health and safety in engineering workshops...

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Health and Safety Executive

Health and safety in engineering workshops

This is a free-to-download, web-friendly version of HSG129 (Second edition, published 1999). This version has been adapted for online use from HSE’s current printed version.

Youcanbuythebookatwww.hsebooks.co.ukandmostgoodbookshops.

ISBN 978 0 7176 1717 3 Price £9.50

Health and safety in engineering workshops describes how most serious and frequent hazards arise, how to assess the risks involved, and how to eliminate or control them.

It contains guidance from over 200 separate HSE publications in one easy to read and follow guide – as well as providing a comprehensive list of references and other sources of help.

HSE Books

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© Crown copyright 1999

Firstpublished1995Secondedition1999Reprintedwithamendments2002Reprinted2004

ISBN9780717617173

Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans(electronic,mechanical,photocopying,recordingorotherwise)withoutthepriorwrittenpermissionofthecopyrightowner.

Applicationsforreproductionshouldbemadeinwritingto:TheOfficeofPublicSectorInformation,InformationPolicyTeam,Kew,Richmond,SurreyTW94DUore-mail:[email protected]

ThisguidanceisissuedbytheHealthandSafetyExecutive.Followingtheguidanceisnotcompulsoryandyouarefreetotakeotheraction.Butifyoudofollowtheguidanceyouwillnormallybedoingenoughtocomplywiththelaw.Healthandsafetyinspectorsseektosecurecompliancewiththelawandmayrefertothisguidanceasillustratinggoodpractice.

2004 Reprint

Ingeneral,theamendmentsincludedinthisreprintreflectupdatedpublicationsandregulations.Theoverallguidancehasnotchanged.

HSEgratefullyacknowledgesthehelpofElfOilIndustrialLubricantsDivisioninthepreparationofthecoverillustration.

Healthandsafetyinengineeringworkshops Page3of147


Foreword 5

Managing health and safety 6

How most accidents and cases of work-related ill health arise 7

Instant action checklist 9

How to use this book to start your risk assessment 10

Five steps to risk assessment 13

Working in and moving around the workshop 15Lighting 17Generalventilation,temperatureandtoilets 19Liftingequipment 21Movinggoodssafelybyhand 22Howtoliftsafely 23Liftingandhandling 24Ergonomicmachineoperation,assemblyandpacking 27Movingvehiclessafely 30Lifttrucks 31Controllinghazardoussubstances 33Localexhaustventilation 35Electricity 37Portableelectricalequipment 38Commonproblemswithflexibleleads,theirplugsandsockets 40Pressurisedplantandsystems 42

Machining 43Computercontrolled(CNC)machining 47Buyingandsellingmachinery 49Metalworkingfluids52Noise 55Vibration 61Millingandmachiningcentrework 62Drilling(andreaming) 64Pressing 66Turning 69Grinding 71Sawing 73Bending 74Guillotining 75CNC punch pressing 77Combinationmetalworkingmachines 78Horizontalboringmachines 79Cleaninganddegreasing 80Vapourdegreasingtanks 81

Welding and flamecutting 83Fumecontrol 85Safetymeasuresatresistanceweldingmachines 87Lasersusedforweldingandcutting 88

Radiography 89

Contents



Painting 91Spraypaintingboothsandenclosures 93Paintscontainingisocyanates 95Powdercoating 96Personalprotectiveequipment(PPE) 98

Offices 100

Organising health and safety 102Thelaw 102Accidentsandemergencies 104Firstaid 107

How to obtain publications and further assistance 109Furtherreadingandinformation 111HSEoffices 119Someusefuladdressesforselectingahealthandsafetyconsultancy 120

Appendices1 Liftingandhandlingassessments 1222 Metalworkingfluidsquestionnaires 1293 Workequipmentriskassessment 1314 Keystandardsforengineeringworkshops 1375 Fire-resistantmaterialsforDIYspraybooths 1416 Recordofexaminationandtestoflocalexhaustventilation(LEV) plant 1437 Answerstofrequentlyaskedquestionsaboutworkinengineering

workshops 144



ForewordThisguidancehasbeenwrittenforpeoplewhorunandworkinsmallengineeringworkshops,rangingfromthosewho

n maketheirownproducts,

tothosewho

n maintainandrepairplantandmachineryeitherindependentlyoraspartoflargerenterprises.

Itisintendedtohelpthemmanagetheirownhealthandsafetyandworkinsaferandhealthierways.

Asengineeringisawiderangingactivitythebookletdoesnotdealwitheveryhazardwhichmayariseoreveryprecautionwhichcanbetaken.Itdoes,however,outlinethemostseriousandfrequenthazardsandthebestwaysofdealingwiththem.

The ‘Further reading’ section:

n listsHSEandotherpublicationswhichgivemoredetailonthesubjectsdealtwith;

n providesinformationonothersourcesofhelp.

In this guidance:

‘must’denotesalegalobligation;outlinesofthelawapplyingtoengineeringworkshopsareprovidedinlinedboxesonabluebackgroundjustlikethisparagraph;

n ‘do’and‘don’t’,‘should’and‘shouldnot’andotherrecommendationssuchas‘use’,‘fit’and‘prevent’representgoodpractice,which,ifadopted,willusuallybewhatisreasonablypracticableinthegivencircumstancesalthoughtheremaybeotherlegallyacceptablewaysofachievingthesameobjective.

n textinitalics(whereitisnotareference,sub-headingorcaption)outlinesrequirementsofApprovedCodesofPracticewhichhavebeenapprovedbytheHealthandSafetyCommissionandgiveadviceonhowtocomplywiththelaw.Ifyouareprosecutedforabreachofhealthandsafetylaw,anditisprovedthatyouhavenotfollowedtherelevantprovisionsoftheCode,acourtwillfindyouatfault,unlessyoucanshowyouhavecompliedwiththelawinsomeotherway

n tipsongoodpracticeareindicatedbyphrasessuchas‘thinkabout’and‘consider’

n theearlysectionsdealwithhowtotacklehealthandsafetyissuescommontomostengineeringworkshops;latersectionsdealwithmorespecificactivitieswhichmaynotbecarriedoninallworkshops.



Managing health and safetySuccessfulhealthandsafetymanagementinsmallengineeringworkshopsisaboutidentifyingthemostfrequentandseriousrisksandadoptingtherightprecautions,takingaccountoftime,moneyandresources.

Thisbookidentifieshowmostseriousaccidentshappenandhowmostillhealthiscausedinengineeringworkshops.

Ifyouusemachinesorprocesseswhicharenotdescribedinthisbooklet,seewheretheyaresimilartothosedescribedandworkoutwhethertheyposethesamehazardsandwhethertheprecautionssuggestedwouldberight,aswellasseekingfurtheradvice.

The Management of Health and Safety at Work Regulations 1999 outlined

Employersmust:

n assessriskstothehealthandsafetyoftheiremployeesandnon-employeesarisingin,orfrom,theworkshop,andreviewthemwhenthereissignificantchange.Recordsofsignificantfindingsoftheassessmentmustbekeptwheretherearefiveormoreemployees

n plan,organise,control,monitorandreviewthepreventativeandprotectivemeasurestakenasaresultoftheassessment

n providehealthsurveillancewherenecessary(seepages33–34),forexampletohelpcontrolhealthrisksfrommetalworkingfluids

n appointanycompetentperson(s)neededtohelpthemcomplywithlegalobligations,forexample,whenhavingliftingequipmentthoroughlyexamined

n setoutwhatshouldbedoneincaseofseriousandimminentdangerintheworkshop,suchasthespillageofalargeamountofdegreasingsolvent

n tellemployeesabouttherisksandprecautionsinvolvedintheirwork n trainemployeestoworksafely.

Youmayneedhelpbeyondthatgiveninthisbook.Ifyoudo,tradeandemployerassociations,suchasEEF–TheManufacturers’Organisation,theManufacturingTechnologiesAssociation(formachinesuppliers)orlocalChambersofCommerce,offerarangeofadviceandsupport.Thesesourcesofinformationaregivenonpage108.HSEinspectorsarealwayswillingtohelp(seepage118forinformationonHSEOffices).

Employersmustalsoconsultwithalltheiremployees(includingself-employedworkersclassedasemployedpersonsunderhealthandsafetylaw)onhealthandsafetymatters.Thiswillinvolvenotonlygivinginformationbutalsolisteningtoandtakingaccountofwhatemployeessaybeforeanyhealthandsafetydecisionsaretaken.

Key reference:Management of health and safety at work ApprovedCodeofPracticeL21HSEBooks2000ISBN0717624889



How most accidents and cases of work-related ill health ariseAccidentandill-healthdataforsuchawideandvariedsectorisavailablefromanumberofsources,includingpublishedHSEmaterial,researchpapers,industrystatistics,andtradeassociationandtradeunionpublications,althoughitisdifficulttoseethewholepicture.Theinterpretationoftheavailabledatainthisbookletisbasedupontheexperienceofhealthandsafetyinspectorsgainedovermanyyearsindealingwiththesector.

Accidents and ill health

Therearemanythousandsofaccidentsandcasesofillhealthreportedeveryyearinsmallengineeringworkshops.Almosttwo-thirdsofallsuchaccidentsreportedtoHSEarisefromthemovementofpeople,goodsandvehiclesinto,aroundandoutofworkshops.Ofthese‘movement’accidents:

n abouthalfinvolveliftingandmovinggoods,andn abouthalfinvolveslips,tripsandfallsandhittingstationaryormovingplantand

equipment.

‘Non-movement’accidentsusuallyarisefromtheuseofmachinery;theseaccountforbetween10and15%ofallaccidents.

Electricalaccidentsarenotuncommonandfrequentlyhavethepotentialformoreseriousinjuriesthanthoserecorded.

Themostcommonoccupationaldiseasesaredermatitis,deafness,asthmaandvibrationwhitefinger,andback,hand,arm,shoulderandneckproblems. Inanyparticularworkshopriskswhicharerelevantshouldbeassessed.Thoselikelytobeofmostconcerninclude:

n movementofpeople,goodsandvehiclesaroundtheworkshop,particularlymanualhandling

n machinerysafeguardingn hazardoussubstances,particularlymetalworkingfluids,degreasingsolvents,and

dustorfumefromwelding,brazing,soldering,coatingandpaintingn noise,andn vibration.

Costs

Thecostsofaccidentsandillhealthtosmallengineeringworkshopsmaybedisproportionatelyhigh.Manyemployeesare‘key’workerswhoselossthroughinjuryorillhealthseverelydisruptsproductionandlowersprofitability.



Injuries in engineering industries as reported to HSE’s Field Operations Directorate and local authorities 1998/99 – 2000/01

Non-fatal

98/99 99/00 00/01 (provisional)

Totalofwhichmaincauseinvolved:

15267 15078 14668

Handlingandcarrying 5057(33%) 4955(33%) 4842(33%)

Beingstruck(egbyfallingobjects,movingmachinery)

2826(19%) 2872(19%) 2698(18%)

Slippingandtripping 2318(15%) 2386(16%) 2349(16%)

Machinery 1778(12%) 1734(12%) 1641(11%)

Fallsfromheight 935(6%) 950(6%) 910(6%)

Workplacetransport 331(2%) 331(2%) 360(2%)



Instant action checklistIfyouwanttostartcheckingconditionsrightawayusethisinstantactionchecklist

Check Instant action Long-term solution

Arefixedmachineguardsinpositionandsecured?

Replacediscardedguardsandsecurethembyafixingwhichneedsatooltoundoit.

Iffixedguardsarebeingremovedforfrequentaccess(morethanoncepershift)replacewithinterlockingguards.

Areinterlockingguardsfittedandworking?

Ifnot,restoreorrepairthem. Startaprogrammeofpreventativemaintenance.

Areallworkareaandpassagewayfloorsingoodcondition,keptclearandfreefromtrippingandslippinghazards?

Keepallareastidyandclean,andavoidtrailingleads.Repairholesinfloorsandclearupspillages.

Providenon-slipfloorsurfaces.Markgangways.Trainandinstructemployeestokeepworkplaceunobstructed.

Isanyonerequiredtoliftorcarryheavyorbulkyitemsandequipmentunaided?

Markeachloadwithitsweightandtrainallemployeestoliftandcarrysafely.

Seehowthejobmaybeavoided.Providemechanicalaidswherepossible.

Areanyemployeessufferingfromdermatitis?

GetthemtoseetheirGPsandprovidesuitableglovesifthesewon’taddtorisksatmachinery.

Trytoremovethecause,egredesigntheworksothathandlingthesourceofcontaminationisavoided.

Dometalworkingfluidssmellunpleasant,particularlyafterabreakfrommachining?

Replacewithcleanfluid,aftercleaningthemachineandsump.

Trytofindandeliminatecauseofcontamination.

Isthereavisiblefumemistorhazeintheworkshop?Istheremuchvisibledustfromgrinding,polishingorblasting?

Checkexistingcontrolsandventilation,remedyand,ifnecessary,improvegeneralventilation.

Preventfume,mist,vapourordustfrombeinggeneratedorcaptureitclosetosourcebeforeitcanbebreathedandremoveitfromtheworkshop.

Ifyoucan’thearsomeone2mawaytalkinginanormalvoice.

Makesurenoise/machineenclosuresareclosedandhearingprotectionisbeingworn.

Assess,remove,reduceorenclosenoiseatsource.

Arevibrationlevelsofhand-heldtoolsaslowaspossible?

Checksuppliers’dataonvibrationlevels.Keepequipmentmaintained.

Buyandusereduced-vibrationtoolswhereverpossible.

Ifallvehicles(includingfork-lifttrucks)andpedestriansarekept.

Ensurethatalldriversonsiteareproperlytrainedandfork-lifttruckoperatorsauthorised.Enforcespeedlimitsandreducetheneedforreversing.

Reviewalltransportmovements,includingdeliveryandcustomervehicles.Considerone-waysystemsandclearlymarkandsigntrafficroutes.



How to use this book to start your risk assessmentHerearesomequestionsforfindingouthowdangerousorunhealthyyourworkshopmightbe,andwhattodoaboutit.

Generally If the answer is ‘yes’

Thinkaboutthetimeswhenpeoplehavebeenoffworkrecently:

n Couldtheirabsencesbeputdowntoconditionsatwork?

n Isthereapatterntoanyofthem?n Havethelessonsofanyrecent

accidents,nearmissesorcasesofwork-relatedill-healthbeenmissed?

n Aretherehealthorsafetyaspectsofanyprocesses/operationsyoufeeluneasyabout?

Investigatethepossiblecausesfurther.Themostlikelyonesareoutlinedinthisbooklet.

The workshop itself

Arethereanypartswhichare:

n dirtyn darkn obstructedn poorlyventilatedn unnecessarilywet,orn otherwisedangerousorunhealthy

tomovearoundorworkin?

Seepages15–18fordetailsofthestandardsrequired.



Moving and working with articles by hand; loading/unloading machines; assembly and packing

If the answer is ‘yes’

Hasanyonecomplainedaboutorbeenoffworkwithabadback,orpersistenthand,arm,shoulderorneckproblemswhichcouldbeputdowntowork?

Whatabouttheloadsbeingmoved?Aretheytoo:

n heavyn sharpn largen awkwardn hotorcold?

Doesthejobinvolvealotoffrequent,forcefulorawkwardmovements?

Completethemoredetailedquestionnaireonpages121–122(forlifting)andpages123–127(forhandling).Ifyouhaveproblems,thesolutionssuggestedonpages22–30mayhelp.

Vehicles (including fork-lift trucks)

Isthereanydamagetotheworkshoporplantandmachineryfromvehicles?

Dovehiclesoperateclosetopedestrians?

Arevehiclesrequiredtoreverse?

Doesanyoneusevehicleswithoutbeingproperlyselectedandtrained?

Aretheconditionsinwhichtheyoperatetoodark,obstructed,wetorotherwisedangerous?

Thismayindicatetoofast/carelessdrivingorapoorlylaidoutworkplaceandalsopotentialforinjuries.Investigatefurther.

Seepages30–32foradviceontheselectionandtrainingofdrivers.

Seepages15–18fortheminimumstandardsrequiredforworkshops.



Metalworking – machining and welding

If the answer is ‘yes’

Isitdifficulttohearsomeonetalking(inanormalvoice)2mawayatanypointintheworkshop?

Isitpossibletoreach(DON’TTRY!)anypressing,shearing,rotating,cuttingorsawingtoolsespeciallywhen:loading/unloadingcomponents;removingswarf;ormakingadjustments?

Isthereanyvisiblefume,dust,mistorspray,orcanitbesmelt?

Dosomeoperatorsfrequentlyhavetomanipulateorload/unloadcomponentswhicharetooheavy,hot,awkwardorsharp?

Doyoumachine,weldorworkwithcomponentscontainingcadmium,lead,chromeorsimilarlyhazardoussubstances?

Doemployeescomplainaboutnumbortinglingfingers,‘deadhands’oncolddaysorfingerblanching.

Carryoutanoiseassessment–pages55–60tellyouhowtodothisandmakethemostofitandhowtoreduceandcontrolexcessivenoise.

Seetheindividualmachiningsectionsofthisbooklet,pages62–77,foradviceonhowtoguardmachinery.

Viewinganysuspectedsourcewithastronglight(egaTyndallbeamorvideolight)behinditwillshowwherethefumeis.Seepages33–36onhowtoavoidorcontrolharmfulfume,dust,mistandspray.Seepages128–129forguidanceoncheckingthehealthofpeopleworkingwithmetalcuttingfluids.

Seepages22–29foradviceonliftingandhandling.

Seepages33–36foradviceonhowtocontrolexposurestohazardoussubstances.

Seepage61foradviceonhowtodealwithhand-armvibration.

Cleaning and finishing If the answer is ‘yes’

Doyouuse:

n avapourdegreaser?

n othermeansofdegreasing?

Doyoupaintcomponents,orusecoatingpowders?

Seepages80–81forhowtomaintainitandpreventtheneedtogetinandcleanit.

Seepage79forhowtoavoidandcontrolexposurestoharmfulcleaners.

Seepages90–96forhowtoavoidandcontrolexposurestoharmfulsubstancesinpaintsandcoatingpowders.



Five steps to risk assessmentForalongerlook,takefivestepstoyourriskassessmentThe Five Steps

n Lookforthehazardsn Decidewhomightbeharmedandhown Evaluatetherisksanddecidewhetherprecautionsareadequateormoreshouldbedone

n Recordyourfindingsn Reviewyouassessmentfromtimetotimeandreviseitifnecessary

Key reference:5 Steps to risk assessment INDG163(rev1)(singlecopyfreeorpricedpacksof10ISBN0717615650)

Healthandsafetyinengineeringworkshops

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Metalworkingfluids

Cleaninganddegreasingsolvents

Machinery(includingsettingandmaintenance)

Weldingprocessesandmaterials

Noise

Vibration



Workplace (Health and Safety and Welfare) Regulations 1992 and Approved Code of Practice outlined

A safe place of workYoumusthave:

n buildingsingoodrepairn precautionssuchasfencesorrailstostoppeopleormaterialsfallingfromopenedges*

n spaceforsafemovementandaccess,egtomachineryn safe glazing where necessary, marked to make it easy to seen floors,corridorsandstairsfreeofobstructionn gooddrainageatwetprocessessuchaswashingandcleaningn windowsthatcanbeopened(ifopenable)andcleanedsafely.They should be

designed to stop people falling out or bumping into them when open. You may need to fit anchor points if window cleaners have to use harnesses

n outdoorrouteskeptsafeduringicyconditions,egsalted/sandedandswept.

Safe movementYoumusthave:

n safepassageforpedestriansandvehicles–you may need separate routesn level,evensurfaceswithoutholesorbrokenboardsn handrailsonstairsand ramps where necessaryn safedoors,egvisionpanelsinswingdoorsn surfaceswhicharenotslipperyn well lit outside areas.

Work stationsWorkstationsandseatingmustfittheworkerandthework. Makesurethat:

n back rests support the small of the back and foot rests are provided where necessary

n work surfaces are at a sensible height n there is easy access to controls.

Working in and moving around the workshopAbouttwothirdsofallaccidentsinsmallengineeringworkshopshappenduringthemovementofvehicles,peopleandgoods.Asafe,well-lit,cleanworkplacecanhelppreventmanyofthese.

*Particularlyontheflatroofsofofficesprovidedinsmallindustrialunits,whichareoftenusedforstorage;properstairsshouldbeprovidedforfrequentaccesstotheseareas.



CleanlinessYoumust:

n providecleanfloorsandstairs,whicharedrainedwherenecessaryandnotslippery

n providecleanpremises,furnitureandfittingsn providecontainersforwastematerialsn removedust,refuseandtrade-wasteregularlyn clearupspillagespromptlyn keepinternalwalls/ceilingsclean.They may need painting to help easy

cleaning.

Maintenance

Maintainingtheworkshopandtheequipmentinitmayposedifferenthazardsfromthoseencounteredinthenormalrunofproductionwork.Contractorsaswellasyourownemployeesmaybeatincreasedrisk,particularlyduringtherepairandcleaningofplantcontainingtoxic,flammableorhazardousmaterials,machineryandduringworkatheightsorinconfinedspaces.

Key reference:Workplace health, safety and welfare Approved Code of Practice and Guidance on Regulations

HSEBooks2000ISBN0717604136



LightingPoorlightingisoftenafactorinaccidentsandcanalsoincreasevisualfatigue.

Problems Typical activity Average illuminance lux (lx) in work areas

Minimum measured illuminance (lx) at any point or a suitable place

Generalhazardsfromthemovementofpeople,machinesandvehiclesinandaroundtheworkshopandvisualfatiguefromworkrequiringlimitedperceptionofdetail

Generalworkintheworkshop,assemblyoflargecomponents

100 50

Visualfatiguefromworkrequiringperceptionofdetail

Sheetmetalwork,generalmachining,officework

200 100

Visualfatiguefromworkrequiringperceptionoffinedetail

Drawingofficework,assemblyofelectronicandotherfinecomponents

500 200

The law* on lighting outlined

Youmustprovide:

n goodlight–usenaturallightwherepossiblebuttrytoavoidglaren agoodleveloflocallightingatworkstationswherenecessaryn suitableformsoflighting(fluorescenttubesoperatingatmainsfrequencymaybedangerouswithrotatingmachinerywhentherotatingpartcanappeartohavestopped)

n specialfittingsforflammableandexplosiveatmospheres,eginspraybooths,toreducerisksofignitionandexplosion.

* Workplace Health, Safety and Welfare Regulation 1992.



Avoid:

n largedifferencesinthelightingofadjacentareasn glarefromdirectsunlightbyprovidingblinds,forexample,andfromdirectly

visiblelampsbyexcludingthemsufficientlyfromlinesofsightwhennecessaryn strobeeffectsby:

– supplyingadjacentrunsoflightfittingsfromdifferentphases– providingahighfrequencysupply– washingouttheeffectwithlocaltungstenfilamentlighting– ifhighintensitytungstenhalogenormercurylampsareusedtoprovidelocal

lighting,manufacturers’filtersshouldalwaysbekeptinplace.

Fortheelectricalsafetyoflightingsystemsseepages37–41.

Key reference:Lighting at work HSG38HSEBooksISBN0717612325



General ventilation, temperature and toiletsFansand/oradditionalairinlets(atlowlevel)andoutlets(athighlevel)maybeneededinworkshopswheretherearenomeansofventilationotherthanairleakinginandout(particularlyinunitsonsomefactoryestates)andwhere:

n workgenerateshazardousairbornepollutantsn workshopshavebeensealedtoconserveenergy.

Provideat leastfivelitres/secondperoccupant(eightisrecommendedforcomfort)andairmovementintheworkshopofatleast0.1to0.15metres/second.

Measurevelocities,usingspecialisthelpifneeded,atinletducts(tocalculateairflowsinwards)andinsidetheworkshop(tocalculateairmovements).

The temperature should be at least 16°C unless work involves severe physical effort, in which case the minimum should be 13°C.

The law on temperature outlined

Youmustprovide:

n areasonabletemperatureandathermometerinsideworkshops.

The law on toilets and washing facilities outlined

Youmustprovide:

n suitableandsufficient(andadequatelyventilatedandlit)sanitaryconveniencesand(nearby)washingfacilitieskeptcleanandorderly,in the minimum numbers outlined below

n separateroomsformenandwomen,exceptwheretheyarefortheuseofonepersonandarecapableofbeingsecuredfromtheinside

n hotandcold,orwarmwaterwithmeansofcleaninganddrying.

No of people in workshop No of WCs and wash stations

1–5 1

6–25 2

26–50 3

51–75 4

76–100 5



Alternatively, for sanitary accommodation used only by men, the following numbers are recommended:

No of men No of WCs No of urinals

1–15 1 1

16–30 2 1

31–45 2 2

46–60 3 2

61–75 3 3

76–90 4 4

91–100 4 4

Make separate calculations where groups such as office workers have separate accommodation.

Key reference:Workplace Health, Safety and Welfare Regulations 1992Approved Code of Practice and Guidance on RegulationsL24

HSEBooksISBN0717604136



Lifting equipmentAlthoughlifting,supportingandhandlingequipmentcanlightentheloadofmanualhandlingwhenproperlyused,manyaccidentshappenwhenloadsaredroppedfromliftingequipment,eitherbecauseofpoorslinging,orequipmentfailureoroverloading.

Always:

n maintainallliftingequipment,includingthatusedonlyoccasionally,suchasattachmentstoforklifttrucks

n trainallusers,particularlyintheuseofslingswherenecessaryn planliftsinadvancen ensurethattheweightandthedistributionofanyloadisnotbeyondthe

capacityoftheequipmentbeingusedn providesafeplacesofworkfromwhichtomaintainhoistsandlifts,particularly

atheights;donotallowoverheadtravellingcranestoworkwithin6mofpersonsoncranetracks

n checkthecondition,typeandsizeofanyeyeboltsusedandensurethatthethreadtypematchestheholeintowhichitistobescrewed.

The law* on lifting equipment outlined

Thesameregulationsnowapplytoallliftingequipment,whichincludesanyequipmentusedatworkforliftingorloweringloads,andliftingaccessoriessuchaschains,slings,eyeboltsetc.

Youshouldensurethat:

n liftingequipmentissufficientlystrong,stableandsuitablefortheproposeduse,andmarkedtoindicateitssafeworkingload;

n liftingequipmentispositionedorinstalledtominimisetheriskofinjury,egfromtheequipmentortheloadfallingorstrikingpeople;

n everypartofaload(including,forexample,palletsandstillages)andanythingattachedtotheloadandusedinlifting(includingforexampletheliftingpointsonskips)isofadequatestrength;

n liftingoperationsareplanned,supervisedandcarriedoutinasafemannerbypeoplewhoarecompetent;

n liftingequipment(includingaccessories)isthoroughlyexaminedforanydefectbeforeitisputintoserviceforthefirsttime(unlessitisnewandiscoveredbyanECdeclarationofconformitywhichislessthan12monthsold).Wherethesafetyofliftingequipmentdependsoninstallationconditions,itmustbethoroughlyexaminedafterinstallationandbeforebeingputintouseforthefirsttime.Periodicthoroughexaminationsarealsorequiredatsix-monthlyintervalsforaccessoriesandequipmentusedforliftingpeople,andatleastannuallyforallotherequipment;oratintervalslaiddowninanexaminationschemedrawnupbyacompetentperson.

* Lifting Operations and Lifting Equipment Regulations 1998.

Key reference:Safe use of lifting equipment: Lifting Operations and Lifting Equipment Regulations 1998 L113 HSEBooksISBN0717616282



Moving goods safely by handTheunsafemovementofgoodsbyhand,eitherbyliftingorhandlingcausesmoreaccidentsandillhealthinsmallengineeringworkshopsthananyothersingleactivity,especiallytothosemostatrisk,includingtheyoungermoreinexperiencedemployees,theolderand/orlessphysicallyfit,andthosewhomaymakeanexistinginjuryworse.

Backinjuriesareverycommonasarehand,arm,shoulderandneckinjuries,particularlyfromunsafe,highlyrepetitivework.Cutsandabrasionsfromsharpedgesarealsoverynumerous.

Sharp edges

Thesecauseasmanyasathirdofallaccidentsinsomeengineeringworkshops,resultingincuts,abrasions,infectedwounds,dermatitis,amputationsandoccasionallyfractures.

