hse.health and safety in engineer in workshops
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Health and Saety
Executive
Health and safety in
engineering workshops
This is a ree-to-download, web-riendly version o HSG129 (Second
edition, published 1999). This version has been adapted or online use. The
printed version is no longer available.
Health and safety in engineering workshops describes how most serious and
frequent hazards arise, how to assess the risks involved, and how to eliminate orcontrol 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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Executive
Crown copyright 1999
First published 1995
Second edition 1999
Reprinted with amendments 2002
Reprinted 2004, 2010
ISBN 978 0 7176 1717 3
You may reuse this inormation (excluding logos) ree o charge in any ormat or
medium, under the terms o the Open Government Licence. To view the licence
visit www.nationalarchives.gov.uk/doc/open-government-licence/, write to the
Inormation Policy Team, The National Archives, Kew, London TW9 4DU, or email
Some images and illustrations may not be owned by the Crown so cannot be
reproduced without permission o the copyright owner. Enquiries should be sent [email protected].
This guidance is issued by the Health and Saety Executive. Following the guidance
is not compulsory and you are ree to take other action. But i you do ollow the
guidance you will normally be doing enough to comply with the law. Health and
saety inspectors seek to secure compliance with the law and may reer to this
guidance as illustrating good practice.
2004 Reprint
In general, the amendments included in this reprint relect updated publications andregulations. The overall guidance has not changed.
HSE grateully acknowledges the help o El Oil Industrial Lubricants Division in the
preparation o the cover illustration.
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Foreword 5
Managing health and saety 6
How most accidents and cases o 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 12
Working in and moving around the workshop 14
Lighting 16General ventilation, temperature and toilets 17
Liting equipment 19
Moving goods saely by hand 20
How to lit saely 21
Liting and handling 22
Ergonomic machine operation, assembly and packing 25
Moving vehicles saely 27
Lit trucks 28
Controlling hazardous substances 30
Local exhaust ventilation (LEV) 32
Electricity 34
Portable electrical equipment 35Common problems with lexible leads, their plugs and sockets and how to avoid
them 37
Pressurised plant and systems 39
Machining 40
Computer controlled (CNC) machining 43
Buying and selling machinery 45
Metalworking luids 48
Noise 51
Vibration 57
Milling and machining centre work 58
Drilling (and reaming) 60
Pressing 62Turning 64
Grinding 66
Sawing 68
Bending 69
Guillotining 70
CNC punch pressing 72
Combination metalworking machines 73
Horizontal boring machines 74
Cleaning and degreasing 75
Vapour degreasing tanks 76
Welding and lamecutting 78Fume control 80
Saety measures at resistance welding machines 82
Lasers used or welding and cutting 83
Contents
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Radiography 84
Painting 85
Spray painting booths and enclosures 87
Paints containing isocyanates 89
Powder coating 90
Personal protective equipment (PPE) 92
Oices 94
Organising health and saety 96
Accidents and emergencies 98
First aid 101
How to obtain publications and urther assistance 102
Further reading and inormation 104
HSE oices 112Some useul addresses or selecting a health and saety consultancy 112
Appendices
Liting checklist 114
Metalworking luids questionnaires 121
Work equipment risk assessment 123
Key standards or engineering workshops 129
Fire-resistant materials or DIY spray booths 133
Record o examination and test o local exhaust ventilation (LEV) plant 135
Answers to requently asked questions about work in engineering workshops 136
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ForewordThis guidance has been written or people who run and work in small engineering
workshops, ranging rom those who
make their own products,n
to those who
maintain and repair plant and machinery either independently or as part on
larger enterprises.
It is intended to help them manage their own health and saety and work in saer
and healthier ways.
As engineering is a wide ranging activity the booklet does not deal with everyhazard which may arise or every precaution which can be taken. It does, however,
outline the most serious and requent hazards and the best ways o dealing with
them.
The Further reading section:
lists HSE and other publications which give more detail on the subjects dealtn
with;
provides inormation on other sources o help.n
In this guidance:
must denotes a legal obligation; outlines o the law applying to engineering
workshops are provided in lined boxes on a blue background just like this
paragraph;
do and dont, should and should not and other recommendations such asn
use, it and prevent represent good practice, which, i adopted, will usually
be what is reasonably practicable in the given circumstances although there
may be other legally acceptable ways o achieving the same objective.
text in italics (where it is not a reerence, sub-heading or caption) outlinesn
requirements o Approved Codes o Practice which have been approved by theHealth and Saety Commission and give advice on how to comply with the law.
I you are prosecuted or a breach o health and saety law, and it is proved
that you have not ollowed the relevant provisions o the Code, a court will ind
you at ault, unless you can show you have complied with the law in some
other way
tips on good practice are indicated by phrases such as think about andn
consider
the early sections deal with how to tackle health and saety issues common ton
most engineering workshops; later sections deal with more speciic activities
which may not be carried on in all workshops.
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Managing health and safetySuccessul health and saety management in small engineering workshops is about
identiying the most requent and serious risks and adopting the right precautions,
taking account o time, money and resources.
This book identiies how most serious accidents happen and how most ill health is
caused in engineering workshops.
I you use machines or processes which are not described in this booklet, see
where they are similar to those described and work out whether they pose the
same hazards and whether the precautions suggested would be right, as well as
seeking urther advice.
The Management o Health and Saety at Work Regulations 1999outlined
Employers must:
assess risks to the health and saety o their employees and non-employeesn
arising in, or rom, the workshop, and review them when there is signiicant
change. Records o signiicant indings o the assessment must be kept where
there are ive or more employees
plan, organise, control, monitor and review the preventative and protectiven
measures taken as a result o the assessment
provide health surveillance where necessary (see pages 3031), or example ton
help control health risks rom metalworking luidsappoint any competent person(s) needed to help them comply with legaln
obligations, or example, when having liting equipment thoroughly examined
set out what should be done in case o serious and imminent danger in then
workshop, such as the spillage o a large amount o degreasing solvent
tell employees about the risks and precautions involved in their workn
train employees to work saely.n
You may need help beyond that given in this book. I you do, trade and employer
associations, such as EEF The Manuacturers Organisation, the Manuacturing
Technologies Association (or machine suppliers) or local Chambers o
Commerce, oer a range o advice and support. These sources o inormation are
given on page 102. HSE inspectors are always willing to help (see page 112 orinormation on HSE Oices).
Employers must also consult with all their employees (including sel-employed
workers classed as employed persons under health and saety law) on health
and saety matters. This will involve not only giving inormation but also listening
to and taking account o what employees say beore any health and saety
decisions are taken.
Key reerence:Management of health and safety at wor
Approved Code o Practice L21 HSE Books 2000 ISBN 0 7176 2488 9
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How most accidents and cases
of work-related ill health ariseAccident and ill-health data or such a wide and varied sector is available rom a
number o sources, including published HSE material, research papers, industry
statistics, and trade association and trade union publications, although it is diicult
to see the whole picture. The interpretation o the available data in this booklet is
based upon the experience o health and saety inspectors gained over many years
in dealing with the sector.
Accidents and ill health
There are many thousands o accidents and cases o ill health reported every yearin small engineering workshops. Almost two-thirds o all such accidents reported to
HSE arise rom the movement o people, goods and vehicles into, around and out o
workshops. O these movement accidents:
about hal involve liting and moving goods, andn
about hal involve slips, trips and alls and hitting stationary or moving plant andn
equipment.
Non-movement accidents usually arise rom the use o machinery; these account
or between 10 and 15% o all accidents.
Electrical accidents are not uncommon and requently have the potential or moreserious injuries than those recorded.
The most common occupational diseases are dermatitis, deaness, asthma and
vibration white inger, and back, hand, arm, shoulder and neck problems.
