the printers's guide to health and safety printers...screen printing and cleaning 60 use of...

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Health and Safety Executive

The printer’s guide to health and safety

This is a free-to-download, web-friendly version of ‘The printer’s guide to health and safety’ (Second edition, published 2002). This version has been adapted for online use from HSE’s current printed version.

Youcanbuythebookatwww.hsebooks.co.ukandmostgoodbookshops.

ISBN 978 0 7176 2267 2 Price £12.50

Whatever role in printing, this book can help you comply with the law and reduce the risks of injuries and ill health. The new edition includes safety guidelines on a wider range of processes and up-to-date advice resulting from research into the causes of printing accidents. It also deals with recent changes in legislation and has a comprehensive index.

HSE Books

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© Crown copyright 2002

Firstpublished1998Secondedition2002

ISBN9780717622672

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

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

ThisguidanceisissuedbytheHealthandSafetyExecutive.Followingtheguidanceisnotcompulsoryandyouarefreetotakeotheraction.Butifyoudofollowtheguidanceyouwillnormallybedoingenoughtocomplywiththelaw.Healthandsafetyinspectorsseektosecurecompliancewiththelawandmayrefertothisguidanceasillustratinggoodpractice.

ThePrinter’sguidetohealthandsafety Page3of187


What is PIAC?

ThePrintingIndustryAdvisoryCommittee(PIAC)wasformedinJuly1979toadvisetheHealthandSafetyCommission(HSC)onmattersconcerningtheprintingindustry.ThemembersofPIACarenominatedbytheCBIandtheTUCandappointedbyHSCtoworktogetherwiththeHealthandSafetyExecutive(HSE)toadvisetheindustryonhealthandsafety.

Why does PIAC exist?

Everyyearpeopleworkingintheprintingindustryareseriouslyinjured.Manyotherssufferillhealthwhichpreventsthemfromdoingtheirnormalwork.Almostallofthesecasescouldbeprevented.

PIACisdeterminedtotakeactiontoimprovehealthandsafetyperformanceintheprintingindustry.AspartofthisprocessPIAChasproducedthisguidancebooktohelpthoseresponsibleforhealthandsafetyintheindustryunderstandtheirresponsibilitiesandtakethenecessaryaction.

Acknowledgements

Assistancefromthefollowinginprovidingphotographsisgratefullyacknowledged:

MatthewsthePrintersHarmsworthQuaysPrintingLtdDeltaDisplaysHeidelbergGraphicEquipmentPrintoWrappingsGossGraphicSystemsLtdPalamaticHandlingSystemsLtdStrategicSafetySystemsHealthandSafetyLaboratoryNewsInternationalNewspapersLtd

Members of the Printing Industry Advisory Committee

MrADPorter Chair,HealthandSafetyExecutiveMrIWilcock BritishPrintingIndustriesFederationMrRAHudspith Graphical,PaperandMediaUnionMrDBarker Graphical,PaperandMediaUnionMrAClarke Graphical,PaperandMediaUnionMrGMcintyre NationalUnionofJournalistsMrGCooper NewspaperSocietyMrGMcNab ScottishPrintEmployersFederationMrBPurkis NewspaperPublishersAssociationMrWStothard BritishPrintingIndustriesFederationMsSWhittaker NewspaperPublishersAssociationMrMGriffiths Graphical,PaperandMediaUnionMrMDWilcock Secretary,HealthandSafetyExecutive

Members of PIAC safety and human factors sub-committee

MrMDWilcock Chair,HealthandSafetyExecutiveMrRAHudspith Graphical,PaperandMediaUnion



MsZDenmark JarrardPrintingLtdMrPChambers StrategicSafetySystemsMrDWallis GossGraphicSystemsLtdMrPBryant GossGraphicSystemsLtdMrMMcGilly WestFerryPrinters

TheassistanceprovidedbySPeace,SHuggans,JHardy,KMarriottandTStonleyisgratefullyacknowledged.



ContentsIntroduction

What is in this book for me? 11

The law and guidance 11

Chapter 1 Managing health and safety

Relevant legislation 13

Health and safety in the printing industry 13

Setting your policy 14

Organising your staff 15

Planning and risk assessment 15Riskassessment 15

Monitoring 17Inspectionandchecks 17Evaluationofaccidents,illhealthandnearmisses 17

Auditing and review 17

Home working 18

Lone working 18

Accidents and emergencies 18Thelawandreportingaccidents 18Investigatingaccidentsandemergencies 19Dealingwithemergencies 21Firstaid 21

Permits to work 22

Working time 22Theproblem 22ApplicationofWTR 22Workingtimelimits 23Healthassessment 23Nightshiftriskassessment 23Records 23Peoplewithmorethanonejob 24Goodtimemanagementisgoodbusiness 24