Thoseworkingwithsheetmetal,eitherflatorcoiled,heavysharpitems,suchastoolsandcutters,andscrapmetalandswarfaremostatrisk.

Considerhowtoavoidhandlingsharpedges,andifthisisnotreasonablypracticable,reduceexposuretothem.

Reducing the risks

n Askyoursuppliertoremoveorprotectsharpedges,egbymachiningoutsharpedgesorfittingplasticcoversorpadding.

n Removesharpedgesorprotectthembeforehandling.n Avoidhandlingbyusing,forexample,trays,jigs,holdersorbaskets.n Minimisehandlingbyautomatingprocessesbyusing,forexample,conveyors,

feedanddischargechutes.n Storearticlescorrectlysothattheyareretrievedeasily.

Usepersonalprotectiveequipmentsuchasgloves,gauntletsandaprons,butonlywherethesedonotaddtootherrisksfrommachinery,suchasentanglement.

See Appendix 1 for checklists.

Manual Handling Operations Regulations 1992 outlined

Employersmust:

n avoidtheneedforhazardousmanualliftingandhandlingifreasonablypracticable

n assesstheriskofinjuryfromanyhazardousmanualliftingandhandlingwhichcannotbeavoided;and

n reducetheriskofinjuryaccordingly.

Employeesmust:

n followsafesystemsofworklaiddownbytheiremployersn usemechanicalaidsprovidedbytheiremployersproperlyn remembertousethetrainingprovidedonlifting.

Key reference:Manual Handling

Operations Regulations 1992 Guidance on

RegulationsL231998HSEBooks

ISBN0717624153



How to lift safelyHerearesomeimportantpoints,usingabasicliftingoperationasanexample.

Planthelift.Whereistheloadtobeplaced?Useappropriatehandlingaidsifpossible.Doyouneedhelpwiththeload?Removeobstructionssuchasdiscardedwrappingmaterials.Foralonglift,suchasfloor-to-shoulderheight,considerrestingtheloadmid-wayonatableorbenchinordertochangegrip.

Position the feetFeetapart,givingabalancedandstablebaseforlifting(tightskirtsandunsuitablefootwearmakethisdifficult).Leadinglegasfarforwardasiscomfortable.

Adopt a good postureWhenliftingfromalowlevel,bendtheknees.Butdonotkneeloroverflextheknees.Keepthebackstraight(tuckinginthechinhelps).

Leanforwardalittleovertheloadifnecessarytogetagoodgrip.Keeptheshoulderslevelandfacinginthesamedirectionasthehips.

Trytokeepthearmswithintheboundaryformedbythelegs.Thebestpositionandtypeofgripdependsonthecircumstancesandindividualpreference;butitmustbesecure.Ahookgripislesstiringthankeepingthefingersstraight.Ifyouneedtovarythegripastheliftprogresses,doitassmoothlyaspossible.

Keep close to the loadKeeptheloadclosetothetrunkforaslongaspossible.Keeptheheaviestsideoftheloadnexttothetrunk.Ifacloseapproachtotheloadisnotpossible,slideittowardsyoubeforetryingtolift.

Liftsmoothly,keepingcontroloftheload.

Don’ttwistthetrunkwhenturningtotheside.

Ifprecisepositioningoftheloadisnecessary,putitdownfirst,thenslideitintothedesiredposition.

Training for lifting and handling

Thisshouldcover:

n howtorecogniseharmfulmanualhandlingn appropriatesystemsofworkn useofmechanicalaidsn goodhandlingtechnique.

(a) Planthelift

(b) Determinethebestlifting

technique

(d) Pulltheloadincloseto

yourbody

(c) Getasecuregrip



Lifting and handlingAssessing risks

AssessmentSomeoftheimportantquestionstoask

Job: Toohightolift/lower? Toorushed? Toofartocarry? Toorepetitive? Toomuchtwistinginvolved?

Load: Tooheavy? Toolarge? Toounstable? Toohot/cold? Toosharp? Toodifficulttograsp?Work area: Toodark? Tooslippery? Tooobstructed? Toomanysteps?

Individual: Fitforthejob? Inneedofspecialconsiderationortraining?


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Hea

lth

and

Saf

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Loading/unloading

lorries/vansbyhand

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Hea

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Loading/unloading

machines

Assem

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packing

Preparing,

maintaining,m

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andrepairing

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rightheight/po

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Job



Ergonomic machine operation, assembly and packingTo minimise risks

n avoidapplyingtoomuchforcefortoolongortoofrequentlyusinganawkwardpostureofthehand,wristorarm.

Consider

Reducing the force involved by,forexample:

n keepingcuttingtoolssharpn providingalargergrippingarean supportingtoolsbymeansofbalancersortensioners(whichmayalsohelp

minimisevibration).

Reducing highly repetitive movementsby,forexample:

n restructuringjobssotheycontainmorevariedworkn automation.

Reducing the need for awkward posturesby,forexample:

n changingtheorientationofthepartbeingworkedupontoenablethewristtobestraight

n movingtheoperatorsoworkismorecomfortable.

Training is vital,particularly:

n topreventtherepetitionofold,badwaysofworkingn toprotectneweremployeesfromworkingtooquicklytoosoon.

Amodifiedhandledesigncanleadtoamorecomfortablehandposition



Key reference: Upper limb disorders in the workplaceHSG60HSEBooksISBN0717619788

Most ill healtharisesfrom:

n prolongedforcefulorrepetitivegripping,twisting,reachingorothermovementwithoutenoughrestorrecovery.Thiscausespain,arestrictionofjointmovementandsofttissueswelling,leadingsometimestopermanentdisability,mostlyinthehands,armsandshoulders

n liftingandhandlinggoodsunsafelybyhand.

Considerworkstationswherebothstandingandsittingispossible.Ingeneralitislessphysicallystressfultosit,providedthereareopportunitiesformovingaround.



Zoneofconvenient

reach

Normalworkingarea

Horizontalreach–distancesinmillimetres

0 100 200 300 400 500 600 700700 600 500 400 300 200 100100

200

300

400

100

200

300

400

Ergonomic aspects to consider

For operating machinery

n makefrequentlyoperatedhandcontrolseasytoreachandworkn ifseatsareprovidedleavesufficientroomforkneesandlegsn avoidbendingandtwistingtoload/unloadmachinesbyhavingmaterial/binson

rackswhichcanberaisedandloweredtokeepthematwaistheightn consider‘lean-on’or‘sit-stand’,wheeled,sliding,suspendedorfixedseatsn seepages99–100fornormalchairs.

For process or assembly work

n arrangetheworkinasemi-circlen provideaswivelchairn bringtheworktotheworkern considerchairswithforward-tiltingseatsandbackreststohelpworkersreach

furtherwithoutlossofsupport,andconsiderworksurfacesandcomponenttrayswhichslopetowardstheworker

n racksformaterialandfinisheditemsshouldbeadjustablesothatworkiscomfortabletoreachandputaway.

For precision work

n Toavoidtensepostures,aforwardtiltingseatandaworksurfacewhichslopestotheworkermaybeparticularlyhelpful.

Sit-standseat

Tiltingseat

Foldawayseat

Key reference:Seating at work HSG571997HSEBooksISBN0717612317



Moving vehicles safelyLorries,vans,carsandothervehiclesandmobileplantareinvolvedinmanyaccidents,whenreversingandmanoeuvringinoraroundsmallworkshops.Theseaccidentscauseinjuriesandoccasionallydeathswhenvictimsarerunoverorcrushed.

Toreducerisks:

n Identifyandclearlymarksaferoutesandlocationsfordeliveriesanddespatcheswhichare:

– awayfrompedestriansasmuchaspossible– ingoodcondition– welllitatalltimeswhenbeingused– awayfromvulnerableplant– markedclearlywithsuitablylowspeedlimits.

n Provideloadingbayswithanexitfromlowlevelorarefugetopreventcrushingn Donotallowuntraineddriverstodrivevehiclesn Avoidreversing(egbysuitabletrafficroutingforexample)orprovidehelpfor

reversingdriversifpossible(egaguide)n Usespeedbumpstolimittrafficspeedswherenecessaryandmakesurethere

aregapsforanylifttruckswhichhavetocrossthemn Selectandtrainyourowndriverswithcare.

Loading and unloading vehicles

Accidentsfrequentlyhappenwhenpeoplefallfromvehicles.Avoidtheneedtoclimbonloads(byusingcurtainsonthesidesofvehiclesormechanicalorproprietarysheetingsystems),orprovidesafeaccessandsafesystemsofwork.Ifitisnecessarytowalkonthetopofhighloads,safetylinesandharnessesshouldbeprovidedandworn.

Key reference:Workplace transport safety HSG136HSEBooksISBN0717609359Managing vehicle safety at the workplace

INDG199HSEBooks(singlecopiesfree)



Lift trucksHow most accidents happen

Lifttrucks,(poweredandnon-powered,pedestrianandrider-operated,)areinvolvedinmanyaccidentsinsmallengineeringworkshops.Thesearefrequentlycausedbyreversingunsafely,speeding,overloading,carryingpassengersorliftingpersonnelthetruckwasnotdesignedfor,ordriversnotbeingtrained,andresultinmanyseriousinjuriesandsomedeathseveryyearwhenvictimsarerunoverorcrushed.

Mostill healtharisesfrom:

n usingdieseltrucksinenclosedconfinedworkingareas,leadingtobreathingproblems

n poorseatingandcontrolsleadingtobackandupperlimbdisordersn poorroadwayswhichmaycausevibrationleadingtobackproblems.

The law* on mobile work equipment outlined

n mobileworkequipmentincludesforklifttrucksandanyotherworkequipmentwhichcarriesoutworkwhileitistravellingorwhichtravelsbetweendifferentlocationswhereitisusedtocarryoutwork.

n wheremobileworkequipmentisusedforcarryingpeople,itmustbesuitableforthispurpose.Measuresmustbetakentoreducetheriskstothesafetyofpeoplebeingcarried,theoperator,andanyoneelse.Theseincludemeasurestoreducetherisksfromequipmentrollingover(mostcounter-balanced,seatedcentre-controlforklifttruckshaveaverticalmastwhichpreventsthemrollingmorethan90°).Measures,suchasfittingrestrainingsystems,egseatbelts,mustalsobetakentoreducetheriskofanyonebeingcrushedbetweenanypartoftheequipmentandthegroundifitrollsoveroroverturns.

n youmustensurethatself-propelledworkequipment(ieworkequipmentwhichispropelledbyitsownmotormechanism)hasappropriatefacilitiestoensurethesafetyofpeopleintheworkplace,includingfacilitiesforpreventingitsbeingstartedbyanunauthorisedperson.

* Provision and Use of Work Equipment Regulations 1998.

Approved Code of Practice on rider operated lift trucks – operator training outlined

n Employerstoprovidebasictrainingbyrecognisedinstructorsn Traineestopassatestoftheircompetencen Recordstobekeptoftraining.



Safe lift truck operation

n Gettherighttruckforthejobn Maintainalllifttrucksregularlyinaccordancewiththemanufacturer’sinstructions,ensureseatsaremaintainedtominimiseunhealthyposturesandvibration

n Selectonlysuitablepersonnelfortrainingasoperators/drivers,authoriseoperators/driversinwriting

n Avoidroutesnearvulnerableplant,egflammableliquidstores,orprotectsuchplant

n Segregatebusylifttruckareas/routesfrompedestrianandworkingareasasmuchaspossible,payparticularattentiontobarriers,layout,visibility,lightingandwarningswherelifttrucksandpeopleworkalongsideeachother;enforcerulesforlowspeedandsafereversing

n Ensureoperatingsurfacesarestrongenough,wellmaintainedandgradientsarenottoosteep

n Trainallemployeesonlifttruckmovements,ifthelifttruckisusedontheroad(toloadandunload,forexample)provideasecondpersontohelpwithtraffic,asnecessary

n Rideroperatedlifttrucksusedregularlyontheroadforlongperiods,andtheirdrivers,mustbelicensedbytheDepartmentofTransport

n Keepkeyssecurewhentrucksnotbeingusedn Donotuseforks,palletsorbinstoliftpersonstoworkatheightsunlessthesearesuitablymodified;useproperlydesignedmobileworkplatformsifpossible.

Key references:Rider operated lift trucks – operator training L117HSEBooksISBN0717624552;Safety in working with lift trucks HSEBooks2000

ISBN0717617815



Controlling hazardous substancesExposuretohazardoussubstancesmostfrequentlyoccurswhen:

n machining(seepages43–46forgeneralcontrolofhazardoussubstancesandpages52–54forthecontrolofmetalworkingfluids)

n welding(seepage82)n painting(seepages90–91)andn cleaninganddegreasing(seepage79).

Thecontrolofdust,fume,sprayandvapour–andthepreventionofskincontactbyadequatepersonalprotection–willminimiserisksofadversehealtheffects,butpayparticularattentiontoprecautionswhenmachining,welding,polishingorgrinding:

n nickel-copperandnickel-chromealloys(foundincoins,magnets,chemicalandfoodprocessequipmentandintheaerospaceindustry)

n stainlesssteelandnickelalloys;stainlesssteelandchromiumalloysn leadandleadalloysn copperalloyscontainingberyllium(commonlyfoundintheelectricalindustryand

inhighdefinitiontoolsanddies–used,forexample,inplasticinjectionmouldingmachines)

n cadmium-platedarticles.

Labelsandsafetydatasheetssuppliedwithhazardouschemicalscontainimportantinformationabouthazards(seeCHIPreferencepage112)tohelpyouusethemsafely.

Themostcommonhealtheffectsfromhazardoussubstancesare:

n skindiseasessuchasdermatitisfrommetalworkingfluidsandoilsn lungproblems,suchasasthma,fromisocyanatepaintsandgluesn poisonings,suchasleadpoisoning,andn veryrarelycancer,suchasskincancerfromcertainmineraloils.

The Health and Safety at Work etc Act 1974, section 6 in relation to the supply of substances for use at work outlined

Suppliersmust:

n ensuresofarasisreasonablypracticablethatthesubstancewillbesafeandwithoutriskstohealth

n provideadequateinformationaboutanyriskstohealthorsafetytowhichtheinherentpropertiesofthesubstancemaygiverise.



Ahazardmaybedefinedassomethingthatcancauseharm–suchasthechemicalsinatinofpaint–whileariskmaybeseenasthechanceofharmactuallybeingdone–whichcanvarywithhowthepaintisactuallyused;sprayinginanuncontrolledenvironmentwithoutpersonalprotectioncouldposehighlevelsofrisk.

The Control of Substances Hazardous to Health Regulations outlined

Youmust:

n assessriskstohealthn preventexposure,forexamplebyusing

– alesshazardoussubstance– adifferentprocess

n wherepreventionisnotreasonablypracticable,controlexposureby,forexample,isolatingorenclosingtheprocessor,ifthisisnotreasonablypracticable,localexhaustventilation,and

n wherepreventionorcontrolisinsufficientonitsown,providepersonalprotectiveequipment

n inform,instructandtrainemployeesn carryoutairmonitoringandhealthsurveillancewherenecessary.

Key reference:Control of Substances Hazardous to Health Regulations 2002. Approved Code of Practice and guidance L5(Fourthedition)

HSEBooks2002ISBN0717625346



Local exhaust ventilation (LEV)Selection and use

LEVisafrequentlyusedwayofcontrollingexposuretohazardoussubstancesbydrawingthemawayfromthebreathingzonesofworkersintoahoodandductworkconnectedtoanextractfan.

InmanycircumstancesLEVmaybecheaperandmoreeffectivethandilutionventilation.(Dilutionventilationworksbyintroducingfreshairintotheworkplacetolowerthegenerallevelofthehazardoussubstancesintheair.)

HeatlossesfromLEVmaybeminimisedbyheatrecoverysystemsorrecirculationoffilteredair,butthelatteronlyafterspecialistadvicetopreventtherecirculationofhazardousmaterialsinharmfulquantities.

Someonewithsufficienttraining,knowledge,skillsandexperienceisrequiredforthemaintenance,examinationandtestingofLEV,andinsurancecompaniesfrequentlyhavethecompetencerequired.

To make the most of LEV

n Getanexperttodesignandinstallthemostappropriatesystem,withtherighthoods/enclosures,ductwork,airvelocitiesandcleaningandfiltrationsystems

n Keepthehoodasclosetothesourceofcontaminationaspossiblen Makesurethefandrawsairawayfromtheoperatorn Makesurepartialenclosuresarelargeenoughtocontaintheworkandthat

sprayersdonotstandbetweentheworkpieceandpointofextraction;consideraturntableforheavyitems

n Checkandmaintainthesystem,regularlyparticularlyflexibleductworkn Providesufficientlighting(suitablyprotected)withintheenclosuretoencourage

worktobedonewithintheextractedarea.

The law* on maintenance, examination and testing of LEV outlined

Inmostsmallengineeringworkshops,employersmustensurethatthoroughexaminationsandtestsarecarriedout:

n every14monthsformostprocessesn everysixmonthswheremetalarticlesareabradedorpolishedformorethan12hoursaweek.

Employersmustalsokeepappropriaterecordsforatleastfiveyears.

See Appendix 6 for details which should be recorded.

* Control of Substances Hazardous to Health Regulations, regulation 9.

LEVusedtohelpdrawwelding

fumefromthebreathingzoneof

awelder



CommoncausesofLEVfailure,whichyoucancheckeasilyandfrequentlyyourselftokeepitworkingproperlyinclude:

n physicaldamagetoandpoorpositioningofhoodsandboothsn damagedand/orblockedductworkn blocked,damaged,unsuitableorincorrectlyinstalledfiltersn toohigh/lowwaterlevelsinwetcollectorsn wearorcorrosionoffanbladesleadingtobuildupofcontaminantonbladesn slippingdrivebeltstofansn poorlubricationoffanbearings.

Ithelpstokeeparecordofthesechecks.

Sprayinginthedirectionofexhaustventilationairmovement;aturntablecanhelpasprayeravoid

standingbetweentheitembeingsprayedandthepointofairextractionfromthebooth

Key reference:Introduction to local exhaust ventilation HSG37HSEBooksISBN0717610012



ElectricityHow most accidents happen

n Mostaccidentsarisefromcontactwith liveconductorsorequipmentmadelive byfaultywiringandconnections.

n Equipmentusing240vACmaybeasdangerousasthatusing415vAC,dependingoncircumstances.

Eachyear,theuseofelectricitycausesfatalandotherinjuries(egburns)fromelectricshockandfire.

Precautionsnecessarytopreventaccidentsrequireeveryoneintheworkshop(includingtheself-employed)touseequipmentsafelyandco-operatewiththeemployerwherenecessary.

Employers in particular need to:

n developasuitablesystemofmaintenanceforbothfixedinstallationsandportableequipment–advicefromacompetentpersonmayberequired

n ensurethatelectricalcontractorsarecompetentfortheworktheyareexpectedtodo;forexample,aretheyregisteredwithsuchorganisationsastheNationalInspectionCouncilforElectricalInstallationContractingorequivalent?

n selectequipmentwhichissuitableforthejob(usingreducedlow-voltageequipmentlowerstheriskofseriousinjury)

n checkthatwiringandequipmentissoundandproperlyinstalled,especiallysothatprotectionequipmentsuchasfuseandswitchgearwilloperateadequatelyinthecaseoffaults.UniversallyacceptedstandardsaredescribedinBS7671Requirements for electrical installations

n ensureanyelectriciansworkingforyouarecompetent.LevelsofqualificationestablishedbytheElectricalJointIndustriesBoardmaybeofhelphere,butcheckthatqualificationsarerelevant;afullyqualifiedTVtechnicianmaynotbecompetenttore-wireabuilding.

The law* on ‘live’ electrical work outlined

Noelectricalworkshouldbecarriedout‘live’wherethereisapossibilityofcontactwithapotentiallydangerousliveconductorunless:

n itisunreasonableinallthecircumstancesfortheequipmenttobedead;andn itis reasonableinallthecircumstancesfortheworktobecarriedoutonornearitwhileitislive;and

n suitableprecautions(including,wherenecessary,suitableprotectiveequipment)havebeentakentopreventinjury,suchasproperworkplanningandtheuseofadequatelytrainedandsupervisedstaff.

* See Key references.

Key references:Memorandum of guidance on the Electricity at Work Regulations 1989 HSR25HSEBooksISBN0717616029;

Electrical safety and you INDG231(singlecopiesfree)



Portable electrical equipmentUse this list to check whether you are managing the risks from portable electrical equipment. Have you:

n preparedandimplementedasystemofmaintenanceforportable(andtransportable)electricalequipment

n madesurethatallitemsofportableelectricalequipmentareincludedinthemaintenancesystem

n decidedhowtodealwith‘unauthorised’equipmentbroughtinbyemployees,egportable,mains-operatedradios

n collectedinformationonwhereandhowequipmentisused.Thisinformationwillhelpyoudecidewhatsortofchecks/inspections/testsarerequiredandatwhatfrequencies

n providedstraightforwardtrainingandinformationforallusers(includingyourself)tohelpthemcarryoutusercheckswhenequipmentisused

n madesurethatallequipmentreceivesaformalvisualinspectionatappropriateintervals,carriedoutbysomeonewhohasbeentrainedinwhattolookfor

n consideredpreparingbriefwrittenguidancerelatingtovisualinspection,whattolookfor,andprocedurestofollowwhenfaultsarefound(andwhenunauthorisedequipmentisfound)

n identifiedequipmentwhichwillneedperiodiccombinedinspectionandtestingn establishedhowoftencombinedinspectionandtestingisappropriate(based

onthetypeofequipment,howitisused,whereitisusedandtheresultsofanypreviouschecks/inspections/tests)

n appointedsomeonewiththeappropriateknowledge,trainingandexperiencetocarryouttheinspectionandtesting

n reviewedtheresultsofchecks/inspections/teststoidentifyanycommontrendsandtoconfirmthatthechoseninspection/testfrequenciesareappropriate

n madesurethatthearrangementswhichyouhavemadearebeingputintopracticeandthatfollow-upactionisbeingtaken?

Remember that choosing the right equipment and carrying out visual inspections are perhaps the most important ways to minimise the risks.



Activity Preferred equipment

Workinsidemetaltankswhichmaybedamporhumid(throughcondensation,forexample)

‡Workonapparatuswherewatermaybepresent(onametalworkingfluidcirculationsystemonamachinetool)

Workinclosecontactwithmetalworkincooldryconditions

Adhocmaintenanceworkandoutsideworkingoodweather

Usepneumaticpowertools.Lighting,ifessential,shouldbe25VdcCTE*maxandfixedoutofreach.

Useequipmentoperatingatvoltagesof50Vac,120Vdcorless.Higher-voltageequipmentshouldbebuilttowaterproofstandard,egBSEN60529:1992Specification for degrees of protectionprovided by enclosures.

Thesupplytoearthedequipmentshouldincorporateback-upprotectionwhichautomaticallydisconnectsthesupplyintheeventofafault,preferablyearthmonitoring.

Useequipmentoperatingatvoltagesof50vac,120vdcorless(110vacCTEmaybeusedinconjunctionwithall-insulatedordouble/insulatedtools).Frequentcleaningofventilationlouvresisnecesary.

Reducedlow-voltageequipmentispreferredsuchas110voltCTE.

* CTE: centre tapped to earth.

Key reference:Maintaining portable and transportable electrical equipment HSG107HSEBooksISBN0717607151



Common problems with flexible leads, their plugs and sockets

Manyaccidentscausingburnandshockinjurieswhicharesometimesfatalarisefrompoorlymaintainedanddamagedleads,plugsandsockets.

Problem Precaution

Failuretoselecttherightequipmentforthejob/environment

Choosetherightequipment.Forexampleinaheavyfabricationshop,armoured,heat-,oil-andfire-resistantleadswilloftenbenecessary.Selectreducedlowvoltageequipment(110VACCTEmax)wheneverpossible.

Failuretogiveadequatesupporttosuspendedcables(suchasonpendantcontrolleadsforoverheadcranes)

Useawireorchaintorelievethecableoftension.

Poorjointsincables Replacecablesratherthanrepairthem,particularlythoseusedforalongtime,orforshortlengthswhenthecostofrepairmaybemorethanreplacement;forlongerlengthscutoffthedamagedpartifitisclosetoanendoruseaproprietaryplug/socketwhichprovidesbothelectricalandmechanicalprotectionforcables.(Ifacouplerisusedthesocketmustbeonthesupplysideandtheplugonthecableconnectedtotheapparatus.)

Repairsshouldbecarriedoutonlybycompetentpersonnel;insulationandsheathdamagecanberepairedbyvulcanisingorusingcompatibleproprietaryself-sealingmaterialtogetherwithaheatshrinkableplasticsleevetogivethefinishedjointnecessaryinsulatingvalue,strengthandwaterproofing.Insulating tapes alone are unsatisfactory.

Leadstrailingtoolongmaypreventcircuitprotectionfromoperatingwithindesignedlimits

Providemoreconvenientsockets,closertowork.

andhowtoavoidthem



Problem Precaution

Cablesandconductorsinsufficientlyprotectedandliabletodamage

Whereliabletodamage,forexampleinabusyarea,re-routeorprovideasuitablecover,egaconduit.

Cablesandconductorstoooftenflexed,whichmaycausedamagetotheinsulatingsheathorconductor

Checkregularly,especiallywherethecableisterminatedintotheapparatusconcerned,andrepairorreplaceasnecessary.

Damagetocablesandconductorsbyportableequipmentsuchassolderingironsandportablegrinders

Secureleadsasfaraspossibleoutofharmsway,whereriskofdamageisminimised.

Arcingwhenplugswithdrawnonload Above16Aprovideaswitch(interlockedwithplugifpossible)toenablecurrentstobesafelybrokenbeforewithdrawingplug.

Weightandleverageofadaptorsdamagingsocketoutlets

Donotuseadaptorsorotherplug-indeviceswheretheirweightandleveragemaydamagesocketoutlets.Providesufficientsocketoutletsor,ifnecessary,usepurposemade,portablemulti-socketoutlets.

Failureofplugcordgrips Ensurethatitisthesheathwhichisbeinggrippednottheconductors;donotremoveplugsbypullingleads.

Usethecorrecttypeofplug(particularlyforarmouredlead).Considerheavy-dutyindustrialplugs.Ensureitisterminatedasperthemanufacturer’sinstructions.

Lossofsecuringscrewsforplugs Checkthemregularly,andreplacemissingones.

Screenedandarmouredflexiblecablesincorrectlyterminatedinsmallerportableequipment

Securethewholecableusingpurpose-madeglands/terminationsfittedbyaskilledpersonwherenecessary.

Overheatedextensionleaddrums Unwindleadfromdrumcompletelybeforeuse.



Pressurised plant and systems

Pressure testing

n Accidents,somefatal,occurduringpressuretestingwhentheenergycontainedinthevesselundertestisreleasedwithexplosiveforce

n Whereverpracticable,avoidusingcompressedair,steamorgas(whichcontainsmorethan200timestheenergyofwaterofthesamevolume)

n Usehydraulic(liquid)pressurewithsuitableprecautionsandalways,ifpossible,beforeleaktesting(usingair,steamorinertgas)componentsnotintendedaspressurevessels,egvehiclefueltanks,radiators,smallcastings,storagetanksandoildrums.

Injection injuries

n Injuries,occasionallyfatal,maybecausedbyaccidentalordeliberateinjectionofmaterialand/orcompressedaireitherthroughtheskinorintoabodyorifice

n Ordinaryworkingclothesdonotsignificantlyresistthepenetrationofcompressedairintothebody

n High-pressurefluidgunsmayinjectmaterialat3–7000psiandcauseseriousinjuries.Careshouldbetakentoavoidaccidentalinjections

n ‘Horseplay’shouldbestrictlyforbiddenn Becausethedegreeofinjurymaynotalwaysbeimmediatelyapparent,medical

adviceshouldalwaysbesoughtaftercompressedairpenetrationoccursorissuspected.

The law* on pressurised plant and systems outlined

n Allplantandsystemsmustbedesigned,constructedandinstalledtopreventdangern Systemsmustbeproperlymaintainedn Modificationsorrepairsmustnotcausedangern Theremustbeawrittenschemeforexaminationofcertainpressurevessels,suchas

airreceivers,steamboilers,fittingsandpipework,drawnupbyacompetentpersonn Examinationsassetoutinthewrittenschememustbecarriedoutbyacompetent

personn Recordsmustbekeptinmostcases.