In any particular workshop risks which are relevant should be assessed. Those
likely to be o most concern include:
movement o people, goods and vehicles around the workshop, particularlyn
manual handling
machinery saeguardingn
hazardous substances, particularly metalworking luids, degreasing solvents, andn
dust or ume rom welding, brazing, soldering, coating and paintingnoise, andn
vibration.n
Costs
The costs o accidents and ill health to small engineering workshops may be
disproportionately high. Many employees are key workers whose loss through
injury or ill health severely disrupts production and lowers proitability.
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Injuries in engineering industries as reported to HSEs Field Operations
Directorate and local authorities 1998/99 2000/01
Non-fatal
98/99 99/00 00/01
(provisional)
Total
o which main cause involved:
15 267 15 078 14 668
Handling and carrying 5057 (33%) 4955 (33%) 4842 (33%)
Being struck (eg by alling
objects, moving machinery)
2826 (19%) 2872 (19%) 2698 (18%)
Slipping and tripping 2318 (15%) 2386 (16%) 2349 (16%)
Machinery 1778 (12%) 1734 (12%) 1641 (11%)
Falls rom height 935 (6%) 950 (6%) 910 (6%)
Workplace transport 331 (2%) 331 (2%) 360 (2%)
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Instant action checklistIf you want to start checking conditions right away use this instant action checklist
Check Instant action Long-term solution
Are xed machine guards in
position and secured?
Replace discarded guards and
secure them by a xing which
needs a tool to undo it.
I xed guards are being removed
or requent access (more than
once per shit) replace with
interlocking guards.
Are interlocking guards tted and
working?
I not, restore or repair them. Start a programme o preventative
maintenance.
Are all work area and passagewayfoors in good condition, kept clearand ree rom tripping and slippinghazards?
Keep all areas tidy and clean, andavoid trailing leads. Repair holes infoors and clear up spillages.
Provide non-slip foor suraces.
Mark gangways. Train and instruct
employees to keep workplace
unobstructed.
Is anyone required to lit or
carry heavy or bulky items and
equipment unaided?
Mark each load with its weight and
train all employees to lit and carry
saely.
See how the job may be avoided.
Provide mechanical aids where
possible.
Are any employees suering rom
dermatitis?
Get them to see their GPs and
provide suitable gloves i these
wont add to risks at machinery.
Try to remove the cause, eg
redesign the work so that handling
the source o contamination is
avoided.
Do metalworking fuids smell
unpleasant, particularly ater a
break rom machining?
Replace with clean fuid, ater
cleaning the machine and sump.
Try to nd and eliminate cause o
contamination.
Is there a visible ume mist or haze
in the workshop? Is there much
visible dust rom grinding, polishing
or blasting?
Check existing controls and
ventilation, remedy and, i
necessary, improve general
ventilation.
Prevent ume, mist, vapour or dust
rom being generated or capture
it close to source beore it can be
breathed and remove it rom the
workshop.
I you cant hear someone 2 m
away talking in a normal voice.
Make sure noise/machine
enclosures are closed and hearing
protection is being worn.
Assess, remove, reduce or enclose
noise at source.
Are vibration levels o hand-held
tools as low as possible?
Check suppliers data on
vibration levels. Keep equipment
maintained.
Buy and use reduced-vibration
tools wherever possible.
I all vehicles (including ork-lit
trucks) and pedestrians are kept.
Ensure that all drivers on site are
properly trained and ork-lit truck
operators authorised. Enorce
speed limits and reduce the need
or reversing.
Review all transport movements,
including delivery and customer
vehicles. Consider one-way
systems and clearly mark and sign
trac routes.
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How to use this book to start
your risk assessmentHere are some questions or inding out how dangerous or unhealthy your
workshop might be, and what to do about it.
Generally I the answer is yes
Think about the times when people have
been o work recently:
Could their absences be put down ton
conditions at work?
Is there a pattern to any o them?nHave the lessons o any recentn
accidents, near misses or cases o
work-related ill-health been missed?
Are there health or saety aspects o anyn
processes/operations you eel uneasy
about?
Investigate the possible causes
urther. The most likely ones are
outlined in this booklet.
The workshop itsel I the answer is yes
Are there any parts which are:
dirtyn
darknobstructedn
poorly ventilatedn
unnecessarily wet, orn
otherwise dangerous or unhealthy ton
move around or work in?
See pages 1417 or details o the
standards required.
Moving and working with articles by
hand; loading/unloading machines;
assembly and packing
I the answer is yes
Has anyone complained about or been o
work with a bad back, or persistent hand,
arm, shoulder or neck problems whichcould be put down to work?
What about the loads being moved?
Are they too:
heavyn
sharpn
largen
awkwardn
hot or cold?n
Does the job involve a lot o requent,
orceul or awkward movements?
Complete the more detailed
questionnaire on pages 114115
(or liting) and pages 116120 (orhandling). I you have problems,
the solutions suggested on pages
2027 may help.
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Vehicles (including ork-lit trucks) I the answer is yes
Is there any damage to the workshop or
plant and machinery rom vehicles?
Do vehicles operate close to pedestrians?
Are vehicles required to reverse?
This may indicate too ast/careless
driving or a poorly laid out
workplace and also potential or
injuries. Investigate urther.
Does anyone use vehicles without being
properly selected and trained?
See pages 2729 or advice
on the selection and training o
drivers.
Are the conditions in which they operate
too dark, obstructed, wet or otherwise
dangerous?
See pages 1417 or the minimum
standards required or workshops.
Metalworking machining and welding I the answer is yes
Is it dicult to hear someone talking (in a
normal voice) 2 m away at any point in the
workshop?
Carry out a noise assessment
pages 5156 tell you how to do this
and make the most o it and how to
reduce and control excessive noise.
Is it possible to reach (DONT TRY!) any
pressing, shearing, rotating, cutting or sawing
tools especially when: loading/unloading
components; removing swar; or making
adjustments?
See the individual machining
sections o this booklet, pages
5874, or advice on how to guard
machinery.
Is there any visible ume, dust, mist or
spray, or can it be smelt?
Viewing any suspected source with
a strong light (eg a Tyndall beam
or video light) behind it will show
where the ume is. See pages
3033 on how to avoid or control
harmul ume, dust, mist and spray.
See pages 122123 or guidance
on checking the health o people
working with metal cutting fuids.
Do some operators requently have to
manipulate or load/unload components which
are too heavy, hot, awkward or sharp?
See pages 2026 or advice on
liting and handling.
Do you machine, weld or work withcomponents containing cadmium, lead,
chrome or similarly hazardous substances?
See pages 3033 or advice onhow to control exposures to
hazardous substances.
Do employees complain about numb or
tingling ngers, dead hands on cold days
or nger blanching.
See page 57 or advice on how to
deal with hand-arm vibration.
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Cleaning and fnishing I the answer is yes
Do you use:
a vapour degreaser?n
other means o degreasing?n
See pages 7577 or how to
maintain it and prevent the need
to get in and clean it.
See page 75 or how to avoid
and control exposures to harmul
cleaners.
Do you paint components, or use coating
powders?
See pages 8591 or how to avoid
and control exposures to harmul
substances in paints and coating
powders.
Five steps to risk assessmentFor a longer look, take ive steps to your risk assessment
The Five Steps
Look or the hazardsn
Decide who might be harmed and hown
Evaluate the risks and decide whether precautions are adequate or moren
should be done
Record your indingsn
Review you assessment rom time to time and revise it i necessaryn
Key reference: 5 Steps to ris assessment INDG163(rev1)
(single copy ree or priced packs o 10 ISBN 0 7176 1565 0)
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Usingtheinormationontheprecedingpagesa
ndtherestothisbooklet,identiy
:
Possiblehazards
(changean
d/orinsertyourown
asnecessa
ry)
Whom
ightbeharmed
Whetherexisting
measuresare
adequate
Whatmoreneeds
tobedone
Dat
eofthenextreview
Handling
Transportandvehiclemovements
Metalworkin
gfuids
Cleaninganddegreasingsolvents
Machinery(includingsettingand
maintenance)
Weldingpro
cessesandmaterials
Noise
Vibration
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Working in and moving around
the workshopAbout two thirds o all accidents in small engineering workshops happen during the
movement o vehicles, people and goods. A sae, well-lit, clean workplace can help
prevent many o these.
