010. Increasing awareness and knowledge of occupational health is an important activity underpinning these programmes.

The Sheffield Occupational Health Development Group (SOHDG) is a partnership between HSE, HSL, the Engineering Employers' Federation, the University of Sheffield, General Practitioners, Trade Unions, the Sheffield Chamber of Commerce, Sheffield City Council and the local National Health Service. These organisations are committed

to sharing good practice in occupational health with companies that generally lack the resources to invest in training and services for their staff. To meet this need SOHDG has delivered education, training and information services.

SOHDG organises lunchtime meetings aimed at those with a basic knowledge of occupational health. The meetings include talks and practical demonstrations given by experienced professionals. In the last five years SOHDG has delivered 17 events attended by over 700 people from various companies in the Yorkshire region and other parts of the UK. Topics covered have included respiratory and skin diseases, musculoskeletal disorders, stress and abuse

“Increasing awareness and knowledge of occupational health is an important activity underpinning strategic programmes”

of drugs in the workplace. The Group also delivers courses that

provide in-depth training on topics such as hand arm vibration syndrome, skin and respiratory disease and musculoskeletal damage. These courses all carry Continuing Professional Development (CPD) points, a vital ingredient for professionals seeking to maintain their accreditation.

Articles about occupational illnesses and the value of health surveillance are published in a quarterly newsletter which also advertises the network meetings and training events. The Group's website (www.healthyworksheffield.org.uk) contains similar information along with hyperlinks to other occupational health support groups



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and electronic copies of the newsletters. It is visited by over 2,000 people each month and has raised the group's profile worldwide. The website is regularly updated to ensure it meets the needs of employers, employees and health and safety representatives in small to medium sized companies.

Feedback questionnaires are circulated following each training event to evaluate the services provided by SOHDG. Larger surveys of around 1,000 businesses in the Yorkshire and Humberside region have also been conducted. The responses demonstrate that SOHDG activities are meeting the needs of companies in this region, but also identify a growing demand for advice and training about occupational health.

“The Group also delivers courses that provide in-depth training on topics such as hand arm vibration syndrome, skin and respiratory disease and musculoskeletal damage”

The meetings include talks and practical demonstrations given by experienced professionals



Case Study 3 Handling baggage at airports

At airports, musculoskeletal disorders (MSDs) are responsible for 40% of all personal injury

incidents reported to HSE, the majority of which involve ground crew. The loading and unloading of passenger bags, particularly on narrow-bodied aircraft, has been identified as a high risk operation for MSD. The industry, HSE, and other European enforcement agencies are, therefore, keen to address this issue.

A variety of methods are used to load and unload narrow-bodied aircraft. HSE field intelligence found that many risk assessments concentrated on the height of the aircraft sill to decide the work method, and did not always adequately identify all the risk factors.

“Repetitive handling of bags while kneeling and with the hands at a distance from the low back were the main high risk elements”

In association with one of HSE’s specialist inspectors, HSL has re-examined the MSD risk factors present during loading and unloading of Boeing 737 series aircraft. The study looked particularly at the ramp-based baggage handling operation. External handling of baggage between carts and the aircraft, with and without the use of conveyors, was studied, as well as the manual packing and unpacking of the baggage within the aircraft hold.

The highest risk elements were associated with the in-hold tasks, especially

Improved labelling of bag weights is a proposed immediate risk reduction measure

the stacking of bags during the on-load operation. These tasks are conducted in confined spaces, often with only around one metre of headroom. Repetitive handling of bags while kneeling and with the hands at a distance from the low back were the main high risk elements. Opinion in the scientific literature is mixed on whether it is better to handle bags while standing stooped, sitting, or kneeling in such circumstances. HSL’s review suggests that handling while kneeling for short periods inside the hold is preferable.

For external baggage handling, the use of a conveyor was found to lower the risk compared with not using one. Unloading

Davi

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baggage on to flat bed lorries with a handler standing in the hold doorway and loading direct to high hold doorways presented a high risk of injury. In some cases equipment and baggage carts had to be pulled and pushed into position manually, exposing staff to associated risks.

A number of immediate risk reduction measures have been proposed. These include the use of conveyors for all baggage on/off-loading operations, rotation of workers to other tasks and improved labelling of bag weights.

In the longer-term, recommendations for risk reduction include reducing the individual baggage item weight limit based on robust research, establishing an industry forum to identify and review handling equipment and methods, and passenger education. The aviation industry has recently adopted a voluntary 32kg single bag weight limit, which has led to an encouraging reduction in MSD injuries. However, a further reduction in item weight is recommended.

This project has provided useful information to both HSE and the industry, via the Revitalising Health and Safety in Air Transport (RHSAT) Group, on the choice of work methods to ensure that risks from baggage handling are reduced as far as is reasonably practicable.