Control of contractors 24Thelawandmanagingcontractors 24Fivepracticalstagesforworkingwithcontractors 25Contractorsandyouremployees 27



Consulting employees on health and safety 27Inspectorsandenforcement 28Powersofinspectors 28

Chapter 2 Training


Training methods 29

Induction training 30Trainingsafetyrepresentatives 32

Chapter 3 Workplace and transport safety


Fundamentals of workplace health and safety 33Safeplaceofwork 33Lighting 34Movingaroundthepremises 34Designingworkstations 34Cleanliness 35Hygieneandwelfare 35

Safe movement of vehicles 36

Loading and unloading of vehicles 36

Safe stacking and storing 37Generalprinciples 37Rackinginstallations 38Useofpallets 38Reelstorageandstacking 39Manualbreakingdownofpyramidstacks 40

Lift and clamp trucks 40Thelawandlifttrucks 40Healthproblems 41Safetyguidelinesforlifttrucks 41Safetyguidelinesforautomaticguidedvehicles(AGVs) 43

Asbestos in buildings 43Whereisasbestosfoundinbuildings? 44Whatshouldyoudo? 44

Chapter 4 Health risks


Occupational health and rehabilitation 46Occupationalhealthservices 47Healthsurveillance 47Rehabilitation 48



Hazardoussubstances 48Exposurelimits 49AssessmentunderCOSHH 50Preventionorcontrolofexposure 50

Chemical hazards in printing 52

Specific process health hazards 54Designandartwork 54Graphicreproduction 54Platemaking 54Deletionfluids 54Lithographicprinting 54

UK Printing Solvent Substitution Scheme 55Ultraviolet(UV)curablematerials 56

Acrylate Preference Criteria 57Screenprintingandcleaning 60Useofisocyanates 62Disposalofwaste 63

Noise 63Doyouhaveanoiseproblem? 63Measuringnoiselevels 63Noiseandthelaw 63Noisereduction 64Reducingexposure 65Providinghearingprotection 65Commonproblemsandsolutionsforprinters 65Hearingloss 66

Manual handling 67Thelawandmanualhandling 67Riskassessmentfilter 67Whataretherisks? 68Reducingtherisks 69Handlingnewspaperandmagazinebundles 69Training 69Assessingandreducingrisks 71Repetitivehandling 72HowtoassessandtackleULDs 72

Radiation 74Lasers 74Ultraviolet(UV)light 75Infraredsources 76Staticeliminators 77

Skin disease (dermatitis) 77Whatisdermatitis? 77Affectedareas 78Symptoms 78Work-relatedsubstances 78Whyemployersshouldtakeaction 79



Other health issues 79Workplacestress 79Newandexpectantmothersatwork 80Drugsandalcohol 81Passivesmoking 81Humidifierfever 81Legionellosis 82Asbestos 82

Local exhaust ventilation (LEV) 83Maintenance,examination,testingandthelaw 83Selectionanduse 83MakingthemostofLEV 83CommoncausesofLEVfailure 83

Personal protective equipment (PPE) 84PPEandthelaw 84Respiratoryprotectiveequipment(RPE) 85Eyeprotection 86Skinprotection 86StorageofPPE 87

Chapter 5 Process safety


Basic rules of machinery safety 89Machineryguarding 89Interlockingguards 91Machinecontrols 92Controldefinitionsforpressmovement 93

Safe systems of work 94Safesystemsofworkforpresscleaning 94Otheressentialsafeguards 95

Machinery maintenance 95

Safety hazards by process 95Pre-press 95Digitalprintingandcopying 97Printing 98Publishingrooms 117Envelope-makingmachines 119Guillotines 122Othercuttingmachines 127Looseknifepunchingmachines 128Flat-bedcuttingandcreasingmachines 129Autoplatens 130Hand-fedplatensusedforcuttingandcreasing 130Labelpunchingmachines 132Roundcorneringmachines 132Foldergluermachinesusedinboxmaking 132Bindery 133Booksewing 136Finishingmachines 139



Acquiring machinery and other work equipment 146Thelaw 146Wordofcaution 147

Chapter 6 Electricity


General hazards and precautions 148

Particular hazards and precautions for printing 149

Inspection and maintenance 149

Electric shock 150

Chapter 7 Fire and explosion

Relevant legislation 152Riskassessment 152

Fire risk management 152

General fire precautions 155

Process fire precautions 156Mainfirehazards 156Thefiretriangle 156

Charging electrically operated lift trucks 158

Lithographic printing 159Explosionrisksinblanketwashsystems 159

Explosion risks in flexographic and gravure 161

Precautions for dryers 162

Precautions for coating machines 163

Precautions for laminators with glue application 163

Chapter 8 Maintenance


What needs maintenance? 165

Statutory testing and thorough examination 165MaintenanceandinspectionrequiredbyPUWER98 166