Workplace (Health and Saety and Welare) Regulations 1992 andApproved Code o Practice outlined
A safe place of work
You must have:
buildings in good repairnprecautions such as ences or rails to stop people or materials alling romn
open edges *
space or sae movement and access, eg to machineryn
safe glazing where necessary, mared to mae it easy to seen
loors, corridors and stairs ree o obstructionn
good drainage at wet processes such as washing and cleaningn
windows that can be opened (i openable) and cleaned saely.n 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
outdoor routes kept sae during icy conditions, eg salted/sanded and swept.n
Safe movement
You must have:
sae passage or pedestrians and vehicles n you may need separate routes
level, even suraces without holes or broken boardsn
handrails on stairsn and ramps where necessary
sae doors, eg vision panels in swing doorsn
suraces which are not slipperyn
well lit outside areas.n
Work stations
Work stations and seating must it the worker and the work.Make sure that:
bac rests support the small of the bac and foot rests are provided wheren
necessarywor surfaces are at a sensible heightn
there is easy access to controls.n
Cleanliness
You must:
provide clean loors and stairs, which are drained where necessary and notn
slippery
provide clean premises, urniture and ittingsn
provide containers or waste materialsn
remove dust, reuse and trade-waste regularlyn
clear up spillages promptlyn
keep internal walls/ceilings clean.n They may need painting to help easycleaning.
* Particularly on the flat roofs of offices provided in small industrial units, which are often used for storage; proper stairs
should be provided for frequent access to these areas.
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Maintenance
Maintaining the workshop and the equipment in it may pose dierent hazards rom
those encountered in the normal run o production work. Contractors as well as
your own employees may be at increased risk, particularly during the repair and
cleaning o plant containing toxic, lammable or hazardous materials, machinery and
during work at heights or in conined spaces.
Key reerence:Worplace health, safety and welfare
Approved Code of Practice and Guidance on Regulations
HSE Books 2000 ISBN 0 7176 0413 6
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LightingPoor lighting is oten a actor in accidents and can also increase visual atigue.
The law* on lighting outlined
You must provide:
good lightn use natural light where possible but try to avoid glare
a good level o local lighting at work stations where necessaryn
suitable orms o lighting (luorescent tubes operating at mains requency mayn
be dangerous with rotating machinery when the rotating part can appear to
have stopped)
special ittings or lammable and explosive atmospheres, eg in spray booths, ton
reduce risks o ignition and explosion.
* Worplace Health, Safety and Welfare Regulation 1992.
Problems Typical activity Average
illuminance
lux (lx) in
work areas
Minimum
measured
illuminance (lx)
at any point or
a suitable place
General hazards
rom the movement
o people, machines
and vehicles in and
around the workshopand visual atigue rom
work requiring limited
perception o detail
General work in the
workshop, assembly
o large components
100 50
Visual atigue rom work
requiring perception o
detail
Sheet metal work,
general machining,
oce work
200 100
Visual atigue rom work
requiring perception o
ne detail
Drawing oce
work, assembly o
electronic and other
ne components
500 200
Avoid:
large dierences in the lighting o adjacent areasn
glare rom direct sunlight by providing blinds, or example, and rom directlyn
visible lamps by excluding them suiciently rom lines o sight when necessary
strobe eects by:n
supplying adjacent runs o light ittings rom dierent phases
providing a high requency supply
washing out the eect with local tungsten ilament lighting
i high intensity tungsten halogen or mercury lamps are used to provide local
lighting, manuacturers ilters should always be kept in place.
For the electrical saety o lighting systems see pages 3438.
Key reerence:Lighting at worHSG38 HSE Books ISBN 0 7176 1232 5
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General ventilation, temperature
and toiletsFans and/or additional air inlets (at low level) and outlets (at high level) may be
needed in workshops where there are no means o ventilation other than air leaking
in and out (particularly in units on some actory estates) and where:
work generates hazardous airborne pollutantsn
workshops have been sealed to conserve energy.n
Provide at least ive litres/second per occupant (eight is recommended or comort)
and air movement in the workshop o at least 0.1 to 0.15 metres/second.
Measure velocities, using specialist help i needed, at inlet ducts (to calculate airlows inwards) and inside the workshop (to calculate air movements).
The law on temperature outlined
You must provide:
a reasonable temperature and a thermometer inside workshops.n
The temperature should be at least 16C unless wor involves severe physical
effort, in which case the minimum should be 13C.
The law on toilets and washing acilities outlined
You must provide:
suitable and suicient (and adequately ventilated and lit) sanitary conveniencesn
and (nearby) washing acilities kept clean and orderly,in the minimum numbers
outlined below
separate rooms or men and women, except where they are or the use o onen
person and are capable o being secured rom the inside
hot and cold, or warm water with means o cleaning and drying.n
No o people in workshop No o WCs and wash stations
15 1
625 2
2650 3
5175 4
76100 5
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Alternatively, for sanitary accommodation used only by men, the following numbers
are recommended:
No o men No o WCs No o urinals
115 1 1
1630 2 1
3145 2 2
4660 3 2
6175 3 3
7690 4 4
91100 4 4
Mae separate calculations where groups such as office worers have separate
accommodation.
Key reerence:Worplace Health, Safety and Welfare Regulations 1992
Approved Code of Practice and Guidance on Regulations L24
HSE Books ISBN 0 7176 0413 6
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Lifting equipmentAlthough liting, supporting and handling equipment can lighten the load o manual
handling when properly used, many accidents happen when loads are dropped
rom liting equipment, either because o poor slinging, or equipment ailure or
overloading.
Always:
maintain all liting equipment, including that used only occasionally, such asn
attachments to ork-lit trucks
train all users, particularly in the use o slings where necessaryn
plan lits in advancen
ensure that the weight and the distribution o any load is not beyond then
capacity o the equipment being used
provide sae places o work rom which to maintain hoists and lits, particularlynat heights; do not allow overhead travelling cranes to work within 6 m o
persons on crane tracks
check the condition, type and size o any eyebolts used and ensure that then
thread type matches the hole into which it is to be screwed.
The law* on liting equipment outlined
The same regulations now apply to all liting equipment, which includes any
equipment used at work or liting or lowering loads, and liting accessories such
as chains, slings, eyebolts etc.
You should ensure that:
liting equipment is suiciently strong, stable and suitable or the proposed use,n
and marked to indicate its sae working load;
liting equipment is positioned or installed to minimise the risk o injury, eg romn
the equipment or the load alling or striking people;
every part o a load (including, or example, pallets and stillages) and anythingn
attached to the load and used in liting (including or example the liting points
on skips) is o adequate strength;
liting operations are planned, supervised and carried out in a sae manner byn
people who are competent;
liting equipment (including accessories) is thoroughly examined or any deectn
beore it is put into service or the irst time (unless it is new and is coveredby an EC declaration o conormity which is less than 12 months old). Where
the saety o liting equipment depends on installation conditions, it must be
thoroughly examined ater installation and beore being put into use or the irst
time. Periodic thorough examinations are also required at six-monthly intervals
or accessories and equipment used or liting people, and at least annually or
all other equipment; or at intervals laid down in an examination scheme drawn
up by a competent person.