Key reference:*Safety of pressure systems. Pressure Systems Safety Regulations 2000. Approved Code of Practice HSEBooksISBN071761767X

Compressed air safety HSG39HSEBooksISBN0717615316



MachiningHow most accidents happen

Mostaccidentsatalltypesofmachine,includingautomaticandCNCmachines,happentooperatorsduringnormaloperationwhen:

n loading/unloadingcomponentsn removingswarfn takingmeasurementsandmakingadjustments(tothecoolantsupplyin

particular).

On manually operated machines,themostdangerousmachinemovementsaretherotating,cutting,shearing,sawingorpressingmovementsoftools,particularlyon:

n pressesn drillingmachinesn millingmachinesn lathesn metalcuttingsawsn guillotinesandn grindingmachines.

Handsaremostfrequentlyinjured,themostnumerousinjuriesbeingcutsandabrasions,manyofwhicharesevere.Brokenbonesanddislocationsarenumerous.Amputationsoffingersandhandsarenotinfrequentandtherearesomefatalities,oftenarisingfromentanglements,everyyear.Eyeinjuriesarealsocommon.

On automatic and computer controlled machinery,alargerproportionofaccidentshappensatautomaticallyandcomputercontrolledclamps,axes,tables,swarfremovalequipment,chucksandotherworkhandlingequipment.

Atalltypesofmachineryalargenumberofaccidentshappentosetters,electriciansandmaintenancepersonnelduringset-up,inspection,fault-finding,maintenanceandrepair.


n unsafeloading/unloadingandhandlingofcomponents,inparticularwhenhighlyrepetitive,whichmaycausebackinjuriesandupperlimbdisorders

n skincontactwithmetalworkingfluids,forexamplewhenpreparingfluidsorhandlingcomponents,whichmaycauseskinirritationanddermatitis

n breathinginaerosols,oilmistsandfumesfrommetalworkingfluidsduringmachiningwhichmaycauseirritationoftheeyes,noseandthroat,andoccasionallybreathingdifficultiessuchasbronchitisandasthma

n sharpedgesandswarfwhichmaycausecutswhichexacerbatedermatitisn highnoiselevelswhichmaycausedeafnessmostfrequentlyatmachines

whichgenerateimpactswhenoperating,higherspeedmachinesorgroupsofmachinesrunningtogether

n vibration,particularlywhengrinding.



Safety measures

n Topreventaccesstodangerousmovementsduringbatchproductionatmanuallyoperatedmachinesusefixedguardswith:

– jigsandfixtures(suchasslidingtrays)toloadandunloadcomponentsawayfromthetools

– safemeansofremovingswarf(suchasahookorrakewhichmaybeinsertedthroughsmallopeningsinfixedguards)andadjustingcoolant(suchastapsoutsidefixedguards).

n UsefixedandinterlockingguardsorsafetydevicesprovidingequivalentprotectionatautomaticandCNCmachinestoensurealldangerousmovements,notonlytools,areguarded(seepages47–48andindividualmachinesforfurtherguidanceonguardingCNCmachines).

n Controlnoisebyengineeringmeansatsourceoradaptandextendguardstoserveasnoiseenclosures(egbyliningthemwithnoiseabsorbentmaterials).(Seepages58–60.)

n UseguardstohelpencloseandcontrolhazardoussubstanceswithLEVwhereappropriate.

n Manuallyoperatedmachinesusedinfrequentlyforone-offoperationssuchasthoseoftenfoundintoolroomsmayrequireconstantadjustmentandcloseobservation;guardsmayalsoneedtobereadilyadjustableandallowcloseobservation.

Training essentials

Operators should know:

n whatthemaindangersare,howthemainsafeguardsworkandwhoshouldbenotifiedofdefectiveones

n howtostart,operateandstopthemachinesafelyn whattowear(egprotectiveequipment)andwhatnottowear(eglooseclothing

atsomemachines)n howto

– loadandunloadcomponents– removeswarf,and– adjustcoolantflowsafely

n nottocleanmachinesusingcompressedairtoblowmaterialaway–industrialvacuumcleanersorbrushesshouldbeused

n howtoworksafelywithanymetalworkingfluidsused.



Maintenance and setting personnnel should know:

n thatbeforeinspection,cleaning,maintenanceandrepair,machinesmustingeneralbeswitchedoffandisolated

n wherepowerisnecessary,howtoworksafely,forexamplebyusing:

– writtensystemsofwork– permitstoworkoncomplexorhazardousplant,and– warningsigns

n howtomaintainmetalworkingfluidstominimisehealthrisks.

TheProvisionandUseofWorkEquipmentRegulations1998imposerequirementsrelatingnotjusttopreventingaccesstodangerouspartsofmachinery,butalsotothefollowing:

n informationandinstructionn inspectionn safemaintenanceoperationsn startingandstoppingmachinessafely(includingemergencystops)n controlsystemsn meansofisolatingworkequipmentfromsourcesofenergyn stabilityn lightingn markingsn warningdevices.

Youwillneedtocarryoutriskassessmentsonyourexistingmachineryinordertoidentifywhetheritcomplieswithalloftherequirements.YoucanusetheriskassessmentproformainAppendix3tohelp.

The Provision and Use of Work Equipment Regulations 1998 outlined (equipmentincludesmachinery)

Employersandothersmustensurethat:

n suitableequipmentisprovidedforthejobsinvolvedn informationandinstructionareadequaten equipmentismaintainedingoodworkingorderandrepairn trainingisprovidedforoperatorsandsupervisorsn equipmentissafeguardedtopreventrisksfrommechanicalandotherspecifichazards

n equipmentisprovidedwithappropriateandeffectivecontrolsn maintenanceiscarriedoutsafelyn someworkequipmentissubjecttoinspectiontoensurethatissafetouse(seepage46).

TheRegulationsalsocontainrequirementsrelatingtomobileworkequipment(seepage31)andpowerpresses(seepage65).

Key reference:Provision and Use of Work Equipment Regulations 1998 ACOP and Guidance on Regulations L22 HSEBooksISBN0717616266



Inspection of work equipment

Inspectionofworkequipmentshouldbecarriedoutwhereasignificantriskofinjury(onewhichcouldforeseeablyresultinamajorinjuryorworse)mayresultfrom:

n incorrectinstallationorreinstallationoftheequipmentn deteriorationoftheworkequipmentleadingtodanger,orn asaresultofexceptionalcircumstanceswhichcouldaffectthesafeoperation

oftheworkequipment(forexample,ifitisdamaged).

Inspectionwillbenecessarywhenequipmentorpartsofequipmentdeteriorateandleadtodangerandwherethiswillnotbeadequatelycontrolledthroughoperatorchecksandnormalservicingregimes.Itwillnotthereforeapplytoeverydayrisksatworkequipment,whichcanbedetectedandrectifiedduringroutineoperatorchecksandmaintenance.

Thepurposeofaninspectionistoidentifywhethertheequipmentcanbeoperated,adjustedormaintainedsafelyandthatanydeterioration(suchasdamageorwear)canbedetectedandremediedbeforeitresultsinunacceptablerisks.

Inspectionsshouldincludevisualandfunctionalchecksoftheequipment,andsometimestesting.Thiswilldependonthecomplexityoftheequipment,onwhereandhowitisused,andonwhattheriskstohealthorsafetycouldbeiftheequipmentisoperatedinanunsafecondition.

Ariskassessmentshouldbecarriedouttodeterminewhetheraninspectionisnecessaryand,ifso,whatformitshouldtake.Theassessmentshouldalsostatetheintervalsatwhichinspectionsshouldbecarriedout.Recordsoftheassessmentandtheinspectionsshouldbekept.

Some examples of equipment which is likely to be subject to inspection:

n Hydraulic presses and press brakesn Non-lifting parts of fork lift trucksn Die-casting machines



Computer controlled (CNC) machining How most accidents happen

Fromtrappingat,orcontactwith,tools,clamps,tables,swarfremovalequipment,chucksandotherworkhandlingequipment,duringnormaloperatingcycleswhenclearingblockagesandswarf,loading/unloading,cleaningandmakingadjustments.

Manyaccidentsalsooccurduringfaultfinding,setting,andrepairandmaintenancebecausesafeguardingisinadequatelyspecified,poorlydesigned,notunderstoodbytheuser,and/ormisused.

Mostill healtharisesinthesamewaysasatconventionalmachines,frompoorhandling(seepage22),metalworkingfluids(seepage52),andnoise(seepage55),butrisksfrom:

n aerosolmistsfrommetalworkingfluidsmaybehigherbecauseofhigheroperatingpressuresandspeeds,and

n noise,particularlyfromhigh-speedcutting(andespeciallyfromgroupsofmachinesoperatingtogether)maybehigher.

Key safety measures

Asthedegreeofcomputercontrolmayvaryfrom:

n completecontrolofseveraldifferentmachinesworkingtogetherwithassociatedequipment(suchasloading/unloadingdevices),to

n partialcontrolofoneaspectofasinglemachine(suchasconstantsurfacespeedcuttingona‘microprocessor’enhancedlathe)

provide safeguardsappropriatetotherisksposed.Forexample,atafullyprogrammableCNClathe(wheremanysequencesofhigh-speed,high-powermachinemovementsmaybeundercomputercontrol)completeenclosurebyfixedandinterlockingguardsortheirequivalentsisappropriate.

Ata‘microprocessor’enhancedmechanicallathe,however,whereonlyconstantsurfacespeedcuttingisundercomputercontrol,completeenclosuremaynotbenecessaryandsafeguardsmoreappropriatetoamanuallyoperatedlathemaysuffice.

Wherethespeedandpowerofmachinemovementsundercomputercontrolleadstorisksofinjury:

n providefixedandinterlockingguards(orequivalentsafeguards)topreventaccesstoall suchmachinemovements,notonlytometalcuttingtools–workzoneenclosuresmaybenecessary

n arrangeinterlockingsothatpowertodangerousmachinepartsisremovedwheninterlockingguardsareopenormovementsarelimitedtosafeincrementsorspeeds,whichareautomaticallypreventedfromrisingtounsafelevels



n useenclosingguardstohelpreducenoise,andcontrolemissionsofmists,fumeandvapour,eitherfrommetalworkingfluidsorthematerialbeingmachined

n makesureyouunderstandwhichsafetyfunctionsdependoncomputercontrolandhowtocheckandmaintainthem.Ifyoudon’tunderstand,askyoursuppliertoexplain

n checkthatvisionpanelsintendedtocontainpartswhichmaybeejectedfromthemachinearesuitablydesignedandconstructed,havesufficientstrengthandarewellmaintained.

ArangeofCNCsystemsareavailablethatcanbefittedtopreviouslymanuallyoperatedmachinetools,suchasmillingmachinesorlathes.Thesessystemsprovideaselectionoffeatureswhichcansignificantlyimprovetheproductivityofthemachineandthequalityoftheworkproduced.Whenmachinesareretrofitted,newhazardsandtheincreasedriskstotheoperatorthatareassociatedwithCNCmachinesmaybeintroduced.Automationalsochangesthewaytheoperatorinteractswiththemachineand,tosomeextent,thewaythehazardsmaybepresentedtotheoperator.Becauseofthechangefrommanualtoautomaticoperationaretrofittedmachineshouldbesubjecttoariskassessment.Fixedandinterlockedguardswhichpreventaccesstothedangerzoneduringtheautomaticcycleshouldbenormallyprovided.Whereitisnecessarytohavepoweredmovementofamachineelement,withtheinterlockedguardopen,egforsettingpurposes,thisshouldbedoneunderlimitedspeedconditionswithhold-to-runcontrols.

Detailedconsiderationshouldbegiventothesafety-relatedpartsofthemachine’scontrolsystem.AnumberofBSENstandardsprovidespecificguidanceonthismatterandfurtherinformationshouldbeavailablefromthecontrolsystemcomponentsupplier.

Key references:Provision and Use of Work Equipment Regulations 1998 ACoP and Guidance on Regulations L22HSEBooksISBN0717616266

Engineering machine tools: Retrofitting CNC EIS19HSEBooks(free)



Buying and selling machineryNew*

Abuyerof‘new’machineryshouldlookforthe‘CE’mark,whichshouldindicate:

n thesupplier’sclaimtoconformitywiththeSupplyofMachinery(Safety)Regulations,whichimplementstheMachineryDirectiveintheUK

n themachinerymeetsessentialhealthandsafetyrequirementstoeliminaterisksofinjuryfrommostsources

n thereshouldbelittleifanythingfurthertodotomakethemachinerysafeif‘Instructionsforuse’arefollowed.

IfyoubuyamachinewithaCEmark,assessthatitissafeandwithoutriskstohealthby,forexample,checkingitagainstthestandardsonanysimilarmachinesyoumayalreadyhave;itshouldatleastmeetcurrentstandards.YoucanusetheriskassessmentproformainAppendix3tohelpcheckthemachine.

Foraseller of‘new’machinerythe‘CE’markamongotherthingsshouldbeaclaimforthemostcommonlyusedmachinetoolsinengineeringthatatleast:

n hazards,wherereasonablypracticable,havebeendesignedoutn mechanicaldangersaresafeguardedwithguardsandsafetydevicesfittedand

workingtogetherwithclearinstructionsprovidedonhowrisksnotsafeguardedaretobeavoided

n themachineisasquietasisreasonablypracticablewithnoisereducedatsourceorenclosed(thenoiseemissionlevelmustbestatedin‘Informationforuse’)

n stepshavebeentakentocontrolemissionsofharmfulsubstanceswhenthemachineisworkingby,forexample,containmentorbyprovidingforconnectiontoextractionequipment

* ‘New’ means new to the European Union. An old, second-hand machine from the Far East or Eastern

Europe, for example, is regarded as ‘new’ to the European Union for the purposes of the Supply of

Machinery (Safety) Regulations 1992. Carrying out substantial refurbishment, such as fitting a CNC control

to a previously manual machine, may also result in a ‘new’ machine subject to these Regulations.

An outline of what is defined as ‘machinery’ from the Supply of Machinery (Safety) Regulations

n Anassemblyoflinkedpartsorcomponents,atleastoneofwhichmovesincludingtheappropriateactuators,controlandpowercircuits,joinedtogetherforaspecificapplication,inparticularfortheprocessing,treatment,movingorpackagingofamaterial

n Anassemblyofmachineswhich,inordertoachievethesameend,arearrangedandcontrolledsothattheyfunctionasanintegralwhole

n Interchangeableequipmentmodifyingthefunctionofamachinewhichissuppliedforthepurposeofbeingassembledwithanitemofmachinerybytheoperatorhimselfsaveforanyequipmentwhichisasparepartortool

n A‘safetycomponent’placedonthemarketseparatelyfrommachinerytofulfillasafetyfunctionwheninuseandthefailureormalfunctionofwhichendangerssafetyorhealth.



n instructionsforuseareprovidedtoindicateclearlyinEnglishhowthemachinemaybesafelyinstalled,operated,maintained,removedordismantled;whereitisnotimmediatelyclearhowsafeguardsworkasonsomecomputercontrolledmachineryclearinformationshouldbeprovidedon:

– howtheywork– howtheymaybechecked– howtomaintainthem,and– whattodoincaseoffaults/failures

n informationonvibrationisprovidedandvibrationminimisedforhand-heldmachines

n metalworkingfluidscanbecooledwherenecessary,deliveredandremovedsafelywithrisksofcontaminationminimised,egfromfilterblockagesorhighworkingtemperatures;informationforuseshouldspecifyhowtousefluidssafelyatthemachine.

Supply of Machinery (Safety) Regulations 1992 and Amendment Regulations 1994 outlined

Ifyouarearesponsiblepersonforthesupplyofnewmachineryor,fromoutsidetheEU,neworsecondhandmachineryforthefirsttime:

n ASACOMPLETEMACHINE(suchasalathe)n ASINTERCHANGEABLEEQUIPMENTTOMODIFYTHEFUNCTIONOFANOTHERMACHINE(suchasaninternalgrindingattachmentforacentrelathe)

– makesureitcomplieswithessentialhealthandsafetyrequirements(oftheMachineryDirective,listedintheSupplyofMachinery(Safety)Regulations)– keeprelevantinformationonitsdesign,constructionandusesothata‘technicalfile’(orpartofone)maybeassembledifanenforcingauthorityasksforit– provide‘Instructionsforuse’inthelanguageofthecountrywhereitwillbeused– issueaDeclarationofConformitytoyourcustomer– attachthe‘CE’mark– ensurethatitissafe

n ASASAFETYCOMPONENT

– takealltheabovestepsbutdonotattachthe‘CE’mark

n ASPARTOFANOTHERMACHINE,whichcannotfunctionindependently,(egaswarfconveyorintendedforincorporationintoanothermachine)

– takealltheabovestepsandissueaDeclarationofIncorporationinsteadofConformitytoyourcustomer,inwhichcasedonotattachthe‘CE’mark

n SPECIALREQUIREMENTSapplytopressesandotherhighlydangerousmachinesandsomesafetycomponents,whichmusteitherconformtotheBSEN‘C’standardorhaveEC-typeexamination.



Second-hand

Sellersofsecond-handmachineryfromoutsidetheEuropeanUnionmustcomplywiththelawonnewmachinery.

Refurbished machineryfrominsidetheEuropeanUnionmayalsobe‘new’withinthemeaningofthelaw,andhavetocomply.Thedegreeofrefurbishmentwilldecidewhetherthemachineryis‘new’ornot.Asubstantialrefurbishmentwhichgivesmachinerynewfunctions,suchascomputercontrol,whichitdidn’thavebefore,islikelytomakethemachinery‘new’.Anewcoatofpaintandthestraightreplacementofworn-outitems,ontheotherhand,mostlikelywouldnot.

ConsultyourlocalHSEinspectorwhereitisnotclear.

Buyers of second-hand machineryshouldmakesurethatitcomplieswiththerequirementsoftheProvisionandUseofWorkEquipmentRegulations1998(seepages44–48).TheriskassessmentproformainAppendix3canbeusedtohelpcheckcompliance.

The Health and Safety at Work etc Act 1974 section 6, on the supply of machinery, new or old, from whatever source, outlined

Itmustbe:

n sofarasisreasonablypracticabledesignedandconstructedsothatitissafeandwithoutriskstohealth

n accompaniedbyadequateinformationforuse.

Onlyawrittenundertakingfromthebuyerthatspecifiedstepswillbetakentosafeguardthemachinehe/sheisbuyingrelievesthesupplierofhisdutiesinrelationtosecond-handmachinesfromwithintheEU.

Key references:Product standards: Machinery DTI(tel:08701502500)Supplying new machinery INDG270,Buying new machinery INDG271

HSEBooks



Metalworking fluids Correctlymanagingyourmetalworkingfluidswillreducetheriskofillhealth,prolongthelifeofthefluid,increasetoollife,andimprovethemachiningperformance.

Ill healthfrommetalworkingfluids,usedneatormixedwithwater,mostcommonlyarisesfrom:

(a) skin contactduring

n preparation,applicationandremovaloffluidn handlingofworkpiecesn splashingwhenmachiningn changingandsettingoftoolsn maintainanceandcleaningofmachines

causingskinirritationanddermatitis,and(b) breathing inaerosols,mistandfumeswhenmachiningcausingirritationoftheeyes,noseandthroatandoccasionallybreathingdifficultiessuchasbronchitisandasthma. Asmostmetalworkingfluids,eitherasconcentratesorwheninuse,areorcontainhazardoussubstances,thestrategyforcontrollingthemoutlinedonpages33–34isalmostalwaysrelevantanduseful.

Inparticular:

n maintainthemingoodcondition(seenextpage)n operateandmaintainprocessestominimisemist,fume,vapourandsplashingn makesuitablearrangementstocleancontaminatedoverallsandclothingn donotuseunrefinedmineraloilsandmildlyrefineddistilledoilswhichmay

causecancerandforwhichsaferalternativesareavailable.

Casesofoilacne(folliculitis–irritationofthehairrootsfromprolongedandregularcontactwithneatoils)andskincancermustbereportedtoHSE(seepages104–105).

Wherethereissignificantskincontactorexposuretofume,mistsoraerosols,healthsurveillanceislikelytobeneeded.

Appointaresponsiblepersonto:

n encouragehighstandardsofpersonalhygienen undertakeregularskininspections(aboutonceamonth)n checkthatcontrolsareeffectiven encourageemployeestocompletequestionnaires(aboutonceayear)forboth

skinandbreathingsymptomsn reviewabsencerecordsn advisethosewithproblemstoseekfurthermedicaladvice.

Appendix2(pages128–129)givesexamplesofusefulquestionnaires.

Key reference:Working safely with metalworking fluids (pack)HSEBooksISBN0717625613



Safe working with metalworking fluids Minimiserisksby

Maintaining fluids in good conditionDo

n readandfollowsupplier’sguidancen usefluidscompatiblewithmachines,egthosethatwillnot:

– strippaintfromthemachinetoblockfilters,or– dissolvemetalsbeingworkedsuchascobalt,chromiumandnickelwhich

maycausehealthproblemslaterifinhaledorincontactwithskin

n makeuseofspecialexpertise,anddevelopin-housecompetencetomaintainfluidsby,forexample,keepingaweeklyrecordof:

– visualsumpinspectionsforfluidandtrampoilleaks– concentrationandpHmeasurements,and– bacteriadipslidemeasurements

n topupinaccordancewithsuppliersinstructionsn keepmachinescleanandfreefromdebrisn cleansumps,pipeworkandmachinesbeforerefillingwithfluidswhichshould

berecentlymixedoutsidethemachineincleancontainersaddingconcentratetodrinkingqualitywater

n usearefractometertocheckstrengths.

Don’t

n storefluidsoutside,wherestrongsunlightorfrostmaydamagewater-mixfluidsandmoisturemayleadtothecontaminationofneatoils

n addtoomuchbiocidewhichwillincreasetherisksofskinsensitisationandrespiratoryirritation

n usefluidsbeyondtheirnormalworkinglifen allowotheroilsusedtolubricatethemachinetocontaminatemetalworkingfluid

Operating machines safelyDo

n trainandinstructemployeesinthehazardsandsafeguardsn enclosesourcesofemissionsandaerosolsn maintainfluidflowatcorrectvolumesandpressures,as:

– insufficientflowwillleadtohigherworkingtemperaturesandmorefume– higherpressuresmayleadtomoremistformation– largervolumesmayincreaserisksofsplashing

n providelocalexhaustventilationatmachinestoremovefumeandmistatharmfullevelsandhavetheventilationsystemexaminedandtestedbyacompetentpersonevery14months.

Don’t

n allowfluidstooverheatasthisincreasesrisksofbiologicalcontaminationn allowwater-mixfluidstostagnatewhennotinuse(forexample,usesmall

circulationpumpsorpassairgentlythroughthefluid)n useairlinestoblowcomponentsclean–useavacuum-typecleanerinstead.



Maintaining high standards of personal hygiene Do

n usemachines,enclosuresandextractionequipmentproperlytominimisesplashingandbreathingaerosolsandmists

n washwithsoapandwaterregularlytoremovemetalworkingfluidsn useanafter-workcreameachtimeafterwashinganddryingn wearcleanoverallsandkeepoilyragsoutofpocketsn covercutsandabrasionswithwaterproofdressings.

Don’t

n wearjewellery,ringsorwatchstrapsunderwhichfluidsmaycollectandbedifficulttoclean

n eat,drinkorsmokeinworkingareas.

Key reference:Working with metalworking fluids INDG365HSEBooks(singlecopiesfree;ISBN0717625451forpricedpacksof10)



NoiseToomuchloudnoisedamageshearingbycausing:

n deafness,orn permanenttinnitus(ringingintheear).

Ifyoucannothearclearlywhatsomeoneissaying(inanormalvoice)2maway,thenoiselevelislikelytobe85dB(A)orhigher:

Typical minimum noise levels next to operations where no steps have been taken to reduce noise:

Actualnoiselevelscanbehigherthanthoseshownabove.

Measuring noise

Exposuretonoiseismeasuredindecibels–usuallywrittenasdB(A).Thenoiselevel(loudness)ismeasuredasascalefromasilentzerodB(A)to140dB(A)forthenoisiestsituations.Formostjobsriskdependsnotonlyonnoiselevelsbuthowlongpeopleareexposedtothem.Thetotalamountofnoiseexposureoverthewholeworkingdayiscalledthedailypersonalnoiseexposure(usuallyshortenedtoLEP,d).

Manyengineeringworkshopsmayneedtohavetheirnoiselevelsmeasured.ThisshouldbedonebypeoplewhounderstandandcanapplyHSE’sguidanceonhowtomeasurenoise.

dB(A)

airexhaustingfrompneumaticequipment 85–95

grindingonpedestalgrinder 90–95

dischargingmetalobjectsintometaltins/chutes 85–95

generalnoiselevelinfabricationshop 85–95

usingvibratorybowlfeeders 90–100

hammeringsteel 95–100

guillotining 95–100

multi-spindleautomaticturning 95–105

circularsawing–metal 95–105

pressing–blanking 95–110

–punchpressing 110–120

riveting 100–110

Key reference:Reducing noise at

work: Guidance on the Noise at Work

Regulations 1989 L108ISBN0717615111;HSEwebsite:www.hse.gov.uk/noise



Noise at Work Regulations 1989 outlined

ActiontobetakenwhereLEP,dislikelytobe 85dB(A) 90dB(A)

Employers must:n reduceriskofhearingdamagetolowestlevel reasonablypracticable * *

n havenoiseassessedbyacompetentperson * *n keeprecordsofassessmentuntilanewoneis made * *

n reduceexposuretonoiseasfarasisreasonablypracticablebymeansotherthanearprotectors *

n provideinformation,instructionandtrainingtoemployees * *

n markearprotectionzoneswithnotices,asfarasisreasonablypracticable *

n ensuresofarasispracticablethatearprotectorsare:

– providedtoallwhoaskforthem *– providedtoallexposed *– maintainedandrepaired * *– usedbyallexposed *

n ensuresofarasisreasonablypracticablethatallwhogointomarkedearprotectionzonesuseearprotectors *

n ensurethatallequipmentissuedundertheRegulationsisusedandmaintained * *

Employees must, so far as is practicable:n useearprotectors *n useanyotherprotectiveequipment * *n reportanydefects. * *



AnewEuropeanDirectivedealingwithnoisehasbeenagreed.Itisexpectedthatnewnoiseatworklegislationwillcomeintoforcein2006,whentheaboveactionlevelswillbereduced.

Regularhearingchecks(healthsurveillance)mayberequiredundertheManagementofHealthandSafetyatWorkRegulations1992(seepage6)dependingonhownoisytheworkshopis.Itisgoodpracticetocarryouthearingchecksonallemployeeswhosedailypersonalnoiseexposureregularlyequalsorexceeds90dB(A).

Youshouldtakenoiserisksintoaccountwhenbuyingnewworkequipment.Makesurethatyougetproperinformationaboutthelevelsofnoiselikelytobeproducedbytheequipment.Considerapolicyofpurchasingonlylow-noiseequipment.

The law* on noise assessments outlined

Noiseassessmentsmust:

n identifypersonsatriskn enableemployersto:

– reducenoisewherereasonablypracticableotherthanbytheprovisionofearprotection– providetherightsortofearprotection– establishthecorrectprotectionzones– givesuitableinformationtoemployees

n bereviewedwhencircumstanceschange.

* Noise at Work Regulations 1989.

Key reference:Noise at Work: Advice for employers INDG362HSEBooks(singlecopiesfree;ISBN0717625397forpricedpacksof10)



How to make the most of noise assessments

For most industrial situations LEP,d can be calculated using Figure 2 from the key reference below. *(Leqisacontinuousequivalentsoundlevel).

UseprotectivemeasuresasforTask2untiltoolsdesignedtouse

shear/skewcutand/orfeedautomatedand/ordischargechutes/binslined

withnoiseabsorbentmaterialand/orpressenclosed,togive

85dB(A).

Maintainnoisereductionmeasures.Makeearprotection

available.

Provideinformation,instruction,training.