Safety during maintenance work 167Permitstowork 167Isolationandlock-offprocedures 168



Appendices 1

Appendix1Safeguardingterms 169Appendix2Exampleriskassessmentform 172Appendix3Assessinghazardsinasmallprintworks 173

References 174

Further information 185



IntroductionEveryyearpeopleintheprintingindustryareinjuredandbecomeillthroughwork.Theaimofthisbooklet,andothersproducedbyPIAC,istohelpallthoseinvolvedinprinting,includingemployers,employeesandsuppliers,toidentifythemaincausesofaccidentsandillhealthandtoexplainhowtoeliminatethehazardsandcontroltherisks.Ifyouareamanager,itwillhelpyoumanagehealth,safetyandwelfareinyourcompanyandcomplywithyourlegalresponsibilities.Ifyouareanemployeeorsafetyrepresentativeintheindustry,itshouldprovideyouwithsomeusefulinformationaboutwhatstandardstoexpectandhowaccidentsandillhealthmightbeprevented.

What is in this book for me?

Thisbookisa‘one-stopshop’givinghealthandsafetyadvicetoprinters.Allprinters,largeandsmall,shouldfindsomethingofinterestinit.Chapters1,2,3,6,7and8covergeneralhealthandsafetyissuesandwillbeusefultoeveryone,fromnewspaperproducerstohigh-streetcopiersordigitalprinters.Chapters4and5aremorespecialisedandcoverspecifichazardsarisingfromsubstancesorprocessesusedbyprinters.Tohelpyoufindyourwayaroundthebook,eachchapteriscolourcodedandacomprehensiveindexcanbefoundattheback.

Asprintingisawide-rangingactivity,thisbookdoesnotdealwitheveryhazardwhichmayariseoreveryprecautionthatcanbetaken.Itdoes,however,outlinesomeofthemoreseriousandfrequenthazardsandwaysofdealingwiththem.

Thereare‘Relevantlegislation’sectionsatthestartofeachchapterwhichlisttheActs,regulationsetcwhichapplyandmayalsocontainsummariesofthemainlegalrequirements.Thesesectionshaveabluebackground.

Youmayfindthisbooktellsyouallyouneedtoknow,butifnot,the‘References’sectionwillhelpyoufindoutmore.Thisisstructuredinchapterordertomakeiteasiertouse.Seethe‘Furtherinformation’sectionforusefuladdresses.

Lookingatyourbusinessinthewaythisbooksuggestswillhelpyoustaysafe.Followingtheadviceinitwillmeanthatyouaregoingalongwaytosatisfyingthelaw.

The law and guidance

Theterm‘reasonablypracticable’isusedinmuchofUKhealthandsafetylawandwillbefoundinthisbook.Thismeansthatthedegreeofriskinaparticularjoborworkplaceneedstobebalancedagainstthetime,trouble,costandphysicaldifficultyoftakingmeasurestoavoidorreducetherisk.Inotherwords,itwouldhavetobeshownthataparticularriskisinsignificantinrelationtothesacrificeneededtoreduceit.Thisbookwillhelpyoudecidewhatisreasonablypracticableforyourcompany.

Theword‘must’indicatesadefinitelegalrequirement.‘Do’sanddon’ts’,‘shoulds’and‘shouldnots’andotherrecommendationsrepresentbestandgoodpracticewhichwillleadtocompliancewithwhatisreasonablypracticable.However,theremaybeotherlegallyacceptablewaysofachievingthesameobjective.TherequirementsofanApprovedCodeofPractice(ACOP)haveaspecialstatusinlaw;acourtwillfindfaultifyouhavenotfollowedtheCodeordonesomethingequallyeffective.



‘Thinkabout’,‘consider’andsimilarphrasescontainatiporhintwhichmaynotamounttoapreciselegalrequirementbutindicateanapproachtoahealthandsafetyproblemwhichoughttobeconsidered.

A‘safeguard’isameansofreducingrisktohealthand/orsafety.



Chapter 1 Managing health and safetySee the ‘References’ section at the back of the book for details of publications which relate to Managing health and safety

Relevant legislation

TheHealthandSafetyatWorketcAct1974(HSWAct)andtheManagementofHealthandSafetyatWorkRegulations1999placedutiesoncompaniesandindividualstoensurethatadequateprovisionsaremadeforhealthandsafetyatwork.Directors,managersandotherresponsiblepeopleallhavedutiesundertheAct.Commitmenttotheeffectivemanagementofhealthandsafetyshouldcomefromthetop.