* Lifting Operations and Lifting Equipment Regulations 1998.
Key reerence:Safe use of lifting equipment: Lifting Operations and LiftingEquipment Regulations 1998 L113HSE Books ISBN 0 7176 1628 2
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Moving goods safely by handThe unsae movement o goods by hand, either by liting or handling causes more
accidents and ill health in small engineering workshops than any other single
activity, especially to those most at risk, including the younger more inexperienced
employees, the older and/or less physically it, and those who may make an
existing injury worse.
Back injuries are very common as are hand, arm, shoulder and neck injuries,
particularly rom unsae, highly repetitive work. Cuts and abrasions rom sharp
edges are also very numerous.
Manual Handling Operations Regulations 1992 outlined
Employers must:
avoid the need or hazardous manual liting and handling i reasonablyn
practicable
assess the risk o injury rom any hazardous manual liting and handling whichn
cannot be avoided; and
reduce the risk o injury accordingly.n
Employees must:
ollow sae systems o work laid down by their employersn
use mechanical aids provided by their employers properlyn
remember to use the training provided on liting.n
Sharp edges
These cause as many as a third o all accidents in some engineering workshops,
resulting in cuts, abrasions, inected wounds, dermatitis, amputations and
occasionally ractures.
Those working with sheet metal, either lat or coiled, heavy sharp items, such as
tools and cutters, and scrap metal and swar are most at risk.
Consider how to avoid handling sharp edges, and i this is not reasonably
practicable, reduce exposure to them.
Reducing the risks
Ask your supplier to remove or protect sharp edges, eg by machining outn
sharp edges or itting plastic covers or padding.
Remove sharp edges or protect them beore handling.n
Avoid handling by using, or example, trays, jigs, holders or baskets.n
Minimise handling by automating processes by using, or example, conveyors,n
eed and discharge chutes.
Store articles correctly so that they are retrieved easily.n
Use personal protective equipment such as gloves, gauntlets and aprons, but only
where these do not add to other risks rom machinery, such as entanglement.
See Appendix 1 or checklists.
Key reerence:
Manual Handling
Operations Regulations
1992 Guidance onRegulations L23 1998
HSE Books
ISBN 0 7176 2415 3
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How to lift safelyHere are some important points, using a basic liting operation as an example.
Plan the lit. Where is the load to be placed?
Use appropriate handling aids i possible. Do you need help with the load?
Remove obstructions such as discarded wrapping materials. For a long lit, such as
loor-to-shoulder height, consider resting the load mid-way on a table or bench in
order to change grip.
Position the feet
Feet apart, giving a balanced and stable base or liting (tight skirts and unsuitable
ootwear make this diicult). Leading leg as ar orward as is comortable.
Adopt a good postureWhen liting rom a low level, bend the knees. But do not kneel or overlex the
knees. Keep the back straight (tucking in the chin helps).
Lean orward a little over the load i necessary to get a good grip. Keep the
shoulders level and acing in the same direction as the hips.
Try to keep the arms within the boundary ormed by the legs. The best position
and type o grip depends on the circumstances and individual preerence; but it
must be secure. A hook grip is less tiring than keeping the ingers straight. I you
need to vary the grip as the lit progresses, do it as smoothly as possible.
Keep close to the loadKeep the load close to the trunk or as long as possible. Keep the heaviest side o
the load next to the trunk. I a close approach to the load is not possible, slide it
towards you beore trying to lit.
Lit smoothly, keeping control o the load.
Dont twist the trunk when turning to the side.
I precise positioning o the load is necessary, put it down irst, then slide it into the
desired position.
(a) Plan the lit
(b) Determine the best liting
technique
(d) Pull the load in close to
your body
(c) Get a secure grip
Training or liting and handling
This should cover:
how to recognise harmul manual handlingn
appropriate systems o workn
use o mechanical aidsn
good handling technique.n
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Lifting and handling
Assessing risks
Assessment
Some o the important questions to ask
Job: Too high to lit/lower?
Too rushed?
Too ar to carry?
Too repetitive?
Too much twisting involved?
Load: Too heavy?Too large?
Too unstable?
Too hot/cold?
Too sharp?
Too diicult to grasp?
Work area: Too dark?
Too slippery?
Too obstructed?
Too many steps?
Individual: Fit or the job?In need o special consideration or training?
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Assessingrisks
Takingaction
Job
Short-terma
ction
Long-terma
ction
Loading/unloading
lorries/vansbyhand
Providehelporheavy
loads.Usetheright
personorthejob
Palletise
load(s).
Useork
-littrucks
Movingmaterials
to/rommachines
Breakdownloadsinto
easilyhandled
units/containers
Usecon
veyors/hoists/
ork-littrucks
Sorting/counting
compon
ents
Useapprop
riatetrained,
it,personnel
Asksup
plierstopre-sort
beored
elivery.Weigh
insteadocount.
Automatesorting
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Assessingrisks
Takingaction
Job
Short-terma
ction
Long-terma
ction
Loading/
unloading
machines
Raisestillages/binstoright
height/position
Automateload/unload
operations.Usehoists
and/or
mechanicalaids
Assemblingand
packing
Useappropriateit,trained,
personnelattherightplace.
Rotatethew
orktoprevent
toomuchre
petition
Provide
goodworking
environ
ment,welllitand
approp
riatemechanical
aidsan
dtoolstodo
theworkwithoutundue
strain.Designout
thenee
dormanual
assemblyandpacking
Preparing,
maintaining,moving
andrepa
iring
machinery
Useappropriateit,trained
personnel
Provide
unobstructed
access
andmechanical
aidsas
necessary
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Ergonomic machine operation,
assembly and packingTo minimise risks
avoid applying too much orce or too long or too requently using an awkwardn
posture o the hand, wrist or arm.
Consider
Reducing the force involvedby, or example:
keeping cutting tools sharpnproviding a larger gripping arean
supporting tools by means o balancers or tensioners (which may also helpn
minimise vibration).
Reducing highly repetitive movementsby, or example:
restructuring jobs so they contain more varied workn
automation.n
Reducing the need for awkward postures by, or example:
n
changing the orientation o the part being worked upon to enable the wrist tobe straight
moving the operator so work is more comortable.n
Training is vital, particularly:
to prevent the repetition o old, bad ways o workingn
to protect newer employees rom working too quickly too soon.n
Mostill healtharises from:
n prolonged orceul or repetitive gripping,
twisting, reaching or other movement withoutenough rest or recovery. This causes pain, a
restriction o joint movement and sot tissue
swelling, leading sometimes to permanent
disability, mostly in the hands, arms and
shoulders
liting and handling goods unsaely by hand.n
Consider workstations where both standing and
sitting is possible. In general it is less physically
stressul to sit, provided there are opportunities
or moving around.
A modiied handle design can
lead to a more comortable
hand position
Key reerence: Upper limb disorders in the worplace
HSG60 HSE Books ISBN 0 7176 1978 8
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Zone o
convenient
reach
Normal
working
area
Horizontal reach
distances in millimetres
0 100 200 300 400 500 600 700700 600 500 400 300 200 100
100
200
300
400
100
200
300
400
Ergonomic aspects to consider
For operating machinery
make requently operated hand controls easy to reach and workn
i seats are provided leave suicient room or knees and legsn
avoid bending and twisting to load/unload machines by having material/bins onn
racks which can be raised and lowered to keep them at waist height
consider lean-on or sit-stand, wheeled, sliding, suspended or ixed seatsn
see pages 9495 or normal chairs.n
For process or assembly work
arrange the work in a semi-circlen
provide a swivel chairn
bring the work to the workern
consider chairs with orward-tilting seats and backrests to help workers reachn
urther without loss o support, and consider work suraces and component
trays which slope towards the worker
racks or material and inished items should be adjustable so that work isn
comortable to reach and put away.