Linemetalbinswithnoiseabsorbentmaterials,togive

90–91 dB(A).

Markearprotectionzones.Provideandmaintainearprotectorsand

warningsigns.Makesureprotectorsareworn.Provide

information,instruction,training.

Reviewwhencircumstances

change.

Providequietrest/breakroom,togive<85 dB(A).

TASK 1

Operatingapowerpresscarryingoutablanking

operation

Sample Leq* dB(A)98for3hours

givingfractionalexposure ‘f’ value 2.37

TASK 3

Breakstakenat/nearmachines

Sample Leq dB(A)88for1hour

givingfractionalexposure‘f’ value 0.08

TASK 2

Sortingmetalcomponentsintometalbins,aroundworkshop

Sample Leq dB(A)93for4hours

givingfractionalexposure‘f’ value 1.00

Total ‘f’ = 3.45 Assessed LEP,d = 95 dB(A)

REDUCE NOISE

Key reference:Reducing noise at work: Guidance on the Noise at Work Regulations 1989 L108ISBN0717615111;HSEwebsite:

www.hse.gov.uk/noise



How to reduce noise

Noise may be reduced by:

n eliminatingtheneedfortheprocessconcerned,allofthetime......orpartofthetimebysubstitutingaquietermachineorprocess

n bychangingthewayanoperationiscarriedout,oramachineworks

n bymaintainingmachinery

n byenclosingthemachineorprocessinenclosures......orinseparateareas/rooms

n byusingnoiseabsorbentmaterialnearnoisyoperations.

Examples of successful noise reduction

n increasingprecisionincastings,moreaccuratemetalcutting(egbylaser,bymaintainingguillotineblades)mayreducetheneedtotrim,grindorchipexcessmaterial

n operatinganairejectoronapressonlyforthetimerequiredtoejectthecomponent

n weldinginsteadofrivetingn usingquieterrivetingmachinesn usingamechanicalinsteadof

pneumaticejectoronapress

n applyingashearedgetopresstoolsforblanking

n usingonlysufficientairpressuretooperatethemachinereliably

n avoidingorcushioningimpactsbetweennoisypartsby,forexample,usingrubberconveyorsorchutesandbinslinedwithrubberorplastic

n byprovidingeffectivemeansofvibrationisolation

n dampingvibratingsurfacestoreducethetendencyofmetalsurfacestoringbyusingsurfacecoatingsorplates,asonmetalcuttingcircularsawblades

n usingsilencerstoreducenoisecausedbyturbulenceatairexhaustsandjets

n usingtiebarsonC-framepresseswhereprovided

n lubricatingmovingpartsasappropriate

n fittingnoiseabsorbentpanelsasforexamplearoundcoldheadingmachines,powerandpunchpresses

n fittingnoiseabsorbentroomdividerssuchasplasticcurtainstoseparatenoisyfromquietoperations

n fittingsuspendednoiseabsorbersinafabricationworkshoptolowerhighintermittentnoiselevels.

Key reference:Reducing noise at

work: Guidance on the Noise at Work

Regulations 1989 L108ISBN0717615111;

HSEwebsite:www.hse.gov.uk/noise



Engineering control

Inmanycircumstancesengineeringcontrolmaybethemostcosteffectivewayofreducingnoise.Expertanalysisofnoisesources,andidentificationoftherightcontrolmeasuresarenecessary.

Engineering control has been effective in many ways. For example:

Operation

vibratoryfeeders,andconveyors

hydraulicpowerpacksforguillotines

machiningofcastings

blanking

blanking

blanking

Method

dampinghighfrequencyvibrationwithoutaffectingperformance

mountingthemotorpumpunitonarigidframe,isolatingitandthevalvebankfromthemachinebody

reducingthevibrationofthecastingbyusingapairofdampingstraps

introducingsmallamountsofstaggerandshearintothepresstools

isolationofthepressframefromitsfabricatedlegsusing6mmcompositepads

fittingdynamicvibrationabsorberstotheflywheelfromwhich‘bell-like’tonesradiated

Reduction

95dB(A)Leqto73dB(A)Leq






Training specifics

Trainingforthosewhoworkinnoisyareasshouldinclude:

n whattheriskistotheirhearingn howtouseanynoiseenclosureprovidedn whotoreportdefectiveenclosureston howtofollowsystemsofworkdesignedtoreduceexposuren whenandhowtouseearprotectorsprovided,whotoreportdefectiveonesto,andhowtokeepthemclean

n thathearingproblemsmustbereportedtoadoctor,withdetailsofthenoiseinvolved.

Key references:Sound solutions HSG138HSEBooksISBN0717607917Protect your hearing or lose it INDG3622002(singlecopyfree;ISBN0717625397forpricedpacksof10copies)HSEBooks



VibrationVibration White Finger (VWF),knownas‘deadfinger’or‘deadhand’,iswidespreadinsomeworkshopsandisthemostobvioussymptomofhand-armvibrationsyndrome(HAVS):

n Attacksarepainfulandcanresultinthelossofsenseoftouchandoftheabilitytogripproperly

n Themostcommoncausesareworkwith:

– hammersandchisels– poweredpercussivemetalworkingtoolsincludinghammersforriveting,

clinchingandflanging– taggingmachinestoshapebarmaterial– pedestalandhand-heldgrindingandpolishingmachines

althoughanyregularprolongeduseofanyhigh-vibrationtoolormachinewhich causestinglingornumbnessafterfivetotenminutesisapossiblecause.

Personalprotectiveequipmentwillnotnormallyreducetheamountofvibrationreachingtheworker’shands.

To minimise harm

n Identifyhazardousjobsn Considerchangingtheprocessorproductdesigntoeliminateorreducethe

useofvibratingmachineryForexample:

– Mechaniseorautomate– Usehydraulicratherthanpneumaticimpulsiveriveting– Roughmachineratherthanhandgrind

n Chooselowvibrationequipmentsuchas:

– properlybalancedgrindingwheels,rotaryratherthanimpactorimpulseaction-poweredscrewdrivers,nutrunnersandtorquewrenchesforassemblywork,andlow-vibrationorrecoillesschippinghammersormachinesincorporatingvibrationreducingfeaturessuchasisolatinghandles

n Maintainequipmentproperlybykeepingcuttingtoolssharp,dressinggrindingwheelsproperly,andreplacingantivibrationmountstomaintaintheireffectiveness

n Reducetheamountofhandforceneededwhengrinding,forexample,bysupportingheavyworkpiecesandusingjigswithanti-vibrationmounts

n Carryouthealthsurveillanceofexposedworkersunderthegeneralsupervisionofamedicalpractitioner,and

n Havesymptomsinvestigatedfurtherbysomeoneabletoassessthemmedicallyn Ensurethatheatingisadequatetokeephandsandbodywarm.

The law on vibration outlined

Unlikenoisetherearecurrentlynospecificregulationsdealingwithvibration,butwherethehazardexiststheManagementofHealthandSafetyatWorkRegulations(seepage6)andProvisionandUseofWorkEquipmentRegulations(seepage45)apply.However,aEuropeanDirectivewhichdealswithhand-armvibrationriskshasbeenagreedandwillresultinUKRegulationsin2005.

Key references:Hand-arm vibration HSG88HSEBooksISBN0717607437

Vibration solutions HSG170HSEBooksISBN0717609545Power tools: How to

reduce vibration health risks INDG338(single

copiesfree;ISBN0717620085forpricedpacksof15);

HSEwebsite:www.hse.gov.uk/

vibration



Milling and machining centre workHow most accidents happen

n Entanglementandcontactwithrotatingcutterswhen:

– loading/unloadingcomponents– removingswarf– measuring– adjustingcoolantflow.

Thesecauseentanglementinjuriessuchasbrokenbones,anddislocations,amputationsandlacerations

n Notwearingeyeprotectionwhenmachining,cleaningandremovingswarf.


n unsafehandling(seepages22–29),harmfulmetalworkingfluids(seepages52–54),andtoomuchnoise(seepages55–60),butinparticular

n handlingheavierworkpiecesatlargermachineswhichmayrequiremechanicalaidssuchashoists

n noise(whichmaybedifficulttopredictandreduceatsource)fromcuttersoperatingagainstworkpieces.

Training specifics

Aswellasunderstandinggeneralrulesforthesafeoperationofmachinery(seepages44–45),operatorsneedtoknowhowto:

n removeswarfn adjustcoolantflown loadandunloadcomponentssafely.

Key safety measures

Foramanualhorizontalmillingmachineusedforavarietyofworkpieces:

n Fixedguardadjustablebymeansofatooln Falsetabletohelprestrictaccesstocutter.

Key safety measures

Foraverticalmillingmachineusedforbatchproductionwork:

n Fixedandinterlockingmoveableguardstopreventaccesstothecuttersandchipejection

n Foraverticalmillingmachineusedforavarietyofone-offjobs(includingtoolroomapplications)

n Fixedandinterlockedmoveableguards,oranadjustabletableguardn Componentsecurelyfixedinallcases.



Key safety measures

Forasmallmachiningcentre:

n Slidinginterlockingguardstopreventaccesstodangerousmovementswhenguardsareopen

n Ifaccesstomachinemovementsisnecessarywhentheguardsareopen,safeslowmovementsunderhold-to-runcontrolmaybeprovided

n Guardsalsohelpcontrolmetalworkfluidandswarfn Exhaustventilationfittedorcapableofbeingconnected.

Key references:BSEN13128:2001Machine tools – Safety – Milling machines (including boring machines);

BSEN12417:2001Machine tools – Safety – Machining centres



Key safety measures

Foramanuallyoperatedmachineusedforbatchproduction:

Drilling (and reaming)How most accidents happen

n Haircaughtonrotatingspindles,chucksortoolsn Entanglementofgloves,clothing,bandagesandrings,usuallyatthedrilltipn Violentspinningoftheworkpiecebecauseofpoorclamping–causingscalping

injuries,brokenbonesn Notwearingeyeprotectioncausingeyeinjuriesfrommachinecleaning,swarf

removalandunenclosedmachiningn Swarf–causingcuts.


n unsafehandling(seepages22–29)n harmfulmetalworkingfluids(seepages52–54)n toomuchnoise(seepages55–60)

butinparticularrisksfromhandlingandmetalworkingfluidsmaybehigheratmanuallyoperatedmachinesusedforbatchproductionbecauseofmorefrequentloading/unloadingandcontactwithfluids.

Ifappropriatetocomponentsizesandnumbers

n fixedguardn feedmagazinen dischargeslidetopreventaccessto

alldangerousparts

Training specifics

Inadditiontogeneralrulesforsafeoperation(seepages44–45)usersshouldbetrained:

n toweareyeprotection,and

NOT

n towearjewellery,looseclothingorlonghairnottiedbackn towearglovesunlesscompleteenclosureofrotatingchucks,spindlesandattachedrotatingpartsisprovided

n toleavechuckkeysinchucks.



Key safety measures

ForasmallCNCdrillingmachine:

n Slidinginterlockingguardstopreventdangerousmovementswhenguardsareopen

n Ifaccesstomachinemovementsisnecessarywhentheguardsareopen,safer,slowermovementsunderhold-to-runcontrolmaybepermitted

n Exhaustventilationfittedorcapableofbeingconnected.

Key safety measures

Foramauallyoperatedradialarmdrillingmachine:

n Usesuitabletrippingdeviceandregularlycheckitsoperationn Verticaltripnotmorethan75mmfromthetoolandpositionedwithinthefirst90°ofrotationfromtheoperator’sposition

n Clampworkpiecesecurelytomachinetablen Alternativelyfixed,adjustableguardsmaybeused.

Key safety measures

Forasmallmauallyoperatedbenchdrillingmachineusedforavarietyofone-offjobs:

n Fixedadjustableguardadjustedsothatspindleanddrilltipisguardedtothegreatestextentpracticable

n Viceclampedsecurelytotable.

Key references:GuidanceNotePM83Drilling machines: Guarding of spindles and attachments HSEBooksISBN0717615464

BSEN12717:2001Machine tools – Safety – Drilling machines



PressingHow most accidents happen

n Fingersorhandareamputatedorcrushedbetweenclosingtools

– whenloadingandunloadingcomponents– whensettingup.

Mostill health arisesfrom:

n unsafehandling(seepages22–29)andtoomuchnoise(seepages55–60),butinparticular

n noisefromtheimpactoftoolsonworkpieces,airejection,andn handlingofworkpiecesduringhighlyrepetitivebatchproduction.

Provision and Use of Work Equipment Regulations 1998 as applied to power presses

By laweverymetalworkingpressandpressbrakewithaflywheelandclutchanditsguardsmustbethoroughlyexaminedbyacompetentperson†:

n beforeuseonfirstinstallation,whetherneworsecondhandn periodically,presseswithonlyfixedguardsevery12months;otherpresses:every6months

Reportsofdefectsmustbenotifiedinwritingtofactoryoccupiersandcopiedtotheenforcingauthority.

Setterswhopreparepressesforuse:

n mustbe:

– competent– specificallydesignatedinwriting– properlytrained

n mustcarryoutaninspectionofsafetydevices

– afteranyworkonthetoolswhichinvolvesanyalterationtoordisturbanceofanysafetydevice– notlaterthanfourhoursafterthestartofeachworkingdayorshift

n mustsignacertificate,keptnearthepress,thatsafetydevicesareinefficientworkingorder.

†fromaninsurancecompany,forexample.



Allotherpresses,includinghydraulicandpneumatic,shouldhavesimilararrangementstoachievethesameobjectives–aplanned,regularsystemofinspectionsandtestsbycompetentandauthorisedpersonstoenablethesafetyofthepressanditssafetydevicestoberegularlysignedforbyanauthorisedpersononbehalfofthecompany.

Theseinspectionsmaybecarriedoutasdescribedonpage46undertheregulationinspectionrequirementsofPUWER.

Key safety measures

Foramechanicalpress:

n Guardsasnoiseenclosuresn Loading/unloadingcomponentswithoutaccessbetweentoolsusingautomaticfeed.

Guardsopentoshownoiseabsorbentlinings

Key reference:Safe use of power pressesL112ISBN0717616274



Key safety measures

Foramechanicalpowerpressusinginterlockingguards:

n Ensurethatclosinggatesoverlapbyatleast10%oftotalmovementbeforeclutchcanbeoperated

n Preventlooseandslackmovementofconnectedpartsoftheguardbygoodmaintenance

n Shroudfootpedalsn Repairdistortedordamagedbars.

Key safety measures

Forahydraulicpressbrakeusingphotoelectricguards:

n Ensurethatthebackandsidesofthepressareguardedandthatno-onecanstandbetweenthelightcurtainandmachine,orreachunder,aroundoroverthelightcurtainorguardstodangerousparts

n Ensurethatphotoelectriclightcurtainwheninterruptedbringsdownwardmovementtoahaltbeforedangerouspartscanbereached

n Muting(switchingthebeamofftopermitmetalsheetstobeinsertedandbentthroughthelightcurtain)mustonlyoccurwhenthereisasafedistance*betweenthebottomofthetoptoolandthetopsurfaceofthecomponent.

Key safety measures

Forapneumatichand-fedbenchpressusinginterlockingguards:

n Chairsusedbyoperatorsshouldbeadjustedtotherightheightandprovidegoodsupportfortheback.Providefootrests

n Stillagesshouldbepositionedtominimisetwistingandturningwhenliftingandloweringcomponents

n Usetwopneumaticcircuitstocontrolandcheckinterlockingfunctionsoranautomaticscotchtopreventtoolsclosingwhenguardsareopen

n Ensureoverlapofguardandtablebeforepresswilloperaten Interlockthepneumaticpowersupplytothepresswiththemovementoftheguard.

Key references:BSEN692:1996;BSEN693:2001;BSEN12622:2001



TurningHow most accidents happen

n AfatalaccidentarisingfromentanglementonrotatingpartshappenseveryyearorsointheUK

n Entanglementsonworkpieces,chucks,carriersandunguardedstockbarscausemostaccidents

n Manyaccidentshappenusinghand-heldemeryclothtosmoothandpolishcomponents

n Directcontactwithmovingpartscausesmanyinjuriesn Eyeinjuriesfrommachinecleaning,swarfremovalandunenclosedmachining

wheneyeprotectionisnotwornarefrequentn Chuckkeysejectedfromrotatingchucks.

Alargeproportionofinjuriesresultinamputationoffingers,brokenbonesandtornligaments.

Mostill health arisesfrom:

n unsafehandling(seepages22–29),harmfulmetalworkingfluids(seepages52–54)andtoomuchnoise(seepages55–60),butinparticular

n noiselevelsfromstockbarsrotatinginstockbartubeswhichcanbeveryhigh,particularlyonmulti-spindlemachines

n risksfrombreathinginmistsandaerosolsmaybehigherathigherspeedmachines,andthroughouttheworkshopfromgroupsofmachinesoperatingtogether.

Ifrequiredsurfacefinishordimensionalaccuracycannotbeachievedbyturningtechniques,considerusingdedicatedgrinding,honingorpolishingmachinesasappropriateinsteadofhand-heldemerycloth.

Key safety measures

ForasmallCNCturningmachine:

n Slidinginterlockingguardstopreventaccesstodangerousmovementswhenguardsareopen

n Ifaccesstomachinemovementsisnecessarywhenguardsareopen,safer,slowermovementsunderholdtoruncontrolmaybepermittedwhenguardsareopen

n Exhaustextractionfittedorcapableofbeingconnectedn Astrongproperlymaintainedvisionpanel,capableofwithstandingforeseeableejections.



Key safety measures

Foramanuallyoperatedturretlathe:

n Fixedguardatrearofmachinen Chuckguardn Feedandleadscrewsguardedorwellbackfromoperatorn Splashguardforsudsandswarf.

Training specifics

n Weareyeprotectionn Don’twearjewellery,looseclothingorlonghairifit’snottiedback.

Ifusingemeryclothcannotbeavoided,inadditiontogeneralrulesforsafeoperation(seepage44),usersshouldbetrainedaboutthedangersofusingemerycloth:

n NeveruseemeryclothatCNClathesn Ifrequiredfinishmayonlybeobtainedholdingemeryclothagainstrotatingcomponents,thenuse:–abackingboard–atoolpost–a‘nutcracker’–hand-heldabrasive-impregnatedwirebrushes

Backingboard

Toolpost

‘Nutcracker’

Key references:BSEN12415:2000;12478:2001;12840:2001;13788:2001Accidents at metalworking lathes using energy cloth EIS2HSEBooks(free)



GrindingHow most accidents happen

n Injuriesfromcontactwithrotatingabrasivewheelsn Impactinjuriesfromburstingwheels,(sometimesfatal)n Cuttingandcrushinginjuriesfromtrappingbetweenthewheelandworkrestn Firesandexplosionsarisefromthepoorcontrolofgrindingdustcontaining

aluminiummagnesiumandsimilarmaterialsn Eyeinjuriesfromthefailuretoweareyeprotectionoruseprotectivescreens.


n unsafehandling(seepages22–29),harmfulmetalworkingfluids(seepages52–54)

n vibrationfromhandfedorhand-heldgrindingmachineswhichmaycauseaconditioncalledvibrationwhitefinger,whichdamageshandsandarms,sometimespermanently(seepage61)

n toomuchnoisefromthegrindingoperationitself(seepages55–60)andn inhalingtheharmfuldust/fumegenerated.

Tips for operators

Aswellasgeneralrulesforsafeoperation(seepage44),usersshouldbetrained:

n tousetherightwheelandmachineforthejobn nottogrindonthesidesofstraight-sidedwheelsusedforoffhandgrindingn tokeepwheelsusedforoffhandgrindingtruedanddressedtoreduceoutofbalanceandenableworkreststobeadjustedclosetothewheel

n tolubricatespindlesregularlyn torunnewwheelsfreeforaboutaminutewithpersonsstandingclearn tosupportheavyworkpiecesandusejigstoreducevibrationatpedestalandbenchgrindingmachinesusedfrequentlyforlongperiods(seepage61)particularlyfortoolsharpening

n nottostopwheelsbyapplyingpressuretothewheelperipheryorfacen nottoleavewheelsimmersedincoolantwhichmayleadtooutofbalance;coolantshouldbeswitchedoffbeforewheelsarestoppedtoenablethemtodry

n totakecarenottoinsertoversizecomponentsintocentrelessgrinderstominimiserisksofejectionandwheebreakage

n tousewheeldresserswhichminimiserisksofvibrationwhitefinger.



The law* on abrasive wheels outlined

Thespecificrisksassociatedwithmountingabrasivewheelsrequirethatsuchtasksareonlydonebypeoplewhohavebeenspecificallydesignatedtodoso.Adequatetrainingmustbeprovidedforpeoplemountingabrasivewheels.Suchtrainingshouldinclude:

n hazardsarisingfromtheuseofabrasivewheelsandprecautionswhichshouldbeobserved

n methodsofmarkingabrasivewheelsastotypeandspeedn methodsofstoring,handlingandtransportingabrasivewheelsn methodsofinspectingandtestingabrasivewheelstocheckfordamagen thefunctionsofallcomponentsusedwithabrasivewheels,includingflanges,blotters,brushesandnutsusedinmountingandincludingknowledgeofthecorrectandincorrectmethodsofassemblingallcomponentsandcorrectbalancingofabrasivewheels

n thepropermethodofdressingabrasivewheelsn theadjustmentoftherestofanabrasivewheel.

* Provision and Use of Work Equipment Regulations 1998, Regulation 7.

Key safety measures

Atamanuallyoperatedpedestalgrindingmachineusedoccasionallyfortoolsharpening:

n Openinginguardrestrictedtothatneededtoenableworktobedonen Guardofsufficientstrengthtocontainfragmentsofburstingwheelsn Well-adjustedworkrestn rpmofspindleclearlymarkedn Easilyaccessibleandoperatedon/offswitchn Clearfloorarea.

Key safety measures

Foramanuallyoperatedsurfacegrindingmachine:

Asformachineabove,plus:

n Provideextraction,maintainandinspectandtestitevery14months,recordingtheresults

n Secureworkpiecefirmly.

Key references:Safety in the use of abrasive wheels HSG172000HSEBooksISBN0717617394;

BSEN13218:2001Machine tools – Safety – Stationary grinding machines



Sawing Using manually-fed pivoting-head metal-cutting circular saws

How most accidents happen

n Contactwiththerunningsawbladewhen:

– feeding,adjustingorremovingworpieces– cleaningthemachineorremovingswarf.

Most ill healtharisesfrom:

n unsafehandling(seepages22–29)n harmfulmetalworkingfluids(seepages52–54)andn toomuchnoise(seepages55–60)fromtheactionofthebladeagainstthe

workpiece

Noise

Noisehighenoughtodamagehearingiscommonatmanysaws,especiallyhigh-speedsawsfornon-ferrous(egaluminium)cutting.

Reduceatsourceby,forexample:

n clampingworkpiecessecurelyn usingnoise/vibrationabsorbingmaterialsonfeedtablesn avoidingtheuseof‘damaged’sawbladesn enclosingthecuttingheadinnoiseabsorbingmaterialsn using‘damped’sawblades.

Trainingingoodsawingtechniquemayhelpminimisehandlingproblemsandnoise.

Key safety measures

n Fixedadjustableguardsn Linkageoperatedmovingguardtoprevent

– contactwiththebladeintheraisedposition– exposureofthebladeduringcutting

n Gravityoperatedguardsmayonlybeusedwithholdtoruncontrolsn Wherefixedguardsonlyareused,workpiecesshouldbefedandremovedthroughopeningssmallenoughtopreventaccesstoblades

n Ensuretheheadspringbalance(iffitted)isproperlyadjusted.

Key references:Safety at manually-fed pivoting-head metal-cutting circular saws EIS12HSEBooks(free)BSEN13898:2003Machine tools – Safety –

Sawing machines for cold metal



Bending Using 3 roll bending machines

How most accidents happen

n Handsarefrequentlydrawnintocounter-rotatingrollers,particularlyduringinitialfeedingoftheworkpiece

n Handsareoftentrappedbetweenaworkpieceandarollern Wearingglovesincreasestherisksoftrappingn Manyinjuriesareserious;amputationsarenotuncommon.


n unsafefeeding/unloadingofworkpieceswhicharetooheavy/sharp/awkward(seepages22–29).

Key safety measures

n Holdtoruncontrolsshouldautomaticallyreturntostoponreleasen Brakingmayberequiredtoachieveasafestoppingtimen Positiontripdevicestobeeasilyactivatedbyanypersondrawntowardsthematbothsidesofthemachinetobringittoastopbeforeseriousinjury

n Emergencystopbuttonsrequiringmanualresetafterusen Usefeedtablesandrollerstohelpavoidgrippingworkpiecesclosetotherolls.

Training specifics

Inadditiontogeneralrulesforsafeoperation(seepage44),usersshouldbetrainedto:

n notwearglovesduringtheinitialfeedingofworkpiecesn avoidgrippingworkpiecesclosetotherolls;feedtablesandrollerscanhelpn avoidslipsandtripsaroundthemachinebykeepingtheareaclearn clearrollsandmaintainonlywhenthemachineisswitchedoffandisolated.

Key reference:Safeguarding 3 roll bending machines EIS7(rev1)HSEBooks(free)



GuillotiningHow most accidents happen

n Feedingandremovingworkpiecesnearunguardedbladesatthefront,sidesandrearofmachinescausingcutandamputatedfingers.

Noisemaybereducedby:

n noisehoodsn rollerstoreducevibrationsduringsheetfeedingn rubberbasesfittedtoclampsn minimisingthedistanceworkpiecesandscrapfalln liningbinswithnoiseabsorbentmaterial.

Reducecutsfromhandlingbyprovidinggoodqualitygloves,suchaschromedleather.


n unsafehandling(seepages22–29),particularlyheavyand/orsharpedgedworkpieces

n toomuchnoise(seepages55–60),particularlyfromcutworkpiecesfalling,clampingandcuttingoperations,andhighspeedcontinuousshearing.

Key safety measures

Foramedium-sizedpowerguillotine:

n Openinginfrontguardinsufficienttoreachclamp(s)orbladen Builtinlightingandmarkertoseecuttinglinen Slopeddischargechutetoenableworkpiecestoberetrievedwithoutopeningguard.

n Rearinterlockingguardn Shroudedfootpedal.

Training specifics

Inadditiontogeneralrulesforsafeoperationandmaintenance(seepage44),operatorsandothersshouldknowhowto:

n worksafelyattherearofguillotinesfittedwithpoweredbackgaugesandmechanicalhandlingdevices,particularlyonCNCmachines,wherecontrolsystemsmaybecomplex

n changebladessafelyn maintainpoweredmachinestopreventbladesdroppingundergravity.



Specialattentionshouldbepaidtothesafetyofyoungpeople(undertheageof18)usingguillotines.Thelaw*requiresthatemployersassessriskstoyoungpeoplebeforetheystartwork,takingintoaccounttheirinexperience,lackofawarenessofpotentialrisksandtheirimmaturity.Youshouldtakeaccountoftheriskassessmentindeterminingwhethertheyoungpersonshouldusetheequipment.Propertrainingandsupervisionwillbeessential. * Management of Health and Safety at Work Regulations 1992, regulation 3.

Key reference:Safety in the use of metal cutting guillotines and shears HSG42HSEBooksISBN0118854550



CNC punch pressingHow most accidents happen

n Betweenthetoolsduringtoolchanging,cleaningandfaultfinding,causingcrushinginjuriestothehands

n atmovingtables,causinglacerationstofingers. Mostill healtharisesfrom:

n unsafehandling(seepages22–29)andtoomuchnoise(seepages55–60),butparticularlyfrom:

n handlinglargeand/orsharpedgedworkpiecesn noisefromtoolimpacts.

Noisemaybereducedby:

n usingcushionedoranti-vibrationmountingsn ensuringtherightshearangleontoolsn usingnon-metallicclampingfacesn enclosureofthetoolarea.