“The loading and unloading of passenger bags, particularly on narrow-bodied aircraft, has been identified as a high risk operation for MSD”

This project has provided useful information to both HSE and the industry on the choice of work methods to ensure that risks are reduced



Case Study 4 Preventing asbestos disease in building maintenance staff

Fine asbestos fibres were detected for many (69%) plumbers who said that they had not been exposed to asbestos

In May 2004, a new duty to manage asbestos materials in premises came into force with the aim of preventing maintenance

staff, such as plumbers and electricians, unwittingly working with asbestos. These workers have a history of asbestos exposure and, according to death certificate information, they account for a quarter of all deaths from mesothelioma (an asbestos-related cancer). However, as these cancers can take up to 60 years to develop, this statistic does not reflect the current risk.

Before the new duty came into force, HSE asked HSL to conduct a baseline study of asbestos exposure in industrial plumbers.

The established sampling technique for airborne asbestos involves drawing air through a filter with a battery-powered pump. This works well in most situations but, as sampling personnel have to be present, it is difficult to apply to maintenance workers attending a number of short duration jobs in different premises where the location of the asbestos may or may not be known. To overcome these

“Analytical transmission electron microscopy (TEM) was used to identify and count the asbestos fibres present”

difficulties, an improved version of the passive dust sampler developed by HSL was used to monitor a group of 100 plumbers. The sampler (which does not require a power supply) collects airborne particles using a built-in electrostatic charge.

Participants in the study were sent a short questionnaire, simple instructions and a passive dust sampler. The worker simply pinned the sampler to their lapel and removed the protective cap to start



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sampling. The cap was replaced at the end of each working day, and after sampling for five consecutive working days the sampler was posted back to HSL.

Half of those who were sent a passive sampler returned them and were then sent a second sampler for a further week’s monitoring. A total of seventy-four samplers were returned for analysis. Analytical transmission electron microscopy (TEM) was used to identify and count the asbestos fibres present.

About half the passive samplers had measurable levels of asbestos by TEM. Of the plumbers who reported that they had worked with asbestos during the sampling period, 93% were found to have asbestos on

their samplers. However, fine asbestos fibres were detected for many (69%) plumbers who said that they had not been exposed to asbestos. Thirty-one percent of the samples had asbestos which met the regulatory definition of a fibre (as measured by light microscopy) and would have been counted in assessing compliance with the control limit. These results suggest that this group of workers are frequently and unknowingly being exposed to asbestos.

This study has emphasised the need to manage asbestos-containing materials in buildings to prevent exposure of maintenance workers, and has underlined the importance of introducing the new duty to manage asbestos regulations. “The worker simply

pinned the sampler to their lapel and removed the protective cap”

The results suggest that this group of workers are frequently and unknowingly being exposed to asbestos



Case Study 5 Evaluation of safety nets by modelling and experiment

“In 2003/04, 48 people died and 3,884 suffered a serious injury in the UK as a result of falling from height”

Falls are the single largest cause of fatal and major injury in the construction industry, although

injuries due to falls occur throughout all industrial sectors. In 2003/04, 48 people died and 3,884 suffered a serious injury in the UK as a result of falling from height.

While it is important to prevent falls by using safe systems of work, a back-up system of fall arrest is also necessary. Safety nets offer a passive system of fall arrest that does not rely on individual actions, such as clipping on a lanyard. Guidance issued by HSE recommends safety nets as a means of providing collective rather than individual protection.

There is enormous potential for mistreatment of safety nets on construction sites and nets regularly require repair after service. Anecdotal evidence suggests that nets are sometimes struck by sparks from

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welding operations, used to lower building materials or damaged by being used as a means of access. The effects of mistreatment and abnormal loading on the performance of safety nets are not fully understood. This was graphically illustrated by a fatal accident at Old Trafford in 2000, when a worker fell into a safety net whilst carrying a quantity of roofing material.

To address some of these issues, HSL has constructed a dynamic experimental facility, unrivalled in the UK. This facility can support nets up to 15 m by 7.5 m in size and has 450 attachment points for connection at every mesh on the border of the net. Adjacent to the facility is a 25 m drop tower with a lifting and release system capable of dropping masses of up to 250 kg onto any position on the net. Drop items include a standard 100 kg sphere and an anthropomorphic test dummy.

Safety nets offer a passive system of fall arrest that does not rely on individual actions, such as clipping on a lanyard



Drop items include a standard 100 kg sphere and an anthropomorphic test dummy

“Tests are building up baseline data for safety nets under a range of non-ideal loading conditions which are likely to occur in service”

Fourteen moveable loadcells can be installed anywhere, allowing either global load distributions or more detailed localised loads to be measured.

The current test programme is supported by FASET, the trade association representing the safety net industry, and its members have contributed information and test samples.

These tests are building up baseline data for safety nets under a range of non-ideal loading conditions which are likely to occur in service. These conditions include gathering (or bagging) of excess netting, net sag, defects and repairs, edge loading, and multiple and repeat loadings.