For precision work
To avoid tense postures, a orward tilting seat and a work surace whichnslopes to the worker may be particularly helpul.
Sit-stand seatTilting seat
Foldaway seat
Key reerence:Seating at worHSG57 1997 HSE Books ISBN 0 7176 1231 7
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Moving vehicles safelyLorries, vans, cars and other vehicles and mobile plant are involved in many accidents,
when reversing and manoeuvring in or around small workshops. These accidents
cause injuries and occasionally deaths when victims are run over or crushed.
To reduce risks:
Identiy and clearly mark sae routes and locations or deliveries andn
despatches which are:
away rom pedestrians as much as possible
in good condition
well lit at all times when being used
away rom vulnerable plant
marked clearly with suitably low speed limits.
Provide loading bays with an exit rom low level or a reuge to prevent crushingn
Do not allow untrained drivers to drive vehiclesn
Avoid reversing (eg by suitable traic routing or example) or provide help orn
reversing drivers i possible (eg a guide)
Use speed bumps to limit traic speeds where necessary and make sure theren
are gaps or any lit trucks which have to cross them
Select and train your own drivers with care.n
Loading and unloading vehicles
Accidents requently happen when people all rom vehicles. Avoid the need
to climb on loads (by using curtains on the sides o vehicles or mechanical or
proprietary sheeting systems), or provide sae access and sae systems o work. I
it is necessary to walk on the top o high loads, saety lines and harnesses should
be provided and worn.
Key reerences:Worplace transport safetyHSG136
HSE Books ISBN 0 7176 0935 9
Managing vehicle safety at the worplace
INDG199 HSE Books (single copies ree)
STOP
Clearance
Let Right
Move towards
Move away
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Lift trucksHow most accidents happen
Lit trucks, (powered and non-powered, pedestrian and rider-operated,) are
involved in many accidents in small engineering workshops. These are requently
caused by reversing unsaely, speeding, overloading, carrying passengers or liting
personnel the truck was not designed or, or drivers not being trained, and result
in many serious injuries and some deaths every year when victims are run over or
crushed.
Most ill health arises rom:
using diesel trucks in enclosed conined working areas, leading to breathingn
problems
poor seating and controls leading to back and upper limb disordersnpoor roadways which may cause vibration leading to back problems.n
The law* on mobile work equipment outlined
mobile work equipment includes ork-lit trucks and any other work equipmentn
which carries out work while it is travelling or which travels between dierent
locations where it is used to carry out work.
where mobile work equipment is used or carrying people, it must be suitablen
or this purpose. Measures must be taken to reduce the risks to the saety o
people being carried, the operator, and anyone else. These include measures
to reduce the risks rom equipment rolling over (most counter-balanced,seated centre-control ork-lit trucks have a vertical mast which prevents
them rolling more than 90). Measures, such as itting restraining systems, eg
seat belts, must also be taken to reduce the risk o anyone being crushed
between any part o the equipment and the ground i it rolls over or overturns.
you must ensure that sel-propelled work equipment (ie work equipmentn
which is propelled by its own motor mechanism) has appropriate acilities to
ensure the saety o people in the workplace, including acilities or preventing
its being started by an unauthorised person.
* Provision and Use of Wor Equipment Regulations 1998.
Approved Code o Practice on rider operated lit trucks operator training outlined
Employers to provide basic training by recognised instructorsn
Trainees to pass a test o their competencen
Records to be kept o training.n
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Sae lit truck operation
Get the right truck or the jobn
Maintain all lit trucks regularly in accordance with the manuacturersn
instructions, ensure seats are maintained to minimise unhealthy postures and
vibration
Select only suitable personnel or training as operators/drivers, authorisen
operators/drivers in writing
Avoid routes near vulnerable plant, eg lammable liquid stores, or protect suchn
plant
Segregate busy lit truck areas/routes rom pedestrian and working areas asn
much as possible, pay particular attention to barriers, layout, visibility, lighting
and warnings where lit trucks and people work alongside each other; enorce
rules or low speed and sae reversing
Ensure operating suraces are strong enough, well maintained and gradientsn
are not too steepTrain all employees on lit truck movements, i the lit truck is used on the roadn
(to load and unload, or example) provide a second person to help with traic,
as necessary
Rider operated lit trucks used regularly on the road or long periods, and theirn
drivers, must be licensed by the Department o Transport
Keep keys secure when trucks not being usedn
Do not use orks, pallets or bins to lit persons to work at heights unless thesen
are suitably modiied; use properly designed mobile work platorms i possible.
Key reerences:Rider operated lift trucs
operator training L117 HSE BooksISBN 0 7176 2455 2; Safety in woring with lift trucs HSE Books 2000
ISBN 0 7176 1781 5
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Controlling hazardous
substancesExposure to hazardous substances most requently occurs when:
machining (see pages 4044 or general control o hazardous substances andn
pages 4850 or the control o metalworking luids)
welding (see pages 7879)n
painting (see pages 85n 86) and
cleaning and degreasing (see page 75).n
The control o dust, ume, spray and vapour and the prevention o skin contact by
adequate personal protection will minimise risks o adverse health eects, but pay
particular attention to precautions when machining, welding, polishing or grinding:
nickel-copper and nickel-chrome alloys (ound in coins, magnets, chemical and oodn
process equipment and in the aerospace industry)
stainless steel and nickel alloys; stainless steel and chromium alloysn
lead and lead alloysn
copper alloys containing beryllium (commonly ound in the electrical industry andn
in high deinition tools and dies used, or example, in plastic injection moulding
machines)
cadmium-plated articles.n
The Health and Saety at Work etc Act 1974, section 6 in relationto the supply o substances or use at work outlined
Suppliers must:
ensure so ar as is reasonably practicable that the substance will be sae andn
without risks to health
provide adequate inormation about any risks to health or saety to which then
inherent properties o the substance may give rise.
Labels and saety data sheets supplied with hazardous chemicals contain important
inormation about hazards (see CHIP reerence page 106) to help you use them saely.
The most common health eects rom hazardous substances are:
skin diseases such as dermatitis rom metalworking luids and oilsn
lung problems, such as asthma, rom isocyanate paints and gluesn
poisonings, such as lead poisoning, andn
very rarely cancer, such as skin cancer rom certain mineral oils.n
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The Control o Substances Hazardous to Health Regulationsoutlined
You must:
assess risks to healthn
prevent exposure, or example by usingn
a less hazardous substance
a different process
where prevention is not reasonably practicable, control exposure by, for example,n
isolating or enclosing the process or, if this is not reasonably practicable, local exhaust
ventilation, and
where prevention or control is insufficient on its own, provide personal protectiven
equipmentinform, instruct and train employeesn
carry out air monitoring and health surveillance where necessary.n
A hazard may be deined as something that can cause harm such as the
chemicals in a tin o paint while a risk may be seen as the chance o harm
actually being done which can vary with how the paint is actually used; spraying
in an uncontrolled environment without personal protection could pose high levels
o risk.
Key reerence:Control of Substances Hazardous to Health Regulations 2002.
Approved Code of Practice and guidance L5 (Fourth edition)HSE Books 2002 ISBN 0 7176 2534 6
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Local exhaust ventilation (LEV)Selection and use
LEV is a requently used way o controlling exposure to hazardous substances by
drawing them away rom the breathing zones o workers into a hood and ductwork
connected to an extract an.
In many circumstances LEV may be cheaper and more eective than dilution
ventilation. (Dilution ventilation works by introducing resh air into the workplace to
lower the general level o the hazardous substances in the air.)
Heat losses rom LEV may be minimised by heat recovery systems or recirculation
o iltered air, but the latter only ater specialist advice to prevent the recirculation o
hazardous materials in harmul quantities.