Key safety measures

ForaCNCpunchpress:

n Turretguardingbyfixedandinterlockingguardstopermit,whenopen,onlyslowermovementsunderhold-to-runcontrol

n Leaveasafedistancebetweenmovingparts/workpiecesandfixedstructuresn Hazardousareasmaybesafeguardedbyfixedperimeterfenceswithinterlockingaccessgatesand/orpressuresensitivematsand/orpresencesensingdevicestopreventdangerouspartsmovingwherepersonshaveaccesstothem

n Whereturretguardandtabledonotpreventaccesstoclosingpunchtoolssafetydevicessuchaspressuresensitivematsorphoto-electricguardsshouldbeprovided

n Largetoolcarouselsandchangersshouldbesafeguardedbyfixedandinterlockingguardsorequivalentmeanswhichmayalsopreventaccesstotrapsbetweenmovingsheetsandtoolgapsinthetable

n Safetydevicesmaybeoverriddentopermitmachinemovementsatslowspeedsunderhold-to-runcontrol,forsettingormaintenance.



Combination metalworking machinesHow most accidents happen

n Workingsmallworkpiecesataworkstation,resultinginamputationsoffingers.


n unsafehandling(seepages22–29)andtoomuchnoise(seepages55–60),butparticularlyfrom:

n handlinglargeand/orsharpedgedworkpiecesn noisefromtoolimpacts.

Key safety measures

n Guardsshould:–preventaccesstoclosingtools,punchesorbladesfromallsides–provideaviewoftheoperationwhereneeded

n Workpiecesshouldbeproperlysupportedbyguidesandstopsn Thetakeoffsideshouldalsobeguardedtoallowonlyworkpiecestopassthrough

n Donottakeoffpiecesbyhand:–useachutewhichdischargesintoaboxforsmallerpieces–andatableorrollertrackforlargerones.

Whenbending,eitherrestrictthegapbetweenthetoolstoasafedistance(seepages68and138)orprovidephoto-electricorothersafeguardsasforpressbrakes(seepage68).

Specialattentionshouldbepaidtothesafetyofyoungpeople(undertheageof18)usingcombinationmetalworkingmachines.Thelaw*requiresthatemployersassessriskstoyoungpeoplebeforetheystartwork,takingintoaccounttheirinexperienceandtheirimmaturity.Youshouldtakeaccountoftheriskassessmentindeterminingwhethertheyoungpersonshouldusetheequipment.Propertrainingandsupervisionwillbeessential.

* Management of Health and Safety at Work Regulations 1992, Regulation 3.

Key reference:Safeguarding of combination metalworking machines EIS13(rev)HSEBooks(free)



Horizontal boring machinesHow most accidents happen

n Mostinjuriesoccurduringactivitiessuchassetting/adjustment,swarfremoval,orobservationforthepurposeofprocesscontrol.

n Thelargestsinglecauseofinjuryisentanglementatrevolvingtools.n Crushingandtrappinghazardsattoolsandthemovingworktablearealsovery

significantcausesofinjury.n Injuriesareoftenverysevereandincludelimbandskullfracturesand

amputations.Thepotentialforfatalinjuryatthesemachinesshouldnotbeunderestimated.


n unsafehandling(seepages22–29)n harmfulmetalworkingfluids(seepages52–54)

Key safety measures

n Preventaccesstotheworkzonebyfixedand/orinterlockedguards.n Tripprobeswithbreakingdevicesmaybeusedinsomecircumstances,butthesewillonlyprovidelimitedprotection,stoppingthemachinequicklyintheeventofcontactwithrevolvingtools.Theydonotprovideprotectionagainstcrushingandtrappinghazards.

n Whereaccesstotheworkzoneisneededforsettingpurposes,dangerousmachinemovementsshouldbecontrolledusingahold-to-runcontrolarrangementorenablingdevice.

n Guardotherhazardouspartssuchastransmissionelementsincludingshafts,gears,pulleysetcusingfixedguards.

n Followsafesystemsofworkforcleaning,maintenance,settingandadjustment,loadingofworkpiecesetc.Activitiessuchasswarfremovalshouldnormallybecarriedoutwiththespindlestopped.

Key reference:Safeguarding at horizontal boring machines EIS28HSEBooks(free);BSEN13128:2001



Cleaning and degreasingManycleaninganddegreasingsubstancesusedarehamfulifnotusedproperly,eitherthroughdirectskinoreyecontactorthroughbreathinginmistorvapourgivenoff,commonlycausingdermatitisandnarcoticeffects.Somecleanersgiveoffvapourwhichiseasilyignited.

To minimise hazards:

n reducetheneedtocleanby,forexample,avoidingcontaminationinthefirstplace

n comparesafetydatasheetsfromsupplierstofindtheleastharmfulcleanerandthecleanerwhichisnon-flammableortheleastflammable(withahigherflashpoint)(differenthazardsposedbysolventsmayneedtobebalancedtoensurethatoverall,hazardstohealthandsafetyareminimised)

n avoidspillsandevaporationbykeepinglidsoncontainersandtransferringliquidsbetweencontainersbypipeworkorpump

n markstoresandtheircontentsclearlyn provideappropriatepersonalprotectiveequipmentsuchasgloves,overalls,eye

andfootprotection,topreventcontactwherenecessaryn youmayneedtodrawupanemergencyplan(seepages104–105)tocope

withgrossspillagesofsomecleaninganddegreasingsubstances.

When using liquids to clean bydipping,wipingorspraying:

n avoidhalogenatedsolventssuchastrichloroethylene(‘trike’).perchloroethylene(‘perk’)methylenechlorideandn-propylbromide(nPB)unlesstheyareenclosedandextractionventilationandothernecessaryprotectiveequipmentisprovided;othersolventsmayalsoneedsimilarcontrols

n usetheleastflammable(withflashpointsideallyabove45°C)hydrocarbonsolventssuchaspetroleumdistillates,terpenesandalcohols

n adoptprecautionsnecessarytominimiserisksfromcontactwithalkalineoracidwater-basedsolutionsorinhalationoffumeordustarisingfromthem

n avoidworkinconfinedspaces(insidemetalfabricationsforexample)unlessabsolutelynecessaryinwhichcasemakeaseparatespecialassessmentofthehazardsposedbythecleaningliquidandsystemofworkproposed.(Specialprecautions,includingcompressedairlinebreathingapparatus,asafetyharnessandasecondpersonstandingby,maybenecessary,seepage82.)

Key reference:Safe use of solvent degreasing plant EIS40HSEBooks(free);Maintenance and cleaning of solvent degreasing plantEIS20(rev1)



Vapour degreasing tanksUsing thembadlymayexposeoperatorsandotherstoharmfullevelsofvapourwhichifinhaledcancausedrowsinessandinextremecasesunconsciousnessorevendeath.Directcontactwiththevapourorliquidcancauseirritationanddermatitis,andshouldneverbefrequentorprolonged.

Solventdegreasingshouldbecarriedoutinanenclosedsystemwherereasonablypracticable.Otherwise,theprocessshouldbeenclosedasfaraspossible.

To minimise exposure: Do

n positiontankinanareafreefromdraughtsn stackcomponentsinsidethedegreasersotheydrainproperlyn allowthemtodryinthefreeboardzonebeforeremovingthemn usecoverswhennotusingthetankn useamechanicalhoistwhenloading/unloadingcomponents.

Don’t

n move,loadorremovecomponentstooquickly,pushingordraggingvapouroutn runhoistsatmorethanthreemetresperminuteverticallyn sprayabovethevapourlayer.

Maintenance minimisesriskstooperatorsandothers:

n fromescapingvapourn fromthebuildupofoilandgreasewhichcancatchfiren andcanprevent the need to enterinordertoremovebaked-onresidues.

Gettingintovapourdegreasingtankscausesasizeableproportionofallfatalaccidentsinsmallengineeringworkshops.

Always

n setthermostatscorrectlyandbalanceheatingandcoolingsystemsn checkandmaintaintheeffectivenessofextractionsystemsn pumpinfluidbelowtheexistingliquidleveln repairleaksn treatpitsinwhichdegreasingtanksaresetasextensionsofthetankitselfn maintainthecorrectsolventleveln checkthesolventconditionn ensureadequatefreeboardheightn ensurethebathhasabottomdrainforremovingsolvent.

Key reference:Surface cleaning and preparation: Choosing the best option GG354AvailablefreefromEnvirowiseonEnvironmentandEnergyHelpline

Tel:0800585794Website:www.envirowise.gov.uk



To avoid entry:

n Fixasignonornearthedegreaserprohibitingentrywithoutauthorisationandbreathingequipment

n Regularlymonitorcontaminationbymeasuringthetemperatureofboilingsolvent;distiloffsolventintoastoragedrum;drainmobileresiduesintoasuitablecontainer,and

n Usealong-handledscrapertoremoveremainingsludge,orn Pumpdirtysolventdirectlyintoacontainerforrecovery.

If entry cannot be avoided:

n Establishasafesystemofworkinwritingusingaformalpermit-to-worksystemforentryauthorisedbyaresponsibleperson

n Removeasmuchsolventandsludgeaspossiblebeforeenteringn Usesuitableself-containedbreathingapparatusorairlinecompressedair

equipment,and

– asafetyharnessorbeltandropeheldorsecuredoutsidethedegreasertopullthepersonoutifnecessary

– asecondpersonstandingbytoraisethealarmandstarttherescue(itisunlikelythatonepersoncouldpullsomeoneoutsingle-handedly–havearescueplanready)

n Provideadditionalbreathingapparatusandothersuitableprotectiveequipmentcapableofbeingusedforrescue

n Makeoxygenresuscitationequipmentimmediatelyavailablen Wearprotectiveclothingresistanttothesolventinvolvedn Checkandmaintainbreathingapparatusandairlinecompressedair

equipment,harnessesandlifelinesatleastonceamonth,andkeeprecordsn Fullytrainallwhomaybecomeinvolved.

If,whilealltheaboveprecautionsarebeingtaken:

n thetankisthoroughlycleaned,testedandcertifiedassafeforentry,andn anadequatesupplyofbreathableairismaintained

breathingapparatusmaynotbeneededforfurtherwork(butseepage80,finalparagraph,andpages83–84,Welding).

The law* on entry into degreasers

Nopersonshallenteradegreasingtankforanypurpose(suchastocleanit),unlessitisnotreasonablypracticabletoachievethatpurposewithoutsuchentry.Ifadegreasingtankisentered,thismustbedoneinaccordancewithasafesystemofworkthatallowsittobedonesafelyandwithoutriskstohealth.* Confined Spaces Regulations 1997.

Key reference:Maintenance and cleaning of solvent degreasing plantEIS20(rev1)HSEBooks(free)



Welding and flamecuttingCommoncausesofill healthare:

n inhalationofharmfulweldingfumen unsafehandlingofworkpiecesandweldingequipment,particularlygascylindersn noise,particularlyfromplasmaarccutting,gougingoperationsandweld

preparationn burnfromultravioletradiation,including‘arceye’n vibrationduringgrindingforweldpreparationn discomfortfromheatanduncomfortablepostures.

Common causes of accidents are:

Asaresultof:

n fallinggascylindersn particlesenteringunprotectedeyesduringchippingafterweldingn electricshocksfromarcweldingequipmentn firesstartedbyflames,sparksandhotmaterialfromweldingandcutting

processesn fingersbeingcrushedbetweentheelectrodesoffixedresistancewelding

machines.

Key safety measures

forarcwelding:

n Extractionequipmentn Provideappropriateprotectiveclothingandensureitisworn,egoveralls,protectiveapron,gloves,safetyboots,respiratoryprotection(ifnecessary)

n Useweldingscreensandeyeprotection(toBS679)topreventarceyen Localisolationswitchn Weldingsettransformern Workpieceearthwhenrequiredn Insulatedelectrodeholdern Insulatedboxforelectrodeholdern Propercableconnectionsn Suitablefireextinguishereasilyaccessiblen Weldingleadsshouldbeinsulated,robustlyconstructedandbigenoughtocarrythecurrentsafely

n Residualcurrentdevicesmayenhancesafetyn Workinconfinedspacesandonlargestructuressupportedonmanipulatingdevicesneedsspecialprecautions(seeFurther reading,page117).

Training specifics

forarcwelding:

n Knowhowtouseextractionequipmentn Donotwearmetallicjewellery,rings,orwatchstrapsn Knowhowtochangeelectrodessafelyn UseaninsulatedboxorhooktoresttheelectrodeholderNOTthefaceshield,clothingorrags.



Maintain welding ventilation and protective equipment

n Havelocalexhaustventilationexaminedandtestedbyacompetentpersonevery14months(seepage35)

n Examinerespiratoryprotectiveequipmentthoroughlyeverymonth(testingairfedequipmentatthesameintervals,checkingthevolumeandqualityofbreathingairsupplied)

n Examineflexiblegasandoxygenhosesregularlyandreplacedamagedones;neverrepairthemwithtape

n Checkandmaintainothersafeguardsasappropriate.

Never applyheattocontainers,tanksordrumswhichmaycontainflammableresidues.Eitherusecold,non-sparkingmethodsorcleanandmakethemgasfreefirst.

Store and use welding gas cylinders safely

n Storefullandemptycylindersinasafe,well-ventilatedplacepreferablyoutsidebuildings

n Neverkeepcylindersbelowgroundlevelnexttodrains,basementsandotherlow-lyingplaces–heavygaseswillnotdisperseeasily

n Donotleavechargedhoseswhereventilationispoorforextendedperiodsincaseofleakinggasesoroxygen

n Somegascylinders,forexampleacetylene,containliquid–storethemwiththeirvalvesuppermost

n Protectcylindersfromdamage,forexamplebychainingunstablecylindersinracksorontrolleys

n Providesuitabletrolleyswithrestrainingchainsformovingoxy-acetylenesetsandothercylinders

n Minimisedamagebyusingthecorrecthoses,clamps,couplesandregulatorsfortheparticulargasandappliancebeingused

n Neverapplygreaseoilorotherlubricantstooxygenfittingsn Preventdamagetohoses.Donotrunthemunprotected,forexample,across

trafficroutesn Turnoffcylindervalvesattheendofeachday’sworkn Changecylindersawayfromsourcesofignitioninawell-ventilatedplacen Minimiseweldingflame‘flash-back’intohosesorcylindersbytrainingoperators

incorrectlightingupandworkingproceduresandbyfittingeffectivenon-returnvalvesandflamearresters

n Usesoapordetergentandwatersolutionstotestforleaks–never a flamen Donotuseoxygenasasubstituteforcompressedairtopowerpneumatic

tools.

Key references:Electrical safety in arc welding HSG118HSEBooksISBN0717607046

The safe use of compressed gases in welding, flame cutting and allied processesHSG139HSEBooksISBN0717606805



Fume controlControlling of fume and gases at welding, flamecutting and similar processes such as solderingFumefromwelding,flamecutting,brazingandsolderingvariesgreatlyincompositionandconcentration.Differentjobsleadtodifferentlevelsofexposuretodifferentsusbtances.Fumefromweldingandflamecuttingmaycause:

n drynessofthethroat,tickling,coughing,tightnessofthechestanddifficultyinbreathing

n anacuteflu-likeillness(metalfumefever)n long-termchangesinthelung.

Weldingorcuttingprocessesreleasingthegreatestquantitiesofharmfulfumeinclude:

n workonmetalliccoatingssuchascadmiumorzincplatingandchromium,manganese,cobaltand/ornickelhardsurfaces

n workonpaintedsurfaceswhichcontainlead,zinc,chromiumorcadmiumpigments

n mechanisedflamecuttingn flamegougingn frequentandregularmanualmetalarcweldingn fluxcoredelectrodeweldingn highercurrentmetalinertgasshieldedweldingparticularlyonstainlesssteel,

andaluminium,copper,nickelandtheiralloysn oxygenarccuttingandgougingn usingcadmium-containingsolder.

Minimise risks by:

n avoidingweldingandflamecutting,usingotherbondingandcuttingtechniqueswherereasonablypracticable

n usingsaferfillermaterials,suchascadmiumfreesilversoldern controllingexhaustfumebyprovidinglocalexhaustventilationunlessadetailed

andthoroughriskassessmentshowsthatharmfulfumeisnotbeinggeneratedorthatitmaybecontrolledbygeneralventilation

n providingrespiratoryprotectiveequipment,butonlyifcontrolmeasuresareunabletoreducefumestosafelevels

n ensuringworkshopshaveenoughlow-levelinletsandhigh-leveloutletsforairchanges

n notweldingnear(10mformostwelding;20mforaluminium)cleaningprocessesusingchlorinatedsolvents;theheatandarcfromweldingmaybreakdownthesolventsintomoreharmfulsubstances.



Flanged head:keepthe

distancebetweenthehead

openingandtheweldless

thanthesmallestdimension

oftheopening

Facevelocityofatleast0.5ms_1

Flexiblearm

Filter

Airvelocityatweldabout1ms_1

Mobile extraction

Consideron-gunextractionparticularlywithsemi-automaticMigweldinggunsandfluxcoredwireswithoutgasshielding.

Welding bench/booth

Extractedairmaybefilteredelectro-statically,forexample,andreturnedtotheworkshoptopreventheatlosses.



Safety measures at resistance welding machinesHow most accidents happen

n Trappingbetweentheelectrodes,causingcrushedandamputatedfingertipsn Spatterflyingintounprotectedeyes.

Mostill health arisesfromtheunsafehandlingofworkpieces(seepages22–29),andtoomuchnoise(seepages55–60),particularlyfromgroupsofmachinestogether.

Key safety measures

forfixedresistanceweldingmachines:

n Fitaneffectivescreentoprotecteyes.Useeyeprotectionifthisisnotpossible

n Limitthegapbetweentheelectrodesto6mmorlesswherepracticablen Wheretheoperatordoesnotneedtoholdthecomponent,use:

– interlockingguardsornon-contact,egphotoelectric,protectivedeviceswithfixedguards– or,wherethesearenotpracticable,two-handcontrol

n Wheretheoperatorneedstoholdthecomponent

– usesensingorlowpressureapproachsystemstopreventfullclosingpressureoftheweldingheadsuntilwithinasafedistanceofthecomponent.Iftheoperatorusesonehandtosupportthecomponent,usearemoteoperatingbuttonandnotafootswitch

n Alwaysshroudfootpedals.

Principle of operation of sensing guard

Obstructionprevents

machinefromoperating

Noobstruction–machineoperates

Machineclearforloading

Key reference:Safeguarding of resistance welding machines InformationDocumentHSEID668/23(seewww.hse.gov.uk/fod/infodocs/668_23.pdf)



Lasers used for welding and cuttingThemostserioushazardsarisefromexposureto:

n laserradiationeitherdirectorreflectedfromprocessmaterialsorsurroundingswhichmaycauseseveretissuedamage.TheeyeisparticularlyvulnerablewiththegreatestriskarisingfromNd-YAGlasers.

n fume,whichmayharmbreathing(seepage85)n contactwithliveelectricalpartsduringmaintenance,whichmaycauseburns

and/orshock(CO2lasersoperateatextremelyhighvoltageswhichmayremainlethalbecauseofstoredenergyafterisolationoftheelectricalsupply)

n dangerousmachinemovementswhichmayphysicallyinjure.

Laseremissionsmayalsobeafirehazard,especiallywherepowersexceedafewwatts.

IEC60825-1:1993(Edition1:1993consolidatedwithamendments1:1997and2:2001)–Safety of laser products,availablefromBSI,isacomprehensiveintroductionformanufacturersanduserstothereductionofrisksfromlaserradiation.Themaximumpermissibleexposurelimits(MPE)giveninthisstandardareregardedasreasonablypracticablelimitstobeachievedundertheHealthandSafetyatWorketcAct1974,Sections2,3and6.

Key safety measures

Makesuretherightsafety measuresandinformationforusehavebeensupplied.(Questionyoursupplierinthefirstinstanceifthereisanythingyouarenotsureof.)

Maintaininparticular:

n anti-scatterguardsatcutting/weldingheadsn installationenclosures,fixedguardsandinterlockingaccessdoorstocontainreflectionsfromhighpowermachines

n ventilatingequipmentn safeguardspreventingaccesstodangerousmachinemovementsn lasersafetyeyewear.

Training specifics

Inadditiontogeneralrulesforsafemachineoperationandmaintenance(seepage44),trainusersandotherstoobservetherulesforsafe:

n entryintoenclosures(usetrappedorkeyexchangesystemswhereprovided)n beamalignmentoradjustmentn workingwithelectricityn useofeyeprotectionwherenecessary.

Key reference:IEC60825-1:1993(including1997and2001amendments)



RadiographyX-rays,gammaraysandotherformsofradiationusedfornon-destructivetesting(NDT)mayinjurebycausingburns,dermatitis,cancer,celldamage,bloodchangesorcataracts.

Other non-destructive testing techniques,suchasmagneticparticleanddyepenetranttechniquesmayinvolvethesprayingofharmfulsolvents.ExposuretoharmfullevelsofsuchsolventsneedstobeassessedinlinewithCOSHH(seepage34)andpreventedorcontrolled.

The Ionising Radiation Regulations 1999 outlined

Ifradiographyiscarriedoutinyourworkshopyou(or,ifacontractorisdoingthework,they)must:

n notifyHSEbeforestartingworkn consultasuitableradiationprotectionadvisern carryoutapriorriskassessmentn arrangeformedicalexaminations/reviewsandroutinedoseassessmentsofemployeeswhomyoudesignateas“classifiedpersons”

n appointoneormoreofyouremployeestosuperviseradiationworkn providelocalrulesandtrainingn makearrangementstodealwithstuckradioactivesources,x-rayexposuresfailingtoterminate,etcandrehearsethem

n getauthorisationfortheuse,storageandsafedisposalofradioactivesubstancesfromtheEnvironmentAgency/SEPA,asappropriate.



To minimise risks:

n alwayscarryoutroutineradiographyofreadilymoveablearticlesinsideapermanentshieldedenclosure,sufficienttolimitdoseratesoutsidetheenclosuretolessthan7.5microsievertsanhour

n makesuretherearenopeoplenearopen-toppedenclosures(inoffices,oroverheadcranecabs,forexample)whomaybeaffected

n ifyouchangeyourgeneratororsourceyoumayhavetoupgradetheenclosuren havetohandanemergencyplanandtheequipmentnecessarytoputtheplan

intoeffect(forradioactivesourcestoincludebagsofleadshot,ashieldedpotandlong-handledtools)andrehearsetheplan

n wearyourdosemeterwhenrequiredandmakesureitisnotdamagedorexposedtoradiationwhennotbeingworn

n useamaintainedandtestedradiationdoseratemetertocheckradiationlevelsaroundthecontrolledareaandalwaysusethemonitorwhenapproachingthesourcecontainertocheckthethatthesealedsourcehasfullyretractedorx-raygeneratorisnolongerproducingx-rays

n maintainradiographycontrols,forexamplewindoutsandguidetubesforsealedsourceequipment,andwarningdevices.

If you can’t do the work in a shielded enclosure, you must:

n notifyHSEatleastsevendaysinadvanceofeachoccasiononwhichyouproposetowork

n plantheworktoensureradiationexposuresaresuitablyrestrictedbyuseofcollimationandlocalisedshielding,barriers,warningsignals,lightingandothermeanstodemarcatethecontrolledarea.

Key reference:Industrial radiography: Managing radiation risksIRIS1(rev1)availablefromHSEBooks(free)



Painting The hazards of using paints, thinners or solvents include:

n breathinginvapourn directskinoreyecontactn swallowingcausingirritationanddiseasesoftheskin,eyesandlungs,andn firesfromtheignitionofflammablevapours.

Therisksofharmactuallyoccurringarehighestwhen:

n usingpaintscontaininglargeproportionsoftoxicmaterialssuchasleadorisocyanates

n paintinginconfinedspacesn sprayinginunventilatedopenworkshops.

To reduce risks

n Usetheleasthazardousmaterialsforthejob(waterbasedpaintsforexampleandalternativestoleadforrustpreventionarewidelyavailable)

n Followtherulesforworkinconfinedspaces(seepages80and82)andn Alwayscontrolspraybyusingventilatedbooths,enclosuresorseparate

workspaces.

Takecarewithpaintsby:

n usingprotectiveclothingandeyeprotectionn usinganypre-workbarrierorprotectiveconditioningcreamprovidedn removingringsorwatcheswhichcantrappaintagainsttheskinn takingcarewithsolventswhencleaningbrushes,spraygunsetcn nevereating,drinkingorsmokingwhilepaintingn keepingoverallsandrespiratorinacleanstatebyregularwashingn washinghandsbeforeeating,andshoweringorbathingattheendofthedayn leavingprotectiveclothingatworktoreducetheriskofharmfulsubstances

beingtakenhome.

Don’tforgettoobtainalicenceforthestorageofpetroleumproductsfromyourlocalpetroleumofficerwhoworksforyourFireBrigadeorlocalTradingsStandardsDepartment.

The law on the main hazards associated with painting outlined

HazardoussubstancesinpaintsmustbecontrolledinlinewiththeControlofSubstancesHazardoustoHealthRegulations(seepage34).

TheHighlyFlammableLiquidsandLiquefiedPetroleumGasesRegulations1972specifystepswhichmustbetakentominimisetherisksofignitingvapoursfrompaintsandsolventswhichareclassifiedashighlyflammableliquids(flashpointlessthan32°C).



Storing and mixing paints

Inordertominimisetheflammable(andtosomeextentother)risksfromvapoursgivenoffbymanypaintsandsolvents:

n keeponlysmallquantities(notmorethan50litres)ontheirowninametalcupboardorbinforimmediateuseattheworkplaceandlargerstocksinafire-resistingstorewithspillageretentionandgoodventilation

n keeplidsoncansandcontainersclosedtostopvapourescaping.Containspillagesbydecantingpaintoveratray.Haveabsorbentmaterialreadilyavailabletosoakupspillages.Keepcontaminatedmaterialinaliddedmetalbinanddisposeofitscontentssafely

n excludesourcesofignitionandusesuitableelectricalequipment.Donotsmokewherepaintsarestoredorused

n ensureadequateventilationwherepaintsaremixed.Breathingprotectionmaybeneeded

n treatcontainersemptiedofliquidthesameasfullones;theywilloftenbefullofvapour.

Key reference:EIS32Chromate primer paints HSEBooks(free)



Spray painting booths and enclosuresIf you make your own spray booth or enclosure:

n usefire-resistantmaterials(seelistinAppendix5)n keepunprotectedelectricalequipmentoutside(forexamplebyinstallinglights

outsideboothsandshiningthemthroughfixedandsealedfireresistingwiredglasspanels)

n getadvicefromacompetentventilationengineerand:

– extracttoasafeplaceintheopenairawayfrompeople,sourcesofignitionandnearbybuildingsandequipment

– useacentrifugalorbifurcatedfan(withthemotoroutsidetheductinginavapourfreeareadrivingthefanthroughagastightshaftseal).Useflexiblearmouredcableforelectricalwiringtowithstandfanvibrationratherthanmineralinsulatedmetalsheathedcable

– usefilterstopreventdepositsofpaintonmotorcasings,fanbladesandinsideducts;depositsmaycausefanstovibrateandrunoutofbalanceanddirectdepositsmayalsocausemotorstooverheatandignite

– provideaccesspointsforinspectionandcleaninginsideducting.

Tomaximisetheefficiencyofanyboothorenclosure:

n providemeanstoindicatewhendryfiltersneedreplacement.Theairspeedintheimmediatevicinityofthesprayerinadryfiltersprayboothorenclosuremaybethelowestintheboothbecauseoftheaccumulationofspraydepositsonthefilter.Hencetheairspeedtendstobeslowestwhereitismostneeded

n keepunnecessaryequipmentoutofbooths.Largedrumsofpaintforexamplecandisturbtheairflowpatternandcauserecirculationofcontaminatedairintothesprayer’sbreathingzone

n providesufficientandsuitablyprotectedlightingintheboothtoremovethetemptationtosprayoutsideit

n givetraininginthetechniquesofspraypaintingtoteachhowtospraywiththeminimumamountofoversprayandbounceback,toobtainthecorrectbalancebetweenairandliquidflowrates,andtoensurethattheminimumpressureforgoodatomisationisalwaysused

n considertheefficiencyofthesprayingequipmentused.Someequipmentgenerateslowerlevelsofsolventvapourandoverspraythanothers.