Subsequent work will look at the long-term effects of ultraviolet light exposure and mistreatment, and will use nets removed from service at various points during their life. Test data will be used to evaluate the feasibility of computer modelling and will be available as a data source for planning the design of net installations and for forensic evaluation of net failures.



Case Study 6 Mechanical ignition of explosive gas and dust atmospheres St

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Mechanical equipment can give rise to sources of ignition when two surfaces rub together, either by

creating hot spots or by tearing away hot material in the form of sparks. The dangers of using such equipment in potentially explosive atmospheres were recognised by the European Explosive Atmospheres (ATEX) Directive in 1994 (Directive 94/9/EC). The behaviour of mechanical ignition sources is not well understood, however, and there is a need to define them and their characteristics more closely, so that the degree of hazard presented by mechanical equipment can be assessed.

HSL is leading a collaborative programme of work known as MECHEX, part funded by the European Commission, to study the characteristics of sparks and hot surfaces produced by impact, friction and grinding processes and assess their potential to ignite explosive atmospheres and combustible dusts. The effects of variable factors including surface properties, relative speed, energy of impact, power loss and duration of contact are also being taken into account.

As well as HSL, the MECHEX research group includes INBUREX and Physikalisch-Technische Bundesanstalt (PTB) in Germany and the Institut National de l'Environnement Industriel et des Risques (INERIS) in France. At HSL, the

Thermal imaging and a sacrificial thermocouple technique are used to measure the temperatures produced during friction events

HSL used its low speed rubbing machine to carry out these tests

characteristics of friction and grinding have been studied to understand the conditions, in terms of rubbing speed, contact force and dissipated power, that lead to potential ignition sources.

HSL used its low speed rubbing machine to carry out these tests. This machine employs a converted lathe bed powered by a 30kW induction motor to produce rubbing velocities from 0.5 to 20 m/s and contact loads up to 5kN. The potentially incendive friction events are produced in a 0.3 m

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vented explosion vessel. Thermal imaging and a sacrificial thermocouple technique are used to measure the temperatures produced during friction events.

Having produced mechanical ignition sources by controlled means with reproducible characteristics, the research team exposed the sources to explosive atmospheres and combustible dust deposits. The experimental data are being used to quantify the energy and power losses necessary to produce ignition sources and thus allow equipment to be categorised according to the type and extent of ignition source it could present.

When the programme of work is complete, it should be possible for manufacturers to define (on the basis of measurements of standard ignitability characteristics) the type of environments where their equipment could be used without risk of ignition. The ignition hazard assessment for mechanical equipment produced by MECHEX will exactly complement the work currently underway to produce a European standard on mechanical ignition sources and ways to prevent them or protect against them.

“Having produced mechanical ignition sources by controlled means with reproducible characteristics, the research team exposed the sources to explosive atmospheres and combustible dust deposits”



“The effects of variable factors including surface properties, relative speed, energy of impact, power loss and duration of contact are also being taken into account”



2004-2005

Operating and financial

Review


The HSL Annual Report and Accounts address many of the issues appropriate to HSL that come within the scope of the Accounting Standards Board's requirements for an Operating and Financial Review.

Of particular importance is a description of HSL's business and aims and objectives (see pages 1 and 25), the membership of the HSL Board (see page 25) and HSL's arrangement for audit (see pages 26 and 29). Also of particular relevance is the Annual Performance Agreement and how well HSL has performed within the financial year against the targets set by HSE (see page 2).

The most significant event in 2004/05 was the collocation, in November 2004, of all HSL's laboratory activities onto its Buxton site in a new purpose-built laboratory, acquired under the terms of a Private Finance Initiative (PFI) contract (further details are given at pages 34 and 43). This has significantly changed HSL's

land and buildings asset base. Also during the year, the status of HSL was reviewed, and further details of this are available in the Chief Executive’s Foreword.

Looking to the immediate future, 2005/06 will see the retirement of two of the four existing Board members. With regard to turnover, HSL, with HSE agreement, is planning to continue to increase significantly the level of business from non-HSE customers, whilst maintaining HSE business broadly at present levels. To this end, a new Business Development Director is being added to the Board from 1st June, 2005.

2004-2005 ANNUAL REPORT & ACCOUNTS HEALTH AND SAFETY LABORATORY

An Agency of the Health & Safety Executive

Sixth Sense!Interesting findings in our latest set of case studies

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& Safety Laboratory | A

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ual Report &

Accounts | 2004-2005



Health & Safety Laboratory Harpur Hill Buxton Derbyshire SK17 9JN United Kingdom Room to move Tel 01298 218000Room to experiment Fax 01298 218590 Email [email protected]

www.hsl.gov.uk

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annual reports and accounts 2004/05 · smre, ohl and oml merge to form hse’s research and...

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