The law* on maintenance, examination and testing o LEV outlined
In most small engineering workshops, employers must ensure that thorough
examinations and tests are carried out:
every 14 months or most processesn
every six months where metal articles are abraded or polished or more thann
12 hours a week.
Employers must also keep appropriate records or at least ive years.
See Appendix 6 for details which should be recorded.
* Control of Substances Hazardous to Health Regulations, regulation 9.
Someone with suicient training, knowledge, skills and experience is required
or the maintenance, examination and testing o LEV, and insurance companies
requently have the competence required.
To make the most o LEV
Get an expert to design andn
install the most appropriatesystem, with the right hoods/
enclosures, ductwork, air
velocities and cleaning and
iltration systems
Keep the hood as close to then
source o contamination as
possible
Make sure the an draws airn
away rom the operator
Make sure partial enclosuresn
are large enough to contain the
work and that sprayers do notstand between the workpiece
and point o extraction;
consider a turntable or heavy
itemsLEV used to help draw welding ume rom the
breathing zone o a welder
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Check and maintain the system, regularly particularly lexible ductworkn
Provide suicient lighting (suitably protected) within the enclosure to encouragen
work to be done within the extracted area.
Common causes o LEV ailure, which you can check easily and requently yoursel
to keep it working properly include:
physical damage to and poor positioning o hoods and boothsn
damaged and/or blocked ductworkn
blocked, damaged, unsuitable or incorrectly installed iltersn
too high/low water levels in wet collectorsn
wear or corrosion o an blades leading to build up o contaminant on bladesn
slipping drive belts to ansn
poor lubrication o an bearings.n
It helps to keep a record o these checks.
Key reerence:Introduction to local exhaust ventilation HSG37HSE Books ISBN 0 7176 1001 2
Spraying in the direction o exhaust ventilation air movement; a turntable can help a sprayer avoid
standing between the item being sprayed and the point o air extraction rom the booth
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Electricity
How most accidents happen
Most accidents arise rom contact withn live conductors or equipment made
live by aulty wiring and connections.
Equipment using 240 V ac may be as dangerous as that using 415 V ac,n
depending on circumstances.
Each year, the use o electricity causes atal and other injuries (eg burns) rom
electric shock and ire.
The law* on live electrical work outlined
No electrical work should be carried out live where there is a possibility o
contact with a potentially dangerous live conductor unless:
it isn unreasonable in all the circumstances or the equipment to be dead; and
it isn reasonable in all the circumstances or the work to be carried out on or
near it while it is live; and
suitable precautions (including, where necessary, suitable protectiven
equipment) have been taken to prevent injury, such as proper work planning
and the use o adequately trained and supervised sta.
* See key references.
Precautions necessary to prevent accidents require everyone in the workshop
(including the sel-employed) to use equipment saely and co-operate with the
employer where necessary.
Employers in particular need to:
develop a suitable system o maintenance or both ixed installations andn
portable equipment advice rom a competent person may be required
ensure that electrical contractors are competent or the work they are expectedn
to do; or example, are they registered with such organisations as the National
Inspection Council or Electrical Installation Contracting or equivalent?
select equipment which is suitable or the job (using reduced low-voltagen
equipment lowers the risk o serious injury)check that wiring and equipment is sound and properly installed, especially son
that protection equipment such as use and switchgear will operate adequately
in the case o aults. Universally accepted standards are described in BS 7671
Requirements for electrical installations
ensure any electricians working or you are competent. Levels o qualiicationn
established by the Electrical Joint Industries Board may be o help here, but
check that qualiications are relevant; a ully qualiied TV technician may not be
competent to re-wire a building.
Key reerences:Memorandum of guidance on the Electricity at Wor
Regulations 1989 HSR25 HSE Books ISBN 0 7176 1602 9;
Electrical safety and you INDG231 (single copies ree)
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Portable electrical equipmentUse this list to check whether you are managing the risks romportable electrical equipment. Have you:
prepared and implemented a system o maintenance or portable (andn
transportable) electrical equipment
made sure that all items o portable electrical equipment are included in then
maintenance system
decided how to deal with unauthorised equipment brought in by employees,n
eg portable, mains-operated radios
collected inormation on where and how equipment is used. This inormationn
will help you decide what sort o checks/inspections/tests are required and at
what requencies
provided straightorward training and inormation or all users (including yoursel)n
to help them carry out user checks when equipment is usedmade sure that all equipment receives a ormal visual inspection at appropriaten
intervals, carried out by someone who has been trained in what to look or
considered preparing brie written guidance relating to visual inspection,n
what to look or, and procedures to ollow when aults are ound (and when
unauthorised equipment is ound)
identiied equipment which will need periodic combined inspection and testingn
established how oten combined inspection and testing is appropriate (basedn
on the type o equipment, how it is used, where it is used and the results o
any previous checks/inspections/tests)
appointed someone with the appropriate knowledge, training and experience ton
carry out the inspection and testing
reviewed the results o checks/inspections/tests to identiy any common trendsn
and to conirm that the chosen inspection/test requencies are appropriate
made sure that the arrangements which you have made are being put inton
practice and that ollow-up action is being taken?
Remember that choosing the right equipment and carrying out visual
inspections are perhaps the most important ways to minimise the risks.
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Key reerence:Maintaining portable and transportable electrical equipment
HSG107 HSE Books ISBN 0 7176 0715 1
Activity Preerred equipment
Work inside metal tanks which may be
damp or humid (through condensation,
or example)
Use pneumatic power tools. Lighting, i
essential, should be 25 V dc CTE* max
and ixed out o reach.
Work on apparatus where water may
be present (on a metalworking luid
circulation system on a machine tool)
Work in close contact with metalwork
in cool dry conditions
Use equipment operating at voltages
o 50 V ac, 120 V dc or less. Higher-
voltage equipment should be built
to waterproo standard, eg BS EN
60529: 1992 Specification for degrees
of protectionprovided by enclosures.
The supply to earthed equipment
should incorporate back-up protection
which automatically disconnects the
supply in the event o a ault, preerablyearth monitoring.
Ad hoc maintenance work and outside
work in good weather
Use equipment operating at voltages
o 50 V ac, 120 V dc or less (110 V ac
CTE may be used in conjunction with
all-insulated or double/insulated tools).
Frequent cleaning o ventilation louvres
is necessary.
Reduced low-voltage equipment is
preerred such as 110 V CTE.
* CTE: centre tapped to earth.
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Common problems with flexible
leads, their plugs and socketsand how to avoid themMany accidents causing burn and shock injuries which are sometimes atal arise
rom poorly maintained and damaged leads, plugs and sockets.
Problem Precaution
Failure to select the right
equipment or the job/
environment
Choose the right equipment. For example in
a heavy abrication shop, armoured, heat-,
oil- and re-resistant leads will oten benecessary. Select reduced low voltage
equipment (110 V ac CTE max) whenever
possible.
Failure to give adequate support
to suspended cables (such as
on pendant control leads or
overhead cranes)
Use a wire or chain to relieve the cable o
tension.
Poor joints in cables Replace cables rather than repair them,
particularly those used or a long time, or or
short lengths when the cost o repair may be
more than replacement; or longer lengths cut
o the damaged part i it is close to an end oruse a proprietary plug/ socket which provides
both electrical and mechanical protection or
cables. (I a coupler is used the socket must
be on the supply side and the plug on the
cable connected to the apparatus.)
Repairs should be carried out only by
competent personnel; insulation and sheath
damage can be repaired by vulcanising or
using compatible proprietary sel-sealing
material together with a heat shrinkable plastic
sleeve to give the nished joint necessary
insulating value, strength and waterproong.
Insulating tapes alone are unsatisactory.