Maintaining booths and enclosures:

n Checkboothsandenclosuresregularlyforleaks,havethemthoroughlyexaminedandtestedevery14monthsbyacompetentperson(eganinsurancecompanyengineeringsurveyororrepresentativeofthesupplier)andkeepthereports

n Maintainaminimumaverageairvelocityof0.7m/satthefrontofopen-frontedboothsandenclosures

n Whereasprayerworksinsideasidedraughtboothorenclosuretheaverageairvelocitywherethesprayerstandsshouldbenotlessthan0.5m/swithaminimummeasuredvalueof0.4m/s

n Thesprayershouldneverstandbetweenthearticlebeingsprayedandthepointofextraction;aturntabletorotatearticlesasnecessaryshouldbeused



n Whereasprayerworksinsideadowndraughtboothorenclosure,airvelocity(measuredtopointsaroundatypicalarticlesprayed)shouldaverage0.4m/swithaminimummeasuredvalueof0.3m/s

n Ensurethatairfloworairpressuredifferentialswitchesareworkingtowarnifdesignedexhaustventilationflowratesarenotmaintained

n Maintainanyinterlocksfittedbetweenspraygunsandexhaustsventilationn Repairdamagedsprayboothandenclosurepanelstomaintainthefire

resistanceoftheunitn Keepescaperoutesandaccesstorescueequipmentclearn Ensurethatairintakesarenotobstructedandthatdischargeventsare

correctlysitedandingoodrepair.

Spraying large articles

Wherearticlestoolargetoenclosearesprayeduseaseparateroomafter:

n ensuringadequatehalf-hourfireresistantseparationfromadjoiningroomsn removingallsourcesofignitionsuchasdirectlyfiredheatersordomestic-type

electricandgasfiresandturningoffandisolatingelectricalequipmentwhichisnotexplosionprotected

n providingventilationtoasafeplacewhilespraying,andn ensuringadequatepersonalprotectioniswornandthatno-oneelse

unprotectedintheworkroomornearbywillbeexposedtothesprayorvapour.

Key references:Introduction to local exhaust ventilationHSG37HSEBooksISBN0717610012

The maintenance, examination and testing of local exhaust HSG54HSEBooksISBN0717614859



Paints containing isocyanatesHealth hazards

Two-packspraypaintscontainingisocyanatesareoftenusedtoachievehard,durable,easytocleanfinishes.Inthesepaints,isocyanatehardenersoractivatorsareaddedtoliquidresinandpigmentstoproduceapolyurethanefilm.

Vapoursandspraymistscontainingisocyanatesarehighlyirritanttotheeyesandrespiratorytractandareknowntocauseasthma.Isocyanatesarerespiratorysensitisers.Thismeanstheycancauseanallergicreactioncalledsensitisation.Onceapersonissensitisedtoisocyanates,furtherexposure,eventothetiniesttracewillcausesymptoms,eg:

n soreeyesn runningnosen sorethroatn coughingn wheezing,tightchestn feverandbreathlessness.

Atfirstthesecomplaintsmayclearupatweekendsorduringholidays,butarelikelytoreturnwhenbackatwork.

Exposuretoisocyanatecontaininggluesduringassemblymaycausesimilarproblemsandrequiresimilaravoidance,controland/orprotectivemeasures.

How can health be protected?

n Considernon-isocyanatetwo-packpaintswhichareavailablen Assessthehazardsandrisksandpreventorcontrolexposureinlinewiththe

COSHHRegulations(seepage34)n Identifyisocyanate-containingtwo-packpaintsfromtheirlabelsorsuppliers’

datasheetsn Ifyousufferfromchronicrespiratorydiseasesuchaschronicasthmadonot

workwithtwo-packpaintscontainingisocyanatesn Consultanoccupationalhealthprofessionalbeforeworkingwithisocyanate-

containingtwo-packpaintsforadviceonasuitablehealthsurveillanceprogramme

n Sprayonlyinmechanicallyventilatedboothsorseparateworkroomsadequatelyventilated

n Useonlymechanicallyventilatedovensforacceleratingcuring.Runthemundernegativepressure

n Ventilatevapourandspray,afterfiltration,toasafeplaceintheopenairwheretheywillnotbedrawnbackintotheworkroomorintonearbypremises

n Whenmixingandsprayingwearprotectiveclothingincludingglovesandeyeprotection;wearairfedorcompressedairlinebreathingapparatus(dependingontheoutcomeofyourriskassessment)evenforsmallsprayingjobs

n Ifafullfacepiececanisterrespiratoriswornformixingorsimilarjobschangethecanisterbeforeitsrecommendedlife(oftenaslittleas15minutes)isexceeded.Gauzefacemasksdonotprovideprotection

n Maintainandkeeprespiratoryprotectiveequipmentclean.

Key references:Safety in motor vehicle

repair: Working with 2-pack isocyanate

paints INDG388HSEBooks(singlecopies

freeISBN071762756Xforpricedpacksof10);Preventing asthma at work: How to control respiratory sensitisers L55HSEBooks1994ISBN0717606619



Powder coatingHealth hazards

Powdercoatingisanalternativefinishingprocesstospraypainting.Thehazardsofusingcoatingpowdersinclude:

n directskincontactwiththepowdersn breathinginpowdersintheairn swallowingpowders.

Somecuringorhardeningagentsusedinpowders,especiallyTGIC(triglycidlisocyanurate)andTMA(tri-melliticanhydride)cancausedirectirritationoftheskin,eyesandlungsorallergicskinreactions.Thereisconcernthatsomecuringagentsmaycauseasthma.

Therisksofharmoccurringarehighestwhen:

n usingpowderscontainingcuringagentssuchasTGICorTMAn sprayingpowderinpoorlyventilatedpowder-coatingboothsn followingpoorsystemsofwork,suchasleaningintothecoatingboothwhen

sprayingn carryingoutpowdertransfer,maintenanceandcleaningwork.

To reduce risks

n Ensurethatyouhavechosenapowdercoatingthatpresentsthelowestrisktoyourworkers’healthandsafety,andtotheenvironment.Talktoyoursupplierortradeassociationforadvice.Forexample,youshouldonlyuseTGIC-basedcoatingpowderswhentheseareneededfortechnicalreasons.Askyoursupplierwhetheryouneedtousethem.Takecarewhenselectinganalternativepowdercoatingassomealsocontainotherhazardoussubstancessuchasisocyanates

n Minimisetheamountofmanualsprayingcarriedout–manycoating-boothsareautomaticallyoperated

n Ensurethatyoursprayboothisworkingatitsoptimumsothattheairenteringthesystemisatleast0.5metrespersecond

n Ifusingconveyorisedsprayboothsstandoutsidetheboothtospray;donotleaninside

n Neverspraytowardsanotheroperatorn Theamountofpowdersprayedshouldbekepttothelevelthatminimisesits

usageandachievesthedesiredfinish,bycontrollinggunsettingsn Providesuitablepersonalprotectiveequipmentandmakesureitisworn

properlyn Trainyouremployeesinsafepowdercoatingtechniquestominimiseexposuren Practisegoodhousekeepingbykeepingworkareasaroundthespraybooths

clean.Useanindustrialvacuumcleanerratherthansweepingupwithabroomn Followsafesystemsofworkforcleaningandmaintenanceactivities;in

particular,theuseofcompressedairforcleaningshouldbekepttoaminimumandoperatorsshouldavoidstandinginsidetheboothtocleanitbyusinglong-handledrubberscrapers(notbrushes)andcompressedairlances

n Ensuregoodstandardsofpersonalhygienebykeepingoverallscleanbyregularwashing,andbywashinghandsbeforeeatinganddrinking.



Otherprecautionstotakeinclude:

n minimisetheriskofafireorexplosionbyregularcleaningtopreventbuildupofdustandexcludesourcesofignition,suchasnakedflames,cigarettes,etcfrompowdercoatingworkareas

n minimisetheriskofelectricshockbyensuringgoodearthingofworkequipmentandregularmaintenanceofelectricalequipment

n maintaincompressedairsystemsassociatedwithpowdercoatingequipment(seepage42).

Key references:Controlling exposure to coating powders HSG2032000HSEBooksISBN0717617610Working safely with coating powders INDG319

HSEBooks2000(singlecopyfreeorpricedpacksof10ISBN0717617769)

The law on the main hazards associated with powder coating outlined

HazardoussubstancesincoatingpowdersmustbecontrolledinlinewiththeControlofSubstancesHazardoustoHealthRegulations(seepage34).



Personal protective equipment (PPE)Ifyouarethinkingofusingpersonalprotectiveequipment(PPE)tocontrolemployees’exposuretosubstanceshazardoustohealthrememberthatCOSHH(seepage34)limitsitsusetosituationswhereitisnotreasonablypracticabletouseothermeasures.

Respiratory protective equipment (RPE) ChoosingWhenchoosingbreathingprotectionconsiderindetailthejobtobedone.Forexample,aretheinsidesorundersidesoflargearticlestobesprayed?

Itislikelythattheventilationwillbelesseffectiveintheseareas.DifferenttypesofRPEofferdifferentlevelsofprotectionandthecorrecttypehastobematchedtothejobandthewearer.Formostsprayjobswiththesprayerinsidethebooth,compressedairlinebreathingapparatuswithafullfacepieceorairfedequipmentmaybemostsuitable.Beforechoosing,assesstheworkcarefullyandconsultyoursuppliersofpaintandprotectiveequipment.

MaintainingThoroughly examine and, where appropriate, test RPE at least once a month and more frequently where conditions are severe. (This does not apply to one-shift disposable respirators.) Half-mask respirators used only occasionally against dust or fumes of relatively low toxicity may be examined at longer intervals, but not less than once every three months.

Ensurethatbreathingairsuppliedtoequipmentissatisfactory;proprietaryequipmenttodothisiswidelyavailable.

The Personal Protective Equipment at Work Regulations 1992 outlined

Employersmust:

n providesuitablePPEfreeofchargetoprotectemployeesagainstriskswhichhavenotbeencontrolledbyothermeans

n takeallreasonablestepstoensureitisproperlyusedn beforeprovidingPPE,assessriskstohealthandsafetywhichhavenotbeenavoidedbyothermeansanddefinethecharacteristicswhichPPEmusthaveagainstthoserisks;thencomparethosecharacteristicsagainstPPEavailable

n maintainPPEprovidedincleanandefficientworkingorderwithappropriateaccommodationforitwhennotinuse

n giveinformation,instructionandtraining.

Employeesmust:

n usePPEprovidedn reportanylossorobviousdefecttotheemployer.



Ear protection

Protectorsshould:

n besuitableforconditionsinwhichtheyaretobeusedn Providesufficientattenuationtoreducethenoiseexposureleveltobelow

90dB(A)andpreferablytobelow85dB(A)n onlybeissuedonapersonalbasisn neverberemovedinanoisyenvironmentn becompatiblewithotherformsofnecessarypersonalprotectiveequipment.

Eye protection

Willhavetobeprovidedandused(sometimesthroughoutthewholeworkshop)whereworkwhichputseyesatriskiscarriedout,eg:

n machining(particularlygrinding)andtheuseofhandtoolswhichleadstotheuncontrolledejectionofmetallicparticles,and

n theuseofharmfulsubstances,suchasmetalworkingfluids,paintsorsolventswhichmaysplashintotheeye.

Theprovisionanduseoffoot protectionwillalsohavetobeconsideredinmostengineeringworkshopswheretherearerisksofinjurytothefeet,forexamplefromheavycomponentsbeingmoved.

WhereanyPPEisneededtohelpcontrolarisktohealthorsafetyofanemployee,itmustbeprovidedandmaintained(includingcleaningofoveralls)freeofchargetotheemployee.

In relation to ear protection, the Noise at Work Regulations 1989 require in outline:

n earprotectiontobemadeavailableonrequestifthedailynoiseexposureexceeds85dB(A)

n earprotectiontobewornifthedailynoiseexposureexceeds90dB(A).

Key references:Personal Protective Equipment at Work Regulations – Guidance on Regulations L25HSEBooksISBN0717604152

The selection, use and maintenance of respiratory protective equipmentHSG53HSEBooksISBN0717615375

Protect your hearing or lose itINDG3631999HSEBooks(singlecopyfreeorpricedpacksof25ISBN0717625400)



OfficesAccidents andcasesof ill healtharegenerallylessfrequentandsevereinoffices.Tominimiserisks:

Do

n clearupspillagesn replace/repairtornfloorcoveringn alsoseethegeneraladviceontheworkplace(seepages15–20)n followlegalrequirements(seeKeyreferencebelow)forcontinuous

orextensiveuseofVDUs,ensureadequatebreaksandprovideworkstationswhicharereasonablyadjustableforcomfort(seepages22–29onhowtoavoidupperlimbdisorders).

Don’t

n allowtrailingleadstocreatetrippinghazards.

Electricity inofficescancausethemostseriousaccidentsfromelectricshockandfire;defectiveplugs,socketsandleadscausemoreaccidentsthanappliancesthemselves.

Do

n provideenoughsocketoutlets;avoidorminimisetheuseofadaptorsn testanyresidualcurrentdevicesfittedn visuallyinspectplugsandleadsandgetthemrepairedbysomeone

competentifnecessaryn considerwhethermoredetailedtestsareneeded(forexample,isthe

equipmentfaultyoronlyworkingintermittently?)n switchoffandunplugbeforecleaning.

Don’t

n usetapedjointsinelectricalcables(seepages40–41).



Key reference:The law on VDUs: An easy guide HSG90HSEBooksISBN0717626024



Organising health and safety

What the law requires

UndertheHSWAct,youhavetoensurethehealthandsafetyofyourselfandotherswhomaybeaffectedbywhatyoudoorfailtodo.Thisincludespeoplewho:workforyou,includingcasualworkers,part-timers,traineesandsub-contractors;useworkplacesyouprovide;areallowedtouseyourequipment;visityourpremises;maybeaffectedbyyourwork,egyourneighboursorthepublic;useproductsyoumake,supplyorimport;oruseyourprofessionalservices,egifyoualsodesignaswellasmakemachinery.

TheActappliestoallworkactivitiesandpremises,andeveryoneatworkhasresponsibilitiesunderit,includingtheself-employed.

Basic legal requirements outlined

Youmust:

n haveawritten,up-to-datehealthandsafetypolicyifyouemployfiveormorepeople

n carryoutariskassessment(andifyouemployfiveormorepeople,recordthemainfindingsandyourarrangementsforhealthandsafety)

n notifyoccupationofpremisestoyourlocalinspectorifyouareacommercialorindustrialbusiness

n displayacurrentcertificateasrequiredbytheEmployers’Liability(CompulsoryInsurance)Act1969ifyouemployanyone

n displaytheHealthandSafetyLawposterforemployeesorgiveouttheleafletn notifycertaintypesofinjuries,occupationaldiseasesandeventsn consultyouremployees,eitherdirectlyorviaappointedunionsafetyrepresentativesoncertainissues,suchasanychangeswhichmightaffecthealthandsafetyandanyinformationandtrainingwhichhastobeprovided.

Youmustnot:

n employchildrenofunderschoolleavingage,apartfromonauthorisedworkexperienceschemes,ifyouareanindustrialundertaking.

Enforcing the law

HealthandsafetylawsrelatingtoyourfirmwillusuallybeenforcedbyahealthandsafetyinspectorfromtheHSE,butwheretheworkshopispartofalargerenterprise,suchasalargedepartmentstorewherehealthandsafetylawisenforcedbythelocalauthority,byalocalauthorityinspector.

Inspectorsmayvisitworkplaceswithoutnoticebutyouareentitledtoseetheiridentificationbeforetheycomein.Theymaywanttoinvestigateanaccidentorcomplaint,orinspectsafety,healthandwelfareintheworkshop.Theyhavetherighttotalktoemployeesandsafetyrepresentatives,takephotographsandsamples,andevenincertaincasestoimpounddangerousequipment.Theyareentitledtoco-operationandanswerstoquestions.



Inspectorswillbeawareofthemainrisksinengineeringworkshopsandwillgiveyouhelpandadviceonhowtocomplywiththelaw.Ifthereisaproblemtheymayissueaformalnoticerequiringimprovementsor,whereseriousdangerexists,onewhichprohibitstheuseofaprocessorequipment.

Inspectorshavepowerstoprosecuteafirm(oranindividual)forbreakinghealthandsafetylaw.

Key reference:Essentials of health and safety at workHSEBooksISBN071760716X



Accidents and emergenciesBefore the event

Inanyworkshop,thingssometimesgowrong.Youneedtobereadytodealwiththeseunplannedevents.Lookatincidentswhichhavecausedinjuriesandillhealthorotherdamage–whatcanyoulearn?Thinkaboutemergencies–planfortheworstthatcanhappen.Youmusthavetherightfirst-aidarrangements.Someeventsneedtobereported–thischaptertellsyouhowtodothis.

Emergency procedures

Whenthingsgowrong,peoplemaybeexposedtoseriousandimmediatedanger.Specialproceduresarenecessaryinengineeringworkshopsforemergenciessuchasseriousinjuries,explosion,poisoning,electrocution,fire,releaseofradioactivityandchemicalspills.

Write an emergency plan if a major incident at your workplace could involve risks to the public, rescuing employees or the co-ordination of emergency services.

Thinkabout:

n Theworstthatcanhappenifthingsgowrongn Howthepersoninchargeandotherswilldealwiththeproblems.Youshould

lookatanyparticularresponsibilitiesandtrainingneedsn Iseveryoneadequatelypreparedandcouldemergencyservicesgettothesite?

Pointstoincludeinemergencyprocedures:

n Considerwhatmighthappenandhowthealarmwillberaised.Don’tforgetnightandshiftworking,week-endsand(possibly)timeswhenthepremisesareclosed,egholidays

n Planwhattodo,includinghowtocalltheemergencyservices.Assisttheemergencyservicesbyclearlymarkingyourpremisesfromtheroad.Considerdrawingupasimpleplanmarkedwiththelocationofhazardousitems

n Ifyouhaveatleast25tonnesofcertaindangeroussubstancesyoumustnotifythefireauthorityandputupwarningsigns

n Decidewheretogotoreachaplaceofsafetyortogetrescueequipment.Provideemergencylightingifnecessary

n Youmustmakesurethereareenoughemergencyexitsforeveryonetoescapequickly,andkeepemergencydoorsandescaperoutesunobstructedandclearlymarked

n Nominate competent persons to take control

The law on accidents and emergencies outlined

TheManagementofHealthandSafetyatWorkRegulations1992coveremergencies.

TherequirementsforfirstaidareintheHealthandSafety(FirstAid)Regulations1981,andforreportingincidentsintheReportingofInjuries,DiseasesandDangerousOccurrencesRegulations1995(RIDDOR).

TheDangerousSubstances(NotificationandMarkingofSites)Regulations1990coversiteswhereatleast25tonnesofcertaindangeroussubstancesareheld.



n Decidewhotheotherkeypeoplearesuchasfirstaidersn Planessentialactionssuchasemergencyplantshut-downormaking

processessafe;clearlylabelimportantitemslikeshut-offvalvesandelectricalisolatorsforplantandmachinery

n Youmusttraineveryoneinemergencyproceduresn Don’tforgettheneedsofpeoplewithdisabilities.

Investigating events

Whenanaccidenthappens:

n takeanyactionrequiredtodealwiththeimmediaterisks,egfirst-aid,putoutthefire,isolateanydanger,fenceoffthearea

n assesstheamountandkindofinvestigationneeded–ifyouhavetodisturbthesite,takephotographsandmeasurementsfirst

n investigate–findoutwhathappenedandwhyn takestepstostopsomethingsimilarhappeningagainn alsolookatnearmissesandpropertydamage.Oftenitisonlybychancethat

someonewasn’tinjured.

Checklist

Tohelpwithyourinvestigations,findoutthefollowing:

n Detailsofinjuredpersonneln Detailsofinjury,damageorlossn Whatwastheworstthatcouldhavehappened?Couldithappenagain?n Whathappened?Where?When?Whatwasthedirectcause?n Weretherestandardsinplaceforthepremises,plant,substances,procedures

involved?n Weretheyadequate?Weretheyfollowed?n Werethepeopleuptothejob?Weretheycompetent,trainedandinstructed?n Whatwastheunderlyingcause?Wastheremorethanone?n Whatwasmeanttohappenandwhatweretheplans?Howwerethepeople

organised?n Wouldinspectionhavepickeduptheproblemearlier?n Hadithappenedbefore?Ifso,whyweren’tthelessonslearnt?

Mostaccidentshavemorethanonecausesodon’tbetooquicktoblameindividuals–trytodealwiththerootcauses.



The law on reporting injuries and other events outlined

TheReportingofInjuries,DiseasesandDangerousOccurrencesRegulations1995(RIDDOR)applytoallemployersandtheself-employedandcovereveryoneatwork.

Themainpointsarethatyoumust:

n notifyyourinspectorimmediately,normallybytelephone,ifanybodydies,receivesamajorinjuryorisseriouslyaffectedby,forexampleanelectricshockorpoisoning

n notifyyourinspectorimmediatelyifthereisadangerousoccurrence,egafireorexplosion,whichstopsworkformorethan24hours,oranoverturnedcrane

n confirminwritingwithinsevendaysonF2508n reportwithinsevendays(onformF2508)injurieswhichkeepanemployeeoffworkorunabletodotheirnormaljobformorethanthreedays

n reportcertaindiseasessufferedbyworkerswhodospecifiedtypesofworkassoonaspossibleonlearningabouttheillness.UseformF2508A.Casesofoccupational

– asthma(fromisocyanatepaints,forexample)– oilacne– vibrationwhitefinger– dermatitis

mayariseinsomeengineeringworkshops.n keepdetailsoftheincidentsreported.

Incident Contact Centre (ICC)Inadditiontotheaboveprocedures,newarrangementswereintroducedforreportingincidentswhichoccurredonorafterApril2001.IncidentscannowbereportedtotheICCbytelephone,fax,postorviatheInternet(www.riddor.gov.ukorwww.hse.gov.uk)

Key reference:Guide to the Reporting of Injuries, Diseases and Dangerous Occurences Regulations 1995 L73HSEBooksISBN0717624315



First aidAfirst-aidboxshouldcontainasufficientquantityofsuitablefirst-aidmaterialsandnothingelsenolotions,medicinesortreatments(includingparacetamol).

Theboxofatypicalsmallworkshopwithnoadditionalorspecialhazardsmayinclude:

Item Quantity

GuidanceCardIND(G)4(P)Rev 1

Individuallywrappedsterileadhesivedressings(assortedsize) 20

Sterileeyepads,withattachment 2

Individuallywrappedtriangularbandages 6

Safetypins 6

Mediumsizedindividuallywrappedsterileunmedicatedwounddressings(approx10cmx8cm)

6

Largesterileandindividuallywrappedunmedicatedwounddressings(approx13cmx9cm)

2

Extralargesterileindividuallywrappedunmedicatedwounddressings(approx28cmx17.5cm)

3

Ifworkinconfinedspaces,suchaslargemetalfabricationsorvapourdegreasingtanksiscarriedout,resuscitatingequipmentshouldbeprovidedandmaintained,andpersonstrainedinitsuse.

Ifcyanideorotherespeciallyhazardoussubstancesareused,appropriateantidotes,equipmentandtrainingshouldalsobeprovided,andthesuppliersofthesubstancesconcerned,orEMAS,consultedinthefirstinstance.

Health and Safety (First Aid) Regulations 1981 outlined

Youmusthave:

n someonewhocantakechargeinanemergency.(Theminimumrequirementisforanappointedpersontobeavailablewheneverpeopleareatwork–andisthelowestgradeoffirstaidcover)

n afirst-aidboxn noticestellingpeoplewherethefirst-aidboxisandwhotheappointedpersonis

n aqualifiedfirstaiderwherethesituationdemands,egifyourworkgivesrisetospecialhazards,suchasthosefromtoxicmaterialsordangerousmachinery

n afirst-aidroomifyouarealongwayfromemergencymedicalservices.



Asyourcompanygrows,lookagainatyourneedforqualifiedfirstaiders.Theymustbeproperlytrainedandhaveavalidfirstaidatworkcertificate.Thesecertificatesareissuedforthreeyearsbutcanberenewedfollowingrefreshertrainingandre-examination.TrainingorganisationsareregisteredwiththeEmploymentMedicalAdvisoryService–askyourEmploymentNursingAdviseratthelocalHSEoffice.

Key references:Basic advice on first aid at work INDG347(singlecopyfreeorpricedpacksof20ISBN0717622614)

First aid at work. Approved Code of Practice and Guidance L74HSEBooksISBN0717610500



How to obtain publications and further assistanceHSE Publications

HSEpricedandfreepublicationscanbeviewedonlineororderedfromwww.hse.gov.ukorcontactHSEBooks,POBox1999,Sudbury,SuffolkCO102WATel:01787881165Fax:01787313995Website:www.hsebooks.co.ukHSEpricedpublicationsarealsoavailablefrombookshops.

ForinformationabouthealthandsafetyringHSE’sInfolineTel:08453450055Fax:08454089566e-mail:[email protected],CaerphillyBusinessPark,CaerphillyCF833GG.Textphone:08454089577.YoucanalsovisitHSE’swebsite:www.hse.gov.uk

Engineeringsectorpages:www.open.gov.uk/hse/fod/engship.htm.HSC Newsletter isavailableonsubscriptionfrom:

HSEBooksSubscriptionsDepartmentPOBox1999,Sudbury,SuffolkCO102WATel:01787881165Fax:01787313995

Other sources of information

BritishSafetyCouncilNationalSafetyCentre,70ChancellorsRoadLondonW69RSTel:02087411231Fax:02087414555

RoyalSocietyforthePreventionofAccidentsEdgbastonPark,353BristolRoadBirminghamB57STTel:01212482000Fax:01212482001

TheManufacturingTechnologiesAssociation62BayswaterRoad,LondonW23PSTel:02072986400Fax:02072986430Website:www.mta.org.uk

SurfaceEngineeringAssociationConfederationHouse10VyseStBirminghamB186LTTel:01212362657Fax:01212371124

EEF.TheManufacturers’OrganisationBroadwayHouse,TothillStreetLondonSW1H9NQTel:02072227777Fax:02072222782Website:www.eef.org.uk



AMICUSAEUEngineeringSectionTerryDuffyHouse,ThomasStreetHollowayCircus,QueenswayWestBromwichB706NTTel:01216431042Fax:01215698910

EnvirowiseHarwellOxfordshireOX110RATel:0800585794Fax:08701906713

Other publications

BritishStandardscanbeobtainedinPDForhardcopyformatsfromtheBSIonlineshop:www.bsigroup.com/ShoporbycontactingBSICustomerServicesforhardcopiesonlyTel:02089969001e-mail:[email protected].

TheStationeryOfficepublicationsareavailablefromTheStationeryOffice,POBox29,NorwichNR31GNTel:08706005522Fax:08706005533e-mail:[email protected]:www.tso.co.uk(Theyarealsoavailablefrombookshops.)StatutoryInstrumentscanbeviewedfreeofchargeatwww.opsi.gov.uk.

HSEvideosareavailablefromHSEBooks.



Further reading and informationUnlessotherwiseindicated,thefollowingtitlesareavailablefromHSEBooks.