Leads trailing too long may
prevent circuit protection rom
operating within designed limits
Provide more convenient sockets, closer to
work.
Cables and conductors
insuciently protected and liable
to damage
Where liable to damage, or example in a busy
area, re-route or provide a suitable cover, eg
a conduit.
Cables and conductors too
oten fexed, which may cause
damage to the insulating sheath
or conductor
Check regularly, especially where the cable is
terminated into the apparatus concerned, and
repair or replace as necessary.
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Problem Precaution
Damage to cables and
conductors by portableequipment such as soldering
irons and portable grinders
Secure leads as ar as possible out o harms
way, where risk o damage is minimised.
Arcing when plugs withdrawn on
load
Above 16 A provide a switch (interlocked with
plug i possible) to enable currents to be saely
broken beore withdrawing plug.
Weight and leverage o adaptors
damaging socket outlets
Do not use adaptors or other
plug-in devices where their weight and
leverage may damage socket outlets. Provide
sucient socket outlets or, i necessary, use
purpose made, portable multi-socket outlets.
Failure o plug cord grips Ensure that it is the sheath which is being
gripped not the conductors; do not remove
plugs by pulling leads.
Use the correct type o plug (particularly or
armoured lead). Consider heavy-duty industrial
plugs. Ensure it is terminated as per the
manuacturers instructions.
Loss o securing screws or plugs Check them regularly, and replace missing
ones.
Screened and armoured fexible
cables incorrectly terminated in
smaller portable equipment
Secure the whole cable using purpose-made
glands/terminations tted by a skilled person
where necessary.Overheated extension lead drums Unwind lead rom drum completely beore
use.
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Pressurised plant and systems
The law* on pressurised plant and systems outlined
All plant and systems must be designed, constructed and installed to preventn
danger
Systems must be properly maintainedn
Modiications or repairs must not cause dangern
There must be a written scheme or examination o certain pressure vessels,n
such as air receivers, steam boilers, ittings and pipework, drawn up by a
competent person
Examinations as set out in the written scheme must be carried out by an
competent person
Records must be kept in most cases.n
Pressure testing
Accidents, some atal, occur during pressure testing when the energyn
contained in the vessel under test is released with explosive orce
Wherever practicable, avoid using compressed air, steam or gas (whichn
contains more than 200 times the energy o water o the same volume)
Use hydraulic (liquid) pressure with suitable precautions and always, i possible,n
beore leak testing (using air, steam or inert gas) components not intended as
pressure vessels, eg vehicle uel tanks, radiators, small castings, storage tanks
and oil drums.
Injection injuries
Injuries, occasionally atal, may be caused by accidental or deliberate injectionn
o material and/or compressed air either through the skin or into a body oriice
Ordinary working clothes do not signiicantly resist the penetration on
compressed air into the body
High-pressure luid guns may inject material at 3n 7000 psi and cause serious
injuries. Care should be taken to avoid accidental injections
Horseplay should be strictly orbiddenn
Because the degree o injury may not always be immediately apparent, medicaln
advice should always be sought ater compressed air penetration occurs or is
suspected.
Key reerences:*Safety of pressure systems. Pressure Systems Safety
Regulations 2000. Approved Code of Practice HSE Books ISBN 0 7176 1767 X
Compressed air safetyHSG39 HSE Books ISBN 0 7176 1531 6
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MachiningHow most accidents happen
Most accidents at all types o machine, including automatic and CNC machines,
happen to operators during normal operation when:
loading/unloading componentsn
removing swarn
taking measurements and making adjustments (to the coolant supply inn
particular).
On manually operated machines, the most dangerous machine movements are
the rotating, cutting, shearing, sawing or pressing movements o tools, particularly on:
pressesndrilling machinesn
milling machinesn
lathesn
metal cutting sawsn
guillotines andn
grinding machines.n
Hands are most requently injured, the most numerous injuries being cuts
and abrasions, many o which are severe. Broken bones and dislocations are
numerous. Amputations o ingers and hands are not inrequent and there are
some atalities, oten arising rom entanglements, every year. Eye injuries are also
common.
On automatic and computer controlled machinery, a larger proportion o
accidents happens at automatically and computer controlled clamps, axes, tables,
swar removal equipment, chucks and other work handling equipment.
At all types o machinery a large number o accidents happen to setters,
electricians and maintenance personnel during set-up, inspection, ault-inding,
maintenance and repair.
Most ill health arises rom:
unsae loading/unloading and handling o components, in particular when highlyn
repetitive, which may cause back injuries and upper limb disordersskin contact with metalworking luids, or example when preparing luids orn
handling components, which may cause skin irritation and dermatitis
breathing in aerosols, oil mists and umes rom metalworking luids duringn
machining which may cause irritation o the eyes, nose and throat, and
occasionally breathing diiculties such as bronchitis and asthma
sharp edges and swar which may cause cuts which exacerbate dermatitisn
high noise levels which may cause deaness most requently at machinesn
which generate impacts when operating, higher speed machines or groups o
machines running together
vibration, particularly when grinding.n
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Saety measures
To prevent access to dangerous movements during batch production atn
manually operated machines use ixed guards with:
jigs and ixtures (such as sliding trays) to load and unload components away
rom the tools
sae means o removing swar (such as a hook or rake which may be
inserted through small openings in ixed guards) and adjusting coolant (such
as taps outside ixed guards).
Use ixed and interlocking guards or saety devices providing equivalentn
protection at automatic and CNC machines to ensure all dangerous movements,
not only tools, are guarded (see pages 4344 and individual machines or urther
guidance on guarding CNC machines).
Control noise by engineering means at source or adapt and extend guards to serven
as noise enclosures (eg by lining them with noise absorbent materials). (See pages5153.)
Use guards to help enclose and control hazardous substances with LEV wheren
appropriate.
Manually operated machines used inrequently or one-o operations such asn
those oten ound in toolrooms may require constant adjustment and close
observation; guards may also need to be readily adjustable and allow close
observation.
Training essentials
Operators should know:
what the main dangers are, how the main saeguards work and who should ben
notiied o deective ones
how to start, operate and stop the machine saelyn
what to wear (eg protective equipment) and what not to wear (eg loose clothingn
at some machines)
how ton
load and unload components
remove swar, and
adjust coolant low saely
not to clean machines using compressed air to blow material awayn industrialvacuum cleaners or brushes should be used
how to work saely with any metalworking luids used.n
Maintenance and setting personnnel should know:
that beore inspection, cleaning, maintenance and repair, machines must inn
general be switched o and isolated
where power is necessary, how to work saely, or example by using:n
written systems o work
permits to work on complex or hazardous plant, and
warning signs
how to maintain metalworking luids to minimise health risks.n
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Key reerence:Provision and Use of Wor Equipment Regulations 1998 ACOP
and Guidance on Regulations L22HSE Books ISBN 0 7176 1626 6
The Provision and Use o Work Equipment Regulations 1998outlined(equipment includes machinery)
Employers and others must ensure that:
suitable equipment is provided or the jobs involvedn
inormation and instruction are adequaten
equipment is maintained in good working order and repairn
training is provided or operators and supervisorsn
equipment is saeguarded to prevent risks rom mechanical and other speciicn
hazards
equipment is provided with appropriate and eective controlsn
maintenance is carried out saelyn
some work equipment is subject to inspection to ensure that is sae to usen
(see below).
The Regulations also contain requirements relating to mobile work equipment
(see page 28) and power presses (see page63).
The Provision and Use o Work Equipment Regulations 1998 impose requirements
relating not just to preventing access to dangerous parts o machinery, but also to
the ollowing:
inormation and instructionn
inspectionn
sae maintenance operationsn
starting and stopping machines saely (including emergency stops)n
control systemsn
means o isolating work equipment rom sources o energyn
stabilityn
lightingn
markingsn
warning devices.n
You will need to carry out risk assessments on your existing machinery in order
to identiy whether it complies with all o the requirements. You can use the risk
assessment proorma in Appendix 3 to help.
Inspection o work equipment
Inspection o work equipment should be carried out where a signiicant risk o injury
(one which could oreseeably result in a major injury or worse) may result rom:
incorrect installation or reinstallation o the equipmentn
deterioration o the work equipment leading to danger, orn
as a result o exceptional circumstances which could aect the sae operationn
o the work equipment (or example, i it is damaged).
Inspection will be necessary when equipment or parts o equipment deteriorate and
lead to danger and where this will not be adequately controlled through operator
checks and normal servicing regimes. It will not thereore apply to everyday risks at
work equipment, which can be detected and rectiied during routine operator checksand maintenance.
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Key reerences:Provision and Use of Wor Equipment Regulations 1998
ACOP and Guidance on Regulations L22 HSE Books ISBN 0 7176 1626 6
Engineering machine tools: Retrofitting CNC EIS19 HSE Books (ree)
The purpose o an inspection is to identiy whether the equipment can be operated,
adjusted or maintained saely and that any deterioration (such as damage or wear)
can be detected and remedied beore it results in unacceptable risks.
Inspections should include visual and unctional checks o the equipment, and
sometimes testing. This will depend on the complexity o the equipment, on
where and how it is used, and on what the risks to health or saety could be i the
equipment is operated in an unsae condition.
A risk assessment should be carried out to determine whether an inspection is
necessary and, i so, what orm it should take. The assessment should also state the
intervals at which inspections should be carried out. Records o the assessment and
the inspections should be kept.
Some examples o equipment which is likely to be subject to inspection:
Hydraulic presses and press braesnNon-lifting parts of for-lift trucsn
Die-casting machinesn
Computer controlled (CNC)
machiningHow most accidents happen
From trapping at, or contact with, tools, clamps, tables, swar removal equipment,
chucks and other work handling equipment, during normal operating cycles when
clearing blockages and swar, loading/unloading, cleaning and making adjustments.
Many accidents also occur during ault inding, setting, and repair and maintenance
because saeguarding is inadequately speciied, poorly designed, not understood
by the user, and/or misused.
Most ill health arises in the same ways as at conventional machines, rom poor
handling (see page 20), metalworking luids (see page 48), and noise (see
page 51), but risks rom:
aerosol mists rom metalworking luids may be higher because o highern
operating pressures and speeds, and
noise, particularly rom high-speed cutting (and especially rom groups on
machines operating together) may be higher.
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Key saety measures
As the degree o computer control may vary rom:
complete control o several dierent machines working together with associatedn
equipment (such as loading/unloading devices), to
partial control o one aspect o a single machine (such as constant surace speedn
cutting on a microprocessor enhanced lathe)
provide saeguards appropriate to the risks posed. For example, at a ully
programmable CNC lathe (where many sequences o high-speed, high-power machine
movements may be under computer control) complete enclosure by ixed and
interlocking guards or their equivalents is appropriate.
At a microprocessor enhanced mechanical lathe, however, where only constant
surace speed cutting is under computer control, complete enclosure may not benecessary and saeguards more appropriate to a manually operated lathe may suice.
Where the speed and power o machine movements under computer control leads to
risks o injury:
provide ixed and interlocking guards (or equivalent saeguards) to prevent access ton
all such machine movements, not only to metalcutting tools work zone enclosures
may be necessary
arrange interlocking so that power to dangerous machine parts is removed whenn
interlocking guards are open or movements are limited to sae increments or speeds,
which are automatically prevented rom rising to unsae levels
use enclosing guards to help reduce noise, and control emissions o mists, ume andn
vapour, either rom metalworking luids or the material being machined
make sure you understand which saety unctions depend on computern
control and how to check and maintain them. I you dont understand, ask your
supplier to explain
check that vision panels intended to contain parts which may be ejected rom then
machine are suitably designed and constructed, have suicient strength and are well
maintained.
A range o CNC systems are available that can be itted to previously manually
operated machine tools, such as milling machines or lathes. Theses systems provide
a selection o eatures which can signiicantly improve the productivity o the machine
and the quality o the work produced. When machines are retroitted, new hazards and
the increased risks to the operator that are associated with CNC machines may beintroduced. Automation also changes the way the operator interacts with the machine
and, to some extent, the way the hazards may be presented to the operator.
Because o the change rom manual to automatic operation a retroitted machine should
be subject to a risk assessment. Fixed and interlocked guards which prevent access
to the danger zone during the automatic cycle should be normally provided. Where it is
necessary to have powered movement o a machine element, with the interlocked guard
open, eg or setting purposes, this should be done under limited speed conditions with
hold-to-run controls.
Detailed consideration should be given to the saety-related parts o the machines
control system. A number o BS EN standards provide speciic guidance on thismatter and urther inormation should be available rom the control system component
supplier.
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Buying and selling machinery
New*
A buyer o new machinery should look or the CE mark, which should indicate:
the suppliers claim to conormity with the Supply o Machinery (Saety)n
Regulations, which implements the Machinery Directive in the UK
the machinery meets essential health and saety requirements to eliminate risksn
o injury rom most sources
there should be little i anything urther to do to make the machinery sae in
Instructions or use are ollowed.
I you buy a machine with a CE mark, assess that it is sae and without risks to
health by, or example, checking it against the standards on any similar machinesyou may already have; it should at least meet current standards. You can use the
risk assessment proorma in Appendix 3 to help check the machine.
An outline of what is defined as machinery from the Supply oMachinery (Saety) Regulations
An assembly o linked parts or components, at least one o which movesn
including the appropriate actuators, control and power circuits, joined
together or a speciic application, in particular or the processing, treatment,
moving or packaging o a material
An assembly o machines which, in order to achieve the same end, aren
arranged and controlled so that they unction as an integral whole
Interchangeable equipment modiying the unction o a machine which isn
supplied or the purpose o being assembled with an item o machinery by
the operator himsel save or any equipment which is a spare part or tool
A saety component placed on the market separately rom machinery ton
ulill a saety unction when in use and the ailure or malunction o which
endangers saety or health.
For a seller o new machinery the CE mark among other things should be a
claim or the most commonly used machine tools in engineering that at least:
hazards, where reasonably practicable, have been designed outnmechanical dangers are saeguarded with guards and saety devices itted andn
working together with clear instructions provided on how risks not saeguarded
are to be avoided
the machine is as quiet as is reasonably practicable with noise reduced atn
source or enclosed (the noise emission level must be stated in Inormation or
use)
steps have been taken to control emissions o harmul substances when then
machine is working by, or example, containment or by providing or connection
to extraction equipment
* New means new to the European Union. An old, second-hand machine from the Far East or EasternEurope, 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.
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instructions or use are provided to indicate clearly in English how the machinen
may be saely installed, operated, maintained, removed or dismantled; where it
is not immediately clear how saeguards work as on some computer controlled
machinery clear inormation should be provided on:
how they work
how they may be checked
how to maintain them, and
what to do in case o aults/ailures
inormation on vibration is provided and vibration minimised or hand-heldn
machines
metalworking luids can be cooled where necessary, delivered and removedn
saely with risks o contamination minimised, eg rom ilter blockages or high
working temperatures; inormation or use should speciy how to use luids
saely at the machine.
Supply o Machinery (Saety) Regulations 1992 and Amendment
Regulations 1994 outlined
I you are a responsible person or the supply o new machinery or, rom outside
the EU, new or secondhand machinery or the irst time:
AS A COMPLETE MACHINE (such as a lathe)n
AS INTERCHANGEABLE EQUIPMENT TO MODIFY THE FUNCTION OFn