Managing health and safety

HSG65 Successful health and safety managementrev1997 ISBN0717612767HSG96 The costs of accidents at workrev1997ISBN0717613437L21 Management of health and safety at work. Management of

Health and Safety at Work Regulations 1999. Approved Code of Practice and guidance (Secondedition)HSEBooks2000ISBN0717624889

INDG324 Starting your business. Guidance on preparing a health and safety policy document for small firms(singlecopyfree;ISBN0717617998forpricedpackof5copies)

HSC13(rev1) Health and safety regulation: a short guide 2003(free)HSE40 Employers’ Liability (Compulsory Insurance) Act 19692002

(free)HSE34 HSE and you2000(free)HSE38 HSE: Working with employers2000(free)INDG275 Management of health and safety. Five steps to success1998

(singlecopyfree;ISBN0717621707forpricedpacksof10copies)

INDG163(rev1) 5 steps to risk assessment1998(singlecopiesfree; ISBN0717615650forpricedpacksof10copies)L87 Safety representatives and safety committees(Thirdedition)

HSEBooks1996ISBN0717612201HSG137 Health risk management1995ISBN0717609057– Essentials of health and safety at work 1994 ISBN071760716XSCB014 Be safe: A guide to health and safety in training availablefrom

DepartmentforEducationandSkills,tel08456022260INDG355 Reduce risks - cut costs: The real cost of accidents and ill

health at work 2002(singlecopyfree;ISBN0717623378forpricedpacksof15copies)

INDG322 Need help on health and safety?2000(singlecopyfree;ISBN0717617904forpricedpacksof10copies)

HSC14 What to expect when a health and safety inspector calls 1998(free)

INDG232 Consulting employees on health and safety: A guide to the Law(singlecopiesfree;ISBN0717616150forpricedpacksof15copies)

INDG218 Guide to risk assessment requirements: Common provisions in health and safety law(singlecopiesfree;ISBN0717612112forpricedpacksof5copies)

HSG165 Young people at work: A guide for employers(Secondedition)2000ISBN0717618897

– A guide to the Working Time Regulations DTI tel08701502500HSG218 Tackling work-related stress: A manager’s guide2001 ISBN0717620506HSG183 Five steps to risk assessment: Case studies1998 ISBN0717615804



L95 A guide to the Health and Safety (Consultation with Employees) Regulations19961996ISBN0717612341

Improving maintenance: A guide to reducing human error 2000 ISBN0717618188

Workshops

HSG194 Thermal comfort in the workplace: Guidance for employers 1999ISBN0717624684

L64 Safety signs and signals. The Health and Safety (Safety Signs and Signals) Regulations1996. Guidance on Regulations 1996ISBN0717608700

L24 Workplace health, safety and welfare. Workplace (Health Safety and Welfare) Regulations 1992. Approved Code of Practice and Guidance 1992ISBN0717604136

INDG244 Workplace health, safety and welfare: A short guide 1997(singlecopiesfree;ISBN0717613283forpricedpacksof10copies)

HSG38 Lighting at work1998ISBN0717612325INDG63(rev) Passive smoking at work: Workplace air pollution 1992(single

copiesfree;ISBN0717608824forpricedpacksof10copies)

INDG225 Preventing slips, trips and falls(singlecopiesfree; ISBN0717611833forpricedpacksof15copies)INDG36(rev2) Working with VDUs(singlecopiesfree;ISBN0717622223for

pricedpacksof10copies)HSG165 Young people at work: A guide for employers(Secondedition)

2000ISBN0717618897HSG122 New and expectant mothers at work: A guide for employers

(Secondedition)2002ISBN0717625834HSG155 Slip and trips. Guidance for employers on identifying hazards

and controlling risks 1996ISBN0717611450

Lifting equipment

L113 Safe use of lifting equipment. Lifting Operations and Lifting Equipment Regulations. Approved Code of Practice and guidance 1998ISBN0717616282

PM55 Safe working with overhead travelling cranes1985 ISBN0118835246

Manual handling

L23 Manual handling. Manual Handling Operations Regulations 1992. Guidance on Regulations(Secondedition)1998

ISBN0717624153INDG90(rev2) Understanding ergonomics at work: Reduce accidents and ill

health and increase productivity by fitting the task to the worker 2003(singlecopiesfree;ISBN0717625990forpricedpacksof15copies)

INDG143(rev1) Getting to grips with manual handling: A short guide for employers 2000(singlecopiesfree);ISBN0717617548forpricedpacksof15copies

INDG171 Aching arms (or RSI) in small businesses: Is ill health due to upper limb disorders a problem in your workplace?2003(single



copiesfree;ISBN0717626008forpricedpacksof15copies)HSG60 Upper limb disorders: A guide to prevention(rev)2002 ISBN0717619788HSG57 Seating at work1998ISBN0717612317HSG115 Manual handling: Solutions you can handle1994 ISBN0717606937HSG121 A pain in your workplace? Ergonomic problems and solutions

1994ISBN0717606686EIS16 Preventing injuries from the manual handling of sharp edges in

the engineering industry(free)INDG390 Choosing a welding set? Make sure you can handle it 2003

(singlecopyfree;ISBN071762773Xforpricedpacksof10copies)

Transport (and storage)

L117 Rider operated lift trucks - operator training. Approved Code of Practice and guidance1999ISBN0717624552

HSG6 Safety in working with lift trucks2000ISBN0717617815INDG148 Reversing vehicles1993(singlecopiesfree;ISBN071761063

2forpricedpacksof15copies)HSG76 Health and safety in retail and wholesale warehouses 1992

ISBN0717604454HSG136 Workplace transport safety1995ISBN0717609359INDG199 Managing vehicle safety at the workplace1995(singlecopies

free;ISBN0717609820forpricedpacksof10copies)INDG313 Safe unloading of steel stock 2000(singlecopiesfreeorpriced

packsof15ISBN0717617653)

Hazardous substances

L132 Control of lead at work. Control of Lead at Work Regulations 2002. Approved Code of Practice and guidance(Thirdedition)HSEBooks2002ISBN0717625656

EH40/2002 Occupational exposure limits ISBN0717620832 Supplement2003ISBN0717621723HSG37 An introduction to local exhaust ventilation 1993 ISBN0717610012HSG54 The maintenance, examination and testing of local exhaust

ventilation 1998ISBN0717614859INDG174 A short guide to the Personal Protective Equipment at Work

Regulations 1992(singlecopiesfree;ISBN0717608891forpricedpacksof10copies)

INDG233 Preventing dermatitis at work(singlecopiesfree; ISBN0717615537forpricedpacksof15copies)INDG95(rev2) Respiratory sensitisers and COSHH (singlecopiesfree; ISBN0717609146forpricedpacksof15copies)INDG188 Asbestos alert for building maintenance, repair and

refurbishment workers(pocketcard)1995(singlecopiesfree;ISBN0717612090forpricedpacksof25copies)

INDG223(rev1) Managing asbestos in workplace buildings1996(singlecopiesfree;ISBN0717611795forpricedpacksof10copies)

INDG136(rev2) COSHH: A brief guide to the Regulations(singlecopiesfree;ISBN0717626776forpricedpacksof10copies)

HSG126 CHIP for everyone2002ISBN071762370X



L5 Control of substances hazardous to health. The Control of Substances Hazardous to Health Regulations 2002. Approved Code of Practice and guidance(Fourthedition)HSEBooks2002ISBN0717625346

L8 Legionnaires’ disease. The control of legionella bacteria in water systems. Approved Code of Practice and guidance (Secondedition)HSEBooks2002ISBN0717617726

INDG181 The idiot’s guide to CHIP 32002(singlecopiesfree; ISBN0717623335forpricedpacksof5copies)HSG53 The selection, use and maintenance of respiratory protective

equipment: A practical guiderev1998ISBN0717615375L25 Personal protective equipment at work. Personal Protective

Equipment at Work Regulations1992.GuidanceonRegulationsHSEBooks1992ISBN0717604152

MS25 Medical aspects of occupational asthmarev1998 ISBN0717615472L55 Preventing asthma at work: How to control respiratory

sensitisers HSEBooks1994ISBN0717606619HSG61 Surveillance of people exposed to health risks at work 1999

ISBN071761705XEH1 Cadmium: health and safety precautions1995 ISBN0717608255EH13 Beryllium: health and safety precautions1995 ISBN0717608247EH60 Nickel and its inorganic compounds: Health and safety

precautions 1997ISBN0717613410HSG193 COSHH essentials: Easy steps to control chemicals. Control of

Substances Hazardous to Health Regulations(Secondedition)2003ISBN0717627373Itcanalsobefreelyaccessedatwww.coshh-essentials.org.uk

HSG188 Health risk management: A guide to working with solvents 1999ISBN0717616649

HSG110 Seven steps to successful substitution of hazardous substances 1994ISBN0717606953

HSG173 Monitoring strategies for toxic substances1997 ISBN0717614115HSG203 Controlling exposure to coating powdersHSG2032000 ISBN0717617610INDG319 Working safely with coating powders2000(singlecopyfreeor

pricedpacksof10ISBN0717617769)

Electricity

HSR25 Memorandum of guidance on The Electricity at Work Regulations 1989,1989ISBN0717616029

HSG85 Electricity at work: Safe working practices2003 ISBN0717621642HSG107 Maintaining portable and transportable electrical equipment

1994ISBN0717607151BS7671:2001 Requirements for electrical installations. IEE Wiring Regulations

ISBN0852969880GS38 Electrical test equipment for use by electricians1995 ISBN071760845XINDG231 Electrical safety and you(singlecopiesfree; ISBN0717612074forpricedpacksof15copies)PM29 Electrical hazards from steam/water pressure cleaners1995

ISBN0717608131



INDG68 Do you use a steam/water pressure cleaner? You could be in for a shock 1997(free)

INDG354 Safety in electrical testing at work: General guidance 2002(singlecopyfreeorpricedpacksof5ISBN0717622967)

Pressurised plant and systems

L122 Safety of pressure systems. Pressure Systems Safety Regulations 2000. Approved Code of Practice.

HSEBooks2000ISBN071761767XGS4 Safety in pressure testing1998ISBN0717616290PM60 Steam boiler blowdown systemsrev1998 ISBN0717615332HSG39 Compressed air safetyrev1998ISBN0717615316

Machinery safeguarding

– Product standards: Machinery - guidance notes on UK regulations Ref95650(free)DepartmentofTradeandIndustry,

tel:08701502500SI1992/3073 Supply of Machinery (Safety) Regulations 1992 (asamendedby

SI1994/2063)L22 Safe use of work equipment. Provision and Use of Work

Equipment Regulations 1998 Approved Code of Practice and guidance1998ISBN0717616266

EIS12 Safety at manually-fed pivoting-head metal-cutting circular saws 1998(free)

EIS7 Safeguarding 3 roll bending machines1998(free)EIS13 Safeguarding of combination metalworking machines 2000

(free)EIS33 CNC turning machines: Controlling risks from ejected parts

2001(free)EIS2 Accidents at metalworking lathes using emery cloth1993(free)PM83 Drilling machines: guarding of spindles and attachments 1998

ISBN0717615464L112 Safe use of power presses. Provision and Use of Work

Equipment Regulations 1998 as applied to power presses. Approved Code of Practice and guidance1998

ISBN0717616274HSG17 Safety in the use of abrasive wheels2000ISBN0717617394HSG42 Safety in the use of metal cutting guillotines and shears1988

ISBN0118854550HSG43 Industrial robot safety: Your guide to the safeguarding of

industrial robots 2000ISBN0717613100BSEN60825 Safety of laser products.Part1:1994Equipment classification,

requirements and user’s guideIEC60825-1:1993 Safety of laser products(including1997and2001

amendments)EIS19 Engineering machine tools: retrofittingCNC1997(free)EIS28 Safeguarding at horizontal boring machines1998(free)HSG236 Power presses: Maintenance and thorough examination 2003

ISBN0717621715HSG180 Application of electro-sensitive protective equipment using light

curtains and light beam devices in machinery1999 ISBN0717615502Video Power presses Parts 1 and 2 1992ISBN071761994X



Metalworking fluids

INDG365 Working safely with metalworking fluids 2003(singlecopyfree; ISBN0717625451forpricedpacksof10copies)– Exposure to hard metals in metalworking fluids during

machining operations BritishLubricantsFederation1994,availablefromBLF,tel:01442230589

Videopackage Metalworking fluids: Effective coolant care and the control of risks to health 1994ISBN0717608751

Pack Working safely with metalworking fluids2002ISBN0717625613

Noise

L108 Reducing noise at work. Guidance on the Noise at Work Regulations 1989 1998ISBN0717615111

INDG362 Noise at work: Advice for employers(singlecopyfree; ISBN0717625397forpricedpacksof10copies)INDG363 Protect your hearing or lose it! 2002(singlecopyfree; ISBN0717625400forpricedpacksof25copies)HSG138 Sound solutions: Techniques to reduce noise at work 1995

ISBN0717607917INDG201 Protect your hearing or lose it (singlecopiesfree; ISBN0717625405forpricedpacksof25copies)PM56 Noise from pneumatic systems1985ISBN0118835297INDG362(rev) Noise at work. Advice for employers1995(singlecopiesfree;

ISBN0717625397forpricedpacksof10copies)EIS26 Noise in engineering1998(free)EIS29 Control of noise at power presses1998(free)

Vibration

INDG126(rev1) Health risks from hand-arm vibration: Advice for employees and the self-employed1998(singlecopiesfree;ISBN0717615545forpricedpacksof15copies)

INDG175 Health risks from hand-arm vibration: Advice for employers rev1998(singlecopiesfree;ISBN0717615537forpricedpacksof10copies).

HSG88 Hand-arm vibration1994ISBN0717607437HSG170 Vibration solutions1997ISBN0717609545INDG338 Power tools: How to reduce health risks. Guide for employers

(singlecopyfreeorpricedpacksof15ISBN0717620085)

Cleaning and degreasing

INDG98 Permit-to-work systems1991(singlecopiesfree; ISBN0717613313forpricedpacksof15copies)L101 Safe work in confined spaces. Confined Spaces Regulations

1997. Approved Code of Practice, Regulations and guidance ISBN0717614050

EIS20(rev1) Maintenance and cleaning of solvent degreasing tanks 1998(free)

EIS21 Immersion and cold cleaning of engineering components(free)GG354 Surface cleaning and preparation: Choosing the best option

Envirowise(seepage80)



EIS40 Safe use of solvent degreasing plant2003(free)EIS34 Surface cleaning: Solvent update including the reclassification

of trichloroethylene2002(free)

Flamecutting and welding

HSG118 Electrical safety in arc welding 1994ISBN0717607046HSE8 Oxygen: Fire and explosion hazards in the use and misuse of

oxygen 1992(free)CS15 Cleaning and gas freeing of tanks containing flammable

residues 1985ISBN0717613658– Health and safety in welding and allied processes(4thEd)

N.Balchin,WeldingInstitute2002ISBN0855735385(availablefromWoodheadPublishing,tel:01223891358)

– Welding fume: A welder’s guide1985WeldingInstitute(availablefromWoodheadPublishing,Tel:01223891358)

BSENISO Health and safety in welding and allied processes. Sampling of 10882-1: 2001 airborne particles and gases in the operator’s breathing zone

BritishStandardsInstitutionBSEN169:2002 Personal eye-protection. Filters for welding and related

techniquesBritishStandardsInstitutionBSEN166:2002 Personal eye-protection. SpecificationsBritishStandards

InstitutionBSEN175:1997 Personal protection. Equipment for eye and face protection

during welding and allied processes BritishStandardsInstitutionHSG139 The safe use of compressed gases in welding, flame cutting

and allied processes 1997ISBN0717606805HSG204 Health and safety in arc welding2000ISBN0717618137INDG327 Take care with acetylene2000(singlecopyfreeorpricedpacks

of10ISBN071761817X)

Radiography

L121 Work with ionising radiation. Ionising Radiations Regulations 1999. Approved Code of Practice and guidance.

HSEBooks2000ISBN0717617467IRIS1(rev1) Industrial radiography: Managing radiation risks2000(free)IRIS2(rev1) Radiation doses: Assessment and recording2000(free)– Radiation safety for site radiographyEngineeringConstruction

IndustryAssociationtel:01717992000ISBN0903393867(o/p;updatedversiondue2004)

Painting

HSG51 Storage of flammable liquids in containers(rev1998) ISBN0717614719HSG140 Safe use and handling of flammable liquids1996 ISBN0717609677EH16 Isocyanates: Health hazards and precautionary measures1999

ISBN0717617017– Code of safe practice: Application of thermosetting coating

powders by electrostatic spraying1997availablefromtheBritishCoatingFederation,tel:01372360660



SI2002/2776 The Dangerous Substances and Explosive Atmospheres Regulations 2002TheStationeryOfficeISBN0110429575

INDG227 Safe working with flammable substances(singlecopiesfree;ISBN071761154Xforpricedpacksof15copies)

EIS15 Control of exposure to triglycidyl isocyanurate (TGIC) in powder coatings 1998(free)

HSG178 The spraying of flammable liquids1998ISBN0717614832

Offices

INDG236 Maintaining portable electrical equipment in offices and other low risk environments(singlecopiesfree;ISBN0717612724forpricedpacksof10copies)

INDG36(rev1) Working with VDUs1998(singlecopiesfree; ISBN0717615049forpricedpacksof10copies)L26 Work with display screen equipment. Health and Safety (Display

Screen Equipment) Regulations 1992 as amended by the Health and Safety (Miscellaneous Amendments) Regulations 2002. Guidance on Regulations(Secondedition)

HSEBooks2003ISBN0717625826INDG173 Officewise1994(singlecopiesfree;ISBN0717607739for

pricedpacksof10copies)HSG90 The law on VDUs: An easy guide. Make sure your office

complies with the Health and Safety (Display Screen Equipment) Regulations 1992 (as amended 2002)2003

ISBN0717626024

Accidents and emergencies

L74 First aid at work. Health and Safety (First Aid) Regulations 1981. Approved Code of Practice and guidance1997

ISBN0717610500FormF2508/ Report of an injury or dangerous occurrence or case of diseaseFormF2508A 1996ISBN0717610780L73 Guide to the Reporting of Injuries, Diseases and Dangerous

Occurrences Regulations 19991999ISBN0717624315HSE31(rev1) RIDDOR explained1999(singlecopiesfree; ISBN0717624412forpricedpacksof10copies)INDG214 First aid at work – your questions answered1997(singlecopies

free;ISBN0717610748forpricedpacksof15copies)INDG215 Basic advice on first aid at work2002(singlecopiesfree; ISBN0717622614forpricedpacksof20copies)

Whileeveryefforthasbeenmadetoensuretheaccuracyofthereferenceslistedinthispublication,theirfutureavailabilitycannotbeguaranteed.



HSE offices(Seewww.hse.gov.uk/contact/local.htmforup-to-datelistofHSElocaloffices)



Association of Consulting EngineersAllianceHouse,12CaxtonStreetLondonSW1HOQL

Association of Noise Consultants6TrapRoad,GuidenMorden,HertsSG8OJE

British Occupational Hygiene SocietyGeorgianHouse,GreatNorthernRoadDerbyDE11LT

British Safety CouncilChancellorsRoad,LondonW69RS

Chartered Institute of Building Services EngineersDeltaHouse,222BalhamHighRoadLondonSW129BS

Council of Independent Inspecting Authorities14StMary’sParsonage,ManchesterM609AP

EEF. The Manufacturers’ OrganisationBroadwayHouse,TothillStreetLondonSW1H9NQ

The Engineering SocietyDevonshireHouse,DevonshireSquareLoughborough,LeicsLE113DW

Independent Safety Consultants Associationc/oHintonandHiggs,TheFirsMarchamRoad,Abingdon,OxonOX141AA

The Institute of AcousticsPOBox320,StAlbans,HertsAL119Z

The Institute of Chemical Engineers165-171RailwayTerrace,Rugby,WarwicksCV213HQ

The Institution of Electrical EngineersSavoyPlace,LondonWC2ROBL

The Institute of Environmental Health OfficersChadwickHouse,RushworthStreetLondonSE1OQTBritish Institute of Non-Destructive Testing1SpencerParade,NorthamptonNN15AA

The Institution of Mechanical Engineers1BirdcageWalk,LondonSW19JJ

The Institute of Occupational HygienistsGeorgianHouse,GreatNorthernRoadDerbyDE11LT

The Institute of Occupational Safety & HealthTheGrange,HighfieldDriveWigston,LeicsLE181NN

The Institute of Radiation Protection64DalkeithRoad,Harpenden,HertsAL55PW

The Royal College of NursingSocietyofOccupationalHealthNursingRCNNorthWesternArea,18FoxStreetPreston,LancsPR12AB

The Royal Environmental Health Institute of Scotland3ManorPlace,EdinburghEH37DH

The Royal Society of ChemistryBurlingtonHouse,Piccadilly,LondonW1VOBN

The Royal Society for the Prevention of AccidentsEdgbastonPark,353BristolRoad,The

Some useful addresses for selecting a health and safety consultancy



Priory,Queensway,BirminghamB57ST

The Society of Occupational Medicine 6StAndrew’sPlace,RegentsParkLondonNW14LB

The Society for Radiological Protection148BuckinghamPalaceRoadLondonSW1W9TR

National Certification Scheme for In-Service Inspection Bodies (NCSIIB)1BirdcageWalk,WestminsterLondonSW1H9JJ

Key reference:Need help on health and safety? INDG322HSEBooks(singlecopiesfree;ISBN0717617904forpricedpacksof15)



Appendix 1 Lifting checklist Section A Summary of assessment

Section A – Preliminary:

Q1 Do the operations involve a significant risk of injury? Yes / No

If‘Yes’gotoQ2.If‘No’ theassessmentneedgonofurther.

Ifindoubtanswer‘Yes’

Q2 Can the operations be avoided/mechanised/automated at reasonable cost? Yes / No

If‘No’gotoQ3.If‘Yes’proceedandthencheckthattheresultissatisfactory.

Q3* Are the operations clearly within the numerical guidelines for assessment contained in

the guidance on the Manual Handling Regulations (pages 60–62)? Yes / No

If‘No’gotoSectionB.If‘Yes’youmaygostraighttoSectionCifyouwish.

* This question can only be answered by using pages 60–62 of the publication referenced below.

Section C – Overall assessment of risk:

Q What is your overall assessment of the risk of injury? Insignificant/Low/Med/High

Ifnot‘Insignificant’gotoSectionD.

If‘Insignificant’theassessmentneedgonofurther.

Section D–Remedial action:

Q What remedial action should be taken, in order of priority?

i..............................................................................................................................................................

ii.............................................................................................................................................................

iii............................................................................................................................................................

iv............................................................................................................................................................

v.............................................................................................................................................................

And finally:

n completetheSUMMARYaboven compareitwithyourothermanualhandlingassessmentsn decideyourprioritiesforactionn TAKEACTION...ANDCHECKTHATITHASTHEDESIREDEFFECT

Operationscoveredbythisassessment: Overallpriorityforremedialaction:Nil/Low/Med/High

Remedialactiontobetaken:

Locations:

Personnelinvolved:

Datebywhichactionistobetaken:

Dateforreassessment:

Assessor’sname:

Dateofassessment: Signature:

Key reference:Manually Handling Operations Regulations 1992. Guidance on RegulationsL23(Secondedition)HSEBooksISBN0717624153



Possible remedial action:

(Makeroughnotesinthis

columninpreparationfor

completingSectionD)

Questions to consider:

(Iftheanswertoaquestionis‘Yes’

placeatickagainstitandthen

considerthelevelofrisk)

The tasks –do they involve:

n holdingloadsawayfromthetrunk?

n twisting?

n stooping?

n reachingupwards?

n largeverticalmovement?

n longcarryingdistances?

n strenuouspushingorpulling?

n unpredictablemovementofloads?

n repetitivehandling?

n insufficientrestorrecovery?

n awork-rateimposedbyaprocess?

The loads – are they:

n heavy?

n bulky/unwieldy?

n difficulttograsp?

n unstable/unpredictable?

n intrinsicallyharmful(egsharp/hot)?

The working environment – are there:

n constraintsonposture?

n poorfloors?

n variationsinlevels?

n hot/cold/humidconditions?

n strongairmovements?

n poorlightingconditions?

Individual capability – does the job:

n requireunusualcapability?

n posearisktothosewithahealthproblem?

n posearisktothosewhoarepregnant?

n callforspecialinformation/training?

Other factors

Ismovementorposturehinderedbyclothingor

personalprotectiveequipment?

Level of risk:

(Tickasappropriate)

Decidingthelevelofriskwillinevitablycallforjudgement.

When you have completed Section B go to Section C.

Section B

Section B – More detailed assessment, where necessary:

YesLowMedHigh



Company/Department:

Workstation: Completedby:

Task:

Worker: Date:

Checking whether handling problems are causing upper limb disorders

Riskfactor Tick your answer Action required

NO YES

Does your job involve a lot of: Ifyouhavenoticks

inthe‘YES’column

onthispage,you

areunlikelyto

haveanyhandling

problemscaused

bywork.Youneed

notgoontothe

followingquestions.

However,ifyou

haveanyticksin

the‘YES’column

onthispage,there

maybeariskin

yourworkplace.

Youshouldgoon

todothefullrisk

assessment.

FREQUENT gripping(atoolorworkpiece)?

or squeezing(egtoolhandles)?

FORCEFUL twisting?

or reaching?

AWKWARD movingthings(pushing,pulling,lifting)?

finger/handmovement(egkeyboard

work)?

Are there any warning signs of hand/shoulder/

neck problems?Forexample:

n Actualcasesinthisorsimilarwork?

n Complaintsbyworkers,egachesandpainsin

hands,wrists,arms,shouldersetc?Askyour

employeesiftheyhaveanyofthesesymptoms.

n Home-made,improvisedchangestowork-stations

ortools(eghandlescushionedormadelonger)?



RISKFACTOR

FULL RISK ASSESSMENT

ArethereanyfactorsinthejobthatmakeULDslikely,suchas:

Need for a lot of force – Does the job involve:

n strongforceatthesametimeasawkwardmovementsorposture,eg

bentwrists,workwitharmsraisedorfullyextended?

n forcefuluseofhand/forearmmuscles?

n tryingtomakedowithill-fittingcomponentsbyforcingthemintoplace?

n toolsnotidealforrepetitiveorfrequentuse–particularlyifsqueezing,twisting,orhammeringactionsarerequired?

n usingequipmentdesignedforalargerorstrongerperson(egwomen

usingtoolsdesignedformen)?

Rapid, awkward or frequent movement – Does the job involve:

n machinepacing,egtokeepupwithconveyor?

n frequentrepetitionofthesamesmallnumberofmovements?

n awkwardmovementssuchastwistingorrotationofwrist,movement

ofwristfromsidetoside,verybentfingersandwrist,orhandorarm

movementsbeyondacomfortablerange?

n pressuresonemployeestoworkfast,egfrompieceworkorbonus

systems?

Is risk present?

NO YES



POSSIBLESOLUTIONS RECOMMENDATION FOR ACTION

Tick

when

action

taken

Redesignworkstations,eg:

n Repositionsupplyofcomponentstoreduce

reachingrequired.

n Movecontrolstomoreconvenientposition.

Redesignjob,workstation,and/ortoolstoavoidover-

useofthehandorforearm.

Maintaintools,egkeepthemsharpandlubricated,

foreaseofuse.

Improvequalityofcomponents,orprovidesuitable

toolsforfittingthem.

ReplacedomesticorDIYhandtoolswithtools

designedforrepetitiveindustrialuse.Redesigntool

handlestoachieveevendistributionofforceacross

hand(powergrippreferabletopinchgrip)andstraight

ratherthanbentwrists.Considerreplacinghandtools

withpowertools.Reducesqueezingforcesbyusing

weakerspringstotriggersetc.

Redesignequipmentortool(egcounter-balancingto

reduceforcerequired).Providepoweredversion.

Selfpacingispreferable.

Replanwork,egtobreakuppause/repetitioncycles

orspreadmovementacrossbothhands.Consider

addingextraactivitiestojob,togivevariety.Consider

scopeforautomationoruseofpowertools.

Redesignworkstation,controlsorshapeoftool

handles.

Considerneedforsuchsystems(butemployeesmay

resistchange).Bettertraininginrisksmayhelp.



Awkward or static posture – Does the job involve:

n crampedbodyposition,and/ornotenoughspacetochangeposture?

n armsstretchedoroverheadforlongperiods?

n workatawkwardlyhighorlowheight(crouching,stooping,orreachingup)?

Work for long periods without breaks or changes of activity –Does the job involve:

n nochangestoworkroutineorvariationoftasks?

n nobreaksorinfrequentbreaks?

n workernotabletohaveshortpauseswhendesired?

No special arrangements for new employees

(orthosereturningtoworkafteralongbreak)– Does the job involve:

n peoplehavingtoworkatfullpaceassoonastheystart(orresume)thejob?

n notraininginrisksandwaysemployeescanreducerisks?

Poor environmental conditions – Is work carried out:

n indimlight,shadoworflickeringlight?

n incoldorotherwiseadverseconditions?

n withtoolsthatvibrate?

RISKFACTOR Is risk present?

NO YES



Improvespaceavailabletoworker.Provideadjustable

workstation(especiallychair)forworkerswhoare

aboveorbelowaverageheightorshape.

Movematerialsorcontrolstomoreconvenientposition.

Movematerialsorcontrolstomoreconvenientposition.

Ifpossible,varytaskstoprovidechangesinactivity.

Ifnot,checkthereareadequaterestbreaks.

Checkthatbreaksaretaken,especiallyifwork

involvescontinuouseffortsuchasholdingtools,or

rapidlyrepeatedmovements(egtyping).

Redesignworktomakeshortpausespossible.

Allowrecruitstobuilduptheirworkratesensibly

astheygainexperience.

Providetraininginskills,posture,andwarning

symptomsforallthoseatrisk.

Providebetterlightingsothatworkersdonothave

toadoptawkwardposturestoseeproperly.

Cold(eginhandlingfrozenfoods)mayincreasethe

risk.Ifitisnotpossibletowarmtheworking

environment,checkthatprotectiveclothingiswell

designedanddoesnotaffectpostureorgrip.

Considerwhetherthejobcanbedoneanotherwayto

avoidneedforhigh-vibrationtools.Orprovide

vibration-absorbinggripandminimisevibrationby

propermaintenance.

Tick when

action

taken

POSSIBLESOLUTIONS RECOMMENDATION

FOR ACTION



Appendix 2 Metalworking fluids questionnairesQuestionnaire for detection of skin abnormalities

To be completed by the employee

NAME:..........................................................................................................................................................................

DATE:...........................................................................................................................................................................

DATEOFBIRTH:.......................................................................................................................................................

JOBTITLE:..................................................................................................................................................................

COMPANY:.................................................................................................................................................................

1 Sinceyourlastrevieworinthelast12monthshaveyouhadanyofthefollowingsymptoms?

(a) redness and swelling of fingers or hands; Yes No

(b) cracking of skin on fingers or hands; Yes No

(c) blisters on fingers or hands; Yes No

(d) flaking or scaling of skin on fingers or hands; Yes No

(e) itching of fingers or hands with skin cracks or splits; Yes No

(f) spots, redness, swelling of any other part; Yes No

2 Didtheseproblemslastformorethanthreeweeks? Yes No

3 Didtheseproblemsoccurmorethanonce? Yes No

4 Doesyourskingetbetterwithperiodsoffwork? Yes No

5 Haveyoulosttimefromworkwithskinproblemssinceyourlast Yes No

assessment?

6 Doyouthinkyouknowwhatcausestheproblems? Yes No

7 Namethesubstance/material/contactyouthinkisresponsible:

To be completed by the responsible person:

8 Problemsconfirmedbytheresponsibleperson? Yes No

9 Actiontaken:

Nameofresponsibleperson:

Date:

Footnote:Anyabnormalitiesfoundshouldbereferredtotheworksoccupationalhealthphysicianornurseifthereis

one.Ifnot,employeesshouldbeadvisedtoconsulttheirgeneralpractitioner.Ineithercase,referraltoaconsultant

dermatologistmaybeappropriate.Acopyofthiscompletedquestionnaireshouldbesuppliedtotheemployee’s

generalpractitioner.



Questionnaire for detection of lung problems

To be completed by the employee

NAME:.........................................................................................................................................................................

DATE:..........................................................................................................................................................................

DATEOFBIRTH:.......................................................................................................................................................

JOBTITLE:.................................................................................................................................................................

COMPANY:.................................................................................................................................................................

Sinceyourlastrevieworinthelast12months:

1 Haveyouhadanyepisodesofwheezesorchesttightness? Yes No

If‘yes’,atwhattime(s)ofday?

2 Haveyoutakenanytreatmentforyourchest? Yes No

3 Haveyouwokenatnightwithcoughorchestiness? Yes No

4 Haveyouhadanyepisodesofbreathlessness? Yes No


5 Haveyouhadanytimeoffworkwithchestdisease? Yes No

6 Haveyoudevelopedchesttightnessorbreathlessnessafterexercise? Yes No

7 Haveyoudevelopeddifficultywithbreathing? Yes No


To be completed by the responsible person:

8 Problemsconfirmedbytheresponsibleperson? Yes No

9 Actiontaken:

Nameofresponsibleperson:

Date:

Footnote:Iftheanswerisyestoanyofthesequestions,theemployeeshouldbereferredtotheworksoccupational

healthphysicianornurseifthereisone.Ifnot,employeesshouldbeadvisedtoconsulttheirgeneralpractitioner.

Ineithercase,referraltoaconsultantchestphysicianmaybeappropriate.Acopyofthiscompletedquestionnaire

shouldbesuppliedtotheemployee’sgeneralpractitioner.



Appendix 3 Work equipment risk assessmentYoumaywishtousetheproformabelowtoassessaspectsofmachinerysafetyaspartofyourriskassessment.Wherefurtheractionisindicated,youshouldrecordwhatisdoneasaresult.Don’tforgettomakesurethatyoualsoconsiderfullyanyriskstohealththatmayariseasaconsequenceofusingtheequipmentbeingassessed.Formobileworkequipment,additionalrequirementswillapply(seepages31–32)

General equipment description

DESCRIPTION:........................................................................................................

LOCATION:.........................................................PLANT/REFNo:........................

NAMEOFASSESSOR:...................................DATEOFASSESSMENT:..................

Generaldescriptionofworkequipment,includingdetailsofancillaryequipmentwhererelevant:

Intendedfunctionofworkequipment:

Assessmentofsuitabilityforintendedfunction:



Work equipment risk assessment 1 Guarding of dangerous parts. Isaccesspossibletoanypartofmachinerythatcouldcauseinjury?

Forthepartsidentifiedabove,whatmethodofsafeguardingisnecessarytominimisetherisk?

Whereguardsarecurrentlyprovided,dotheysatisfythefollowingcriteria?(Y/N)

Machine part Location Part of body at risk Estimated injury

Machine part Fixed guard Other guard Other (jigs, holders etc)

Guard/

device

Suitable? Of good

construction

Easily

by-passed

or disabled?

Adequate

distance

from

danger?

Adequate

view

(if needed)?

Access

only for

maintenance?



2 Maintenance Whatmaintenanceisneededforguardsandprotectiondevices?

3 Inspection Isinspectionoftheworkequipmentnecessary?

4 Information, instruction and training Whatinformation,instructionandtrainingmustbeprovidedforthefollowing

groups?

Guards/protection device Maintenance required Frequency

Inspection required (Y/N) Details of inspection Frequency

Operators Maintenance staff Managers/supervisors



5 Other hazards Whatactionisneededinrespectofthefollowingpossibleadditionalhazards? NOTE: The list in the table below is not exhaustive and is intended as

a GUIDE ONLY

6 Emergency stop controls Isasuitabledesignofemergencystopcontrollocatedatappropriatecontrol

andoperatingpoints?

7 Isolation Howisthemachineisolatedorlockedofffromthefollowingenergysources

(whererelevant)?

Hazard Occurring? (Y/N) Action required to minimise risk

Anyarticleorsubstancefallingor

beingejectedfromthemachine

Aruptureordisintegration

Overheatingorfire

Unintentionalorpremature

dischargeofdust,gas,liquid,

vapourorothersubstance

Anypartofthemachineata

highorlowtemperaturelikely

tocauseinjury

Anyotherhazards?

Identified control/operating points Type of emergency to stop control

Energy source Method of isolation

Electricity

Compressedairorgas

Hydraulic

Steam

Other(eggravityfall)



8 Controls

9 Workplace environment

Yes/No If no, what action is required?

Arecontrolsclearlyvisible,

identifiableandclearlymarked

wherenecessary?

Arecontrolslocatedtoensurethat

operatorsarenotexposedtorisk?

Cantheoperatorseeanyother

personwhomaybeexposed

toriskwhenthecontrolsare

operated?

Aretheresystemsofworkto

ensurethatnooneislikelytobeat

riskwhenthemachinestarts?

Aretheresuitableaudible,visibleor

otherwarnings(ifneeded)?

Yes/No If no, action required?

Isthereadequatenatural

andartificiallight?

Islightingofcontrols

satisfactory,withoutglare?

Islightingofpartsofthemachine

thathavetobeviewedadequate?

Istheworkplacetemperaturein

arangeofcomfortforoperators?

Issuitableseatingrequired?

Isthereadequatespacearound

themachinetoallowsafe

andeasyaccess?

Isstorageformachineparts

andspecialtoolsneeded?

Arefireextinguishersneededclose

tothemachine–ifso,whattype?



10 Personal protective equipment (PPE)

11 Safety signs and warnings Areadequatesignsfittedtothemachineasfollows?

Yes/No If no, what action required?

IsPPEnecessary?

Ifyes,whattype?

Areoperatorsawarethat

PPEisrequired?

Dooperatorsknowhow

PPEshouldbeworn?

Islocalstoragenecessary

andprovided?

IsPPEsubjectto

routinemaintenance?

Yes/No If no, action required?

Hazardoussurfaces

Hazardousmaterials

Hazardouspartsortheirmovement

Prohibitedactions

Correctoperation

Personalprotective

equipment(PPE)

Emergencyaction



Appendix 4 Key standards for engineering workshopsTohelpdesignersandmanufacturersofnewmachinesmeetessentialhealthandsafetyrequirements(seepage49–51),arangeofTransposedHarmonisedStandards(BSENs)hasbeendevelopedtoofferfourlevelsofguidance:

‘A’standardsonbasicsafetyconceptsanddesignprinciplescommontoallmachinery

‘B1’standardsonbasicsafetyaspectssuchassafetydistancesandnoise

‘B2’standardsonsafetyrelateddevicessuchasguardsandinterlockingdevices,and

‘C’standardswhichinterpret‘A’and‘B’standardsandgivesafetyrequirementsforaparticulartypeorgroupofmachines

‘pr EN’standardsareBSENsunderdevelopment,availablefromBSI(seepage110)

Formachinesusedinengineeringworkshops‘C’standardsareplannedforthecommonestmetalworkingmachinesincludingmechanical,hydraulicandpneumaticpressesandpressbrakes;grindingmachinesofallkinds;horizontalandverticalturningmachines,bothCNCandmanuallyoperated;machiningcentres,drilling,millingandboringmachinesofalltypes;andmetalcuttingsawsandelectro-dischargemachines.

Thesestandardswillalsoberelevanttousersofexistingmachinerytohelpthemassessrisksanddecidewhethersafeguardsareadequate.

Standard and title Key contents and requirements

1 Describesmachineryhazards,definessafetyterms,requiresdesignerstoassessrisks,removeorcontrolthem.2 Allhazardsfrommechanical,electrical,thermal,noise,vibration,radiation,materialsorergonomicsourcesincludinganycombination,havetobeconsideredoverthelifetimeofthemachine.

BS EN 292 : Part 1 : 1991Safety of machinery. Basic concepts, general principles for design

BS EN 292 : Part 2 : 1991Safety of machinery. Technical principles and specifications

1 Describesmethodstoreducerisksbydesign.2 Advisesonselection,designandconstructionofsafeguardsforhazardswhichcannotbeeliminatedbydesign.3 Describesinformationforusetobeprovidedforusersbysuppliers.



BS EN 1050 : 1997Safety of machinery. Risk assessment

1 Advisesontheidentificationofhazardsandprovidescriteriaforassessingrisksandselectingsafetymeasuresconsistentwithtechnicalandeconomicrestraints.

2 Outlinesqualitativeandquantitativeriskassessmenttechniquesandriskreductionmeasures.

BS EN 60204-1Safety of machinery. Electrical equipment of machines – Part 1: General requirement

1 Appliestolowvoltageequipment(1000vACand1500vDC,notexceeding200Mz)fromthepointofsupplytoitsuseatthemachine.

2 Coversprotectionagainstelectricshock,measurestoprotectequipmentagainstovercurrent,overspeed,overloadandfromtheenvironment,restartingahazardousoperationfromlossofpower,generalrequirements,electricalcontrols,theaccessibility,layoutandidentificationofcontrols,ergonomicrequirementsforelectricalcontrols,requirementsforcabling,wiring,accessories,lighting,documentationandtesting.

BS EN 953 : 1998Safety of machinery. Guards (fixed, movable)

1 Containsdefinitionsofdifferenttypesofguard.2 Setsrequirementsforwhentouseaparticulartypeofguardandhowto

designguardstominimisehazards.

BS EN 1088 : 1996Safety of machinery. Interlocking devices with and without guard locking

1 Definesbasicconceptsandgeneralprinciplesforinterlockingdevicescontrollinganypowersource.

2 Specifiesrequirementsforelectricalinterlockingdevices,andpartsofguardswhichactivateinterlockingdevices.

BS EN 294 : 1992Safety of machinery. Safety distances to prevent danger zones being reached by upper limbs

1 Twovaluesaregivenforreachinguptodangerzonesandtwotablesforreachingoverprotectivestructures.

2 Designermustdecidewhatistobeuseddependingonwhethersituationsarehighorlowrisk.

3 Standardisnotconcernedwithpreventingclimbingoverbarriers;1800mmmaybesufficientlyhighforthis.

BS EN 349 : 1993Safety of machinery. Minimum distances to avoid crushing parts of the human body

1 Describesfactorstobetakenintoaccountintheassessmenttopreventcrushingonly.

2 Minimumgapsforwholebody,leg,head,foot,toes,arm,hand,andfingeraregiveninanillustratedtable.

3 AnnexA(Informative)illustratesthreetypicalcrushingzonesatamillingmachinetable.

BS EN 626-1 : 1995Safety of machinery. Reduction of risks from hazardous substances emitted by machinery – Part 1: Principles and specifications for machine manufacturers

1 Containsinformationonthetypesofhazardstobeconsidered,withexamples.

2 AnnexA(Informative)providesexamplesofhowexposuretohazardoussubstancesmaybereducedbyeliminatingorreducingrisks.

BS 5304 : 1988Safety of machinery

Anon-harmonisedstandardcontainingmanyusefulprinciplesandexamplesofsafeguardingformachinerywhichisbeingprogressivelyreplacedbyharmonisedstandards.



Safety of a machine Theabilityofamachinetoperformitsfunction,tobetransplanted,installed,adjusted,maintained,dismantledanddisposedof,underconditionsofintendeduse,withoutcausinginjuryordamagetohealth.

HazardAsourceofpossibleinjuryordamagetohealth.

RiskAcombinationoftheprobabilityanddegreeofthepossibleinjuryordamagetohealthinahazardoussituation.

Risk assessmentAcomprehensiveestimationoftheprobabilityofpossibleinjuryordamagetohealthinahazardoussituationinordertoselectappropriatesafetymeasures.

Danger zoneAnyzonewithinand/oraroundmachineryinwhichapersonisexposedtoriskofinjuryordamagetohealth.

Safety deviceDevice(otherthanaguard)whicheliminatesorreducesrisk,aloneorwithaguard.Interlocking deviceMechanical,electricalorothertypeofdevice,thepurposeofwhichistopreventtheoperationofmachineelementsunderspecifiedconditions(generallyaslongasguardisnotclosed).

Hold-to-run control deviceControldevicewhichinitiatesandmaintainsoperationofmachineelementsonlyasthemanualcontrol(actuator)isactuated.Theactuatorreturnsautomaticallytothestoppositionwhenreleased.

Guard Partofamachinespecificallyusedtoprovideprotectionbymeansofaphysicalbarrier.Fixed guard Guardkeptinplace(ieclosed)eitherpermanently(egbywelding)orbymeansoffasteners(screws,nutsetc)makingremoval/openingimpossiblewithoutusingtools.

Movable guardGuardgenerallyconnectedtothemachinebymechanicalmeans(eghingesorslides)whichcanbeopenedwithouttools.Adjustable guardFixedormovableguardwhichisadjustableasawholeorwhichincorporatesadjustablepart(s).Theadjustmentremainsfixedduringaparticularoperation.

Interlocking guardGuardassociatedwithaninterlockingdevicesothat:n thehazardousmachinefunction‘covered’bytheguardcannotoperateuntilthe

guardisclosedn iftheguardisopenedwhilehazardousmachinefunctionsareoperating,astop

instructionisgiven

Useful definitions from BS EN 292: Part 1: 1991



n whentheguardisclosed,thehazardousmachinefunctions‘covered’bytheguardcanoperate,buttheclosureoftheguarditselfdoesnotinitiatetheiroperation.(Toachievethiswouldrequireacontrolguard.)

Guard locking with interlockingPreventstheopeningofaninterlockingguarduntilhazardousmotionsarestopped,andtheirrestartuntiltheguardislocked.

SafeguardAguardorsafetydevice.

Two-hand control deviceHold-to-runcontroldevicewhichrequiresatleastthesimultaneousoperationoftwomanualcontrols(actuation)inordertotriggerandmaintainoperationofthemachineormachineelements,thusaffordingameasureofprotectionforthepersonoperatingtheactuators.

Defining hazardsHazardsatmachinerymayarisefrom:

n mechanicalmovements,suchasshearingn electricityn heatn noisen vibrationn radiationn substancesbeingusedn neglectingergonomicprinciplesindesignn combinationsofhazardsn failuresofenergysupplyn missingsafetymeasures,andn beingtrappedinside.

Enabling (control) deviceAdditionalmanuallyoperatedcontroldeviceusedinconjunctionwithastartcontrolandwhich,whencontinuouslyactuated,allowsamachinetofunction.

Trip deviceDevicewhichcausesamachineormachineelementstostop(orensuresanotherwisesafemachinecondition)whenapersonorapartofabodygoesbeyondasafelimit.

Trip devices may be:n mechanicallyactuated,egtripwires,telescopicprobes,pressuresensitive

devicesetcn non-mechanicallyactuated,egphoto-electricdevices,devicesusingcapacitive,

ultra-sonicetcmeanstoachievedetection.



Appendix 5 Fire-resistant materials for DIY spray boothsEffectivesegregation,ventilationandpreventionofignitioncanbeachievedinhome-madespraybooths,butwithprofessionalandcompetentadvice.

Segregation

Theseparationorisolationshouldbefireresistant.Someexamplesoffloor,wallanddoorconstructionthatwillprovideastandardofhalf-hourfireresistanceare:

FloorsPlainedgeboardingontimberjoistsnotlessthan38mmwidewithaceilingof12.5mmplasterboardand12.5mmgypsumplaster.

Tonguedandgroovedboardingnotlessthan16mmthickontimberjoistsandnotlessthan38mmwidewithaceilingof12.5mmminimumofplasterboardandaskimcoatofgypsumplaster.

Plainedgeboardingontimberjoistsnotlessthan38mmwidewithaceilingoftimberlathandplaster,theplasteratleast16mmthick,coveredontheundersidewitha12.5mmthicknessofplasterboard.

Walls100mmbrick(unplastered).

50mmwoodwoolslabsplasteredatleast12.5mmthickonbothsides,framedconstruction(nonload-bearing).

Steelortimberstuddingwith12.5mmportlandcementplaster,portlandcement/limeplasterorgypsumplasteronmetalortimberlathing(nonload-bearingconditionsonly).

Steelortimberstuddingwith9.5mmthickplasterboardoneachsidewiththeexposedfacingoftheboardingplasteredwith5mmthickneatgypsumplaster(nonload-bearingconditionsonly).

Whereexistingwallsorpartitionsarenotfire-resistingconstructions,thestandardcanbeachievedbyadding12.5mmplasterboard;ensurethatthejointsbetweentheoverlapareformedoverthesupportingframeworkorotherwisesuitablyconstructed.

DoorsFit:Thedoorshouldbereasonablystraightandtrueandlieflushagainstthestopwhenclosed;thegapbetweenthedooredgeandtheframeshouldnotexceed3mm.

Door frame:Shouldhavearebateorstopnotlessthan25mmdeep;existingplantedstopsmaybereplacedoradditionalmaterialscrewedorpinnedandgluedon.

Door furniture:Onepairofmetalhinges,allpartsofwhicharenon-combustibleandhaveameltingpointnotlessthan800º.

Glazing:Anyplainglazingshouldbereplacedby,orbackedwith,6mmwirereinforcedglassnotexceeding1.2m2inareaandfittedwithsolidwoodbeadingnotlessthan13mmincrosssection.



Flush doors*:6mmwallboardcovertobothsidesofthedoor;fixingtobe32mmscrewsatapproximately300mmcentres,orannularnailsatapproximately200mmcentres,drivenintosolidtimber.

Panel, framed, ledged and braced doors*:Protectionasforflushdoorstobothfacesofthedoor;or,ifprotectionagainstfireisneededfromonesideonly,then9mminsulatingboardfixedtoroom-risksideofthedoor,asabove,withthepanelsfirstmadeupwithtightlyfittingcutoutsofplasterboardorsolidwood.

ElectricsUnprotectedelectricalequipmentmustbekeptoutsidespraybooths.

Installlightsoutsideboothsandshinethemthroughfixedandsealedfire-resistingwiredglasspanels.

Useonlyexplosionprotectedelectricalequipmentinsidethebooth.

*Theimportanceoffixingcannotbeover-emphasised.Additionalmaterialmustbesofixedtotheexistingdoorthat,underconditionoffirewherethermalmovementislikelytotakeplacebetweenthedoorandprotectivematerial,thescrewsornailsarenotstressedsothattheyarepulledout.



Appendix 6 Record of examination and test of local exhaust ventilation (LEV) plantAsuitablerecordcontainingatleastthefollowingparticularsshouldbekeptinrespectofeachthoroughexaminationandtestofLEVplant:

(a) Nameandaddressofemployerresponsiblefortheplant(b) IdentificationandlocationoftheLEVplant,process,andhazardoussubstance

concerned(c)Dateoflastthoroughexaminationandtest(d)Conditionsattimeoftest;normalproductionorspecialconditions(eg

maximumuse,stooddown)(e) InformationabouttheLEVplantwhichshows:

(i)itsintendedoperatingperformanceforcontrollingthehazardoussubstance (ii)whethertheplantnowstillachievesthesameperformance (iii)ifnot,therepairsrequiredtoachievethatperformance

(f) Methodsusedtomakejudgementat(e)(ii)and(e)(iii)above(egvisual,pressuremeasurements,airflowmeasurements,dustlamp,airsampling,filterintegritytests)

(g)Dateofexaminationandtest(h)Name,designationandemployerofpersoncarryingoutexaminationandtest(i) Signatureoruniqueauthenticationofpersoncarryingoutexaminationandtest(j) Detailsofrepairscarriedout.



Appendix 7 Answers to frequently asked questions about work in engineering workshops

Question Answer

Is it all right to work alone in the workshop?

Itwouldnotgenerallybereasonableforemployerstopermitemployeestoworkalone,becausethereisusuallysomedangerousmachineryabout.(Fatalaccidentshaveoccurredfollowingentanglementsoncentrelatheswhichmayhavebeenpreventedhadtherebeenanotherpersontoswitchoffthemachineandhelpthetrappedworker.)However,ifjustlow-riskworksuchasassemblyorsomecleaningisbeingplanned,thenprovidedotherrisksareminimisedandasystemofcheckingorlineofcommunicationestablished,itwouldbereasonableforanemployeetoworkalone.Seepage6onhowtomanagesafety.

What are the rules on smoking? Smokingshouldnotbepermittedwhereflammableliquidsareused,oranywhereneardegreasingoperations.Also,smokingmaymakeanydust,fume,mistorvapourmoreharmfulifinhaled.Thereisalsoaslightgeneralhealthrisktonon-smokersfromtobaccosmokeintheworkshopandoffices.Employersshoulddevelopapolicytominimisethisrisk.Restroomarrangementsmustprotectnon-smokersfromdiscomfortcausedbytobaccosmoke.



Do I need to keep an accident book? No,butyouneedtorecorddetailsofaccidentsandoccurrenceswhichmustbereported(seepage105–106).

YoumayusetheDSSB1510AccidentBook,anotherbookoracomputertorecordthefollowingdetails:

n dateandtimeofaccidentoroccurrence

n fullnameandaddressofthepersoninvolvedandtheinjuryorconditionsuffered

n wheretheaccidentoroccurrencehappened

n abriefdescriptionofthecircumstances

n inthecaseofareportablediseasethedateofdiagnosis,theoccupationofthepersonconcernedandthenameornatureofthedisease.

Keeptheaboveinformationforatleastthreeyears.

What can young people do in the workshop?

Employmentofchildrenunder13isforbidden,andchildrenunderthisageshouldnotnormallybeallowedinanengineeringworkshop.Childrenover13butunderminimumschoolleavingagemayonlyworkunderanofficialworkexperiencescheme.

Youngpeopleunder18areoftenexposedtoriskstotheirhealthandsafetywhenusingworkequipmentasaconsequenceoftheirimmaturity,lackofexperience,andabsenceofawarenessofexistingorpotentialrisks.Trainingandpropersupervisionofyoungpeopleisthereforeofparticularimportance.

Ifyouemployayoungperson,themanagementregulationsrequireyoutoassessriskstothembeforetheystartwork,takingtheabovefactorsintoaccount.Youmustusetheriskassessmenttodeterminewhethertheyoungpersonshouldbeprohibitedfromcertainworkactivities,exceptwherenecessaryfortheirtraining.

Question Answer



Youngpeopleshouldnotforexamplebeallowedtousehigh-riskliftingmachineryunlesstheyhavethenecessarymaturityandcompetenceandhavesuccessfullycompletedappropriatetraining.Yourriskassessmentmayindicatethatsimilarprohibitionsareappropriateforhigh-riskmachinessuchaspresses,guillotinesandmillingmachines.

Sufficienttrainingandadequatesupervisionshould,ofcourse,beprovidedforallworkforallemployees.

Do women have to be treated differently in the workshop?

Ingeneralno,butwhereworkwithleadorionisingradiationsisconcerned,theirworkneedscarefulassessmentsothatitcanbemanagedproperlytopreventundueriskstounbornchildren.

What notices do I have to put up? n TheonlynoticenowrequiredtobedisplayedistheHealthandSafetyLawposter(oranapprovedleafletcontainingthesameinformationcanbegiventoeachemployee)

n Electricshockandfirst-aidatworkplacardsarenolongerrequiredtobedisplayedbylawbutcontainadviceforuseinemergencies.

n TheabovepostersmaybeobtainedfromHSEBooksinanencapsulatedformat.

What breaks are workers entitled to, and what hours of work are required?

Aworkerisentitledtoanuninterruptedbreakof20minuteswhendailyworkingtimeismorethansixhours.Additionally,aworkerisentitledtoarestperiodof11consecutivehoursbetweeneachworkingdayandtoanuninterruptedrestperiodofnotlessthan24hourswithineach7-dayperiod.

Theweeklyworkingtimeforaworkermustnotexceed48hoursperweek,averagedovera17-weekperiod.Workersmayindividuallyorcollectivelysignanagreementwiththeiremployertoworkoverthislimit.Thenormalhoursofnightworkersmustnotexceedanaverageof8hoursforeach24hoursovera17-weekperiod.

Key references:Young people at work: A guide for employers HSG165HSEBooksISBN0717618897

New and expectant mothers at work: A guide for employers (Secondedition)HSG122HSEBooksISBN0717625834

Question Answer

PublishedbyHSE03/10 Page147of147


Are eye tests required for users of VDUs?

Users,andthosetobecomeusers,canrequestaneyeandeyesighttestthatyouhavetopayfor,iftheyareyouremployees.IfthetestshowstheyneedglassesspecificallyfortheirVDUwork,youhavetopayforabasicpairofframesandlenses.

Usersareentitledtofurthertestsatregularintervalsafterthefirsttest,andinbetweeniftheyarehavingvisualdifficultieswhichmayreasonablybeconsideredtobecausedbytheirVDUwork.

Ifusers’normalglassesforotherworkaresuitableforVDUworkyoudon’tneedtopayforthem.Youdon’thavetopayforfancyframes,orlenses.Eyeandeyesighttestingisnotanentitlementfortheself-employed.

Whensettingupasystemforprovidinguserswitheyeandeyesighttests,thesepointsmighthelp:

n contactanumberofopticiansandaskwhattheychargefortestsandbasicglasses

n askiftheywillcometothefirmtotesttheusers

n askforstandardinformationabouteachusertheytest,iftheyneedglassesforVDUworkandwhentheyshouldbere-tested

n telluserswhatarrangementsyouhavemade

n makesureusersunderstandwhatyouwillandwon’tpayfor(egtintedlenses,glassesfornon-VDUpurposesarenotyourresponsibility).

Key references: A guide to Working Time Regulations (free)DTI:08701502500Working with VDUs INDG36(rev1) HSEBooks(singlecopyfree;ISBN0717615049forpricedpacksof10)

Question Answer

health and safety in engineering workshops...

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