Youmustensure,sofarasisreasonablypracticable,thehealth,safetyandwelfareofyouremployeesandanyotherswhomaybeaffectedbywhatyoudo.Thiswillincludethosewhoworkforyouascasualworkers,part-timers,traineesandotherswhovisityourpremises,egcustomersorcontractors.Itwillalsoincludethosewhomaybeaffectedbywhatyoudo,egneighbours,clients,salespeople,membersofthepublicandthosewhouseproductsorequipmentyoumake,supplyorimport.

Inaddition,employersmust:

n identifythemeasurestheyneedtotakebycarryingoutariskassessment(andifyouemployfiveormoreyouwillneedtorecordthemainfindings);

n haveawrittenhealthandsafetypolicy(ifyouemployfiveormorepeople);n haveadequatearrangementsforhealthandsafetyand,inparticular,forthe

effectiveplanning,organisation,control,monitoringandreviewofthepreventivemeasuresrequiredunderhealthandsafetylaw;

n provideemployeeswithanynecessaryinformationandtraininginsafepractices;

n appointoneormorecompetentpersonstohelpthemtakethemeasuresnecessarytocomplywiththeirlegalduties.ThisincludesrequirementsimposedbytheFirePrecautions(Workplace)Regulations1997.Acompetentpersonisregardedasapersonwhohashadenoughtraining,experienceorknowledgeandotherqualitiestoenablethemtoprovideeffectivehelp.Employersshouldappointtheirownemployeesforthisroleifpossible.

Health and safety in the printing industry

TheprintingindustryisasignificantemployerintheUnitedKingdom.Thereareapproximately340000workersemployedinover15000companies,makingtheindustryoneofthelargestemployersinthecountry.

AccordingtoHSE’sannualstatistics,theprintingsectorhasaloweraccidentratethanassociatedindustriessuchaspaperandboardproduction.However,thereareaspectsoftheprintingsector’shealthandsafetyrecordwhichcauseconcern,inparticularahighrateofmachinery-relatedaccidents(fivetimeshigherthaninotherindustries)andthenumberofcontractorsinvolvedinaccidents.Therearealsosignificanthealthrisks,suchasdermatitisandotherproblemsassociatedwiththeuseofsolventsthatneedtobeconsidered.



Detailedanalysisofthepatternofaccidentsintheprintingindustryshowsmanysimilaritiestoindustryingeneral,buttherearekeysector-specificdifferences.Particularpartsofthemanufacturingprocess-printingitself,andwarehousing,yardandwastedisposalactivities,consistentlyemergeasthemainareaswhereaccidentsoccur.

Theproportionofaccidentsattributabletofinishingvariesconsiderablyfrom13%inthenewspapersectorto40%inbookbindingandfinishing.Almostaquarterofallaccidentsresultfrommanualhandling,usuallylifting.Manyarealsocausedbycontactwithmovingmachinery.

Foraccidentsdirectlyinvolvingsomeformofmachinery,almostthree-fifthsoccurwhiletheinjuredpersoniscleaningorpreparingtheprintingmachinery,ie‘make-ready’.Oneinfivesuchaccidentsoccurastheinjuredpersonisattemptingtofreeablockageintheirmachine.Cuts,strainsandpinchinjuriesarethemostcommontypeacrosstheindustry.Manyoftheseaccidentscanbeeasilyprevented.Mostwarehouseaccidentsinvolveworkplacetransportorresultfrommanualhandling.

Employersintheprintingsectorneedtolookcarefullyattheirriskassessmentsandthecontrolmeasurestheyusesuchasphysicalsafeguards,safesystemsofworkandtraining.Comparewhereyouarenowwiththebenchmarkstandardsfortheindustrydescribedinthisbook.Thispublicationgivesyouagoodstartingpointforallyourhealthandsafetyneeds.

Setting your policy

Ifyouemployfiveormorepeople,youmusthaveawrittenstatementofyourhealthandsafetypolicy.Itneedstobeacarefullyprepared,well-thought-outandup-to-datedocumentbasedoncommitmentatseniormanagementlevel.

Thestatementshouldbespecifictoyourfirm,settingoutyourgeneralpolicyforprotectingthehealthandsafetyofyouremployeesatworkandspecifyingtheorganisationandarrangementsforputtingthepolicyintopractice.Theprimarypurposeofthisdocumentistosetoutyourbasicactionplanonhealthandsafetyanditshouldleadtobetterstandardsintheworkplace.

Thepolicyneedsto:

n statewhatyourgeneralaimsarewithregardtoyouremployees’healthandsafety.Thestatementshouldbesignedanddatedbyseniormanagementtomakethefirm’scommitmenttothepolicyclear;

n clearlyshowwherethedutiesforhealthandsafetylie.Responsibilityforhealthandsafetyrestsatthehighestmanagementlevel,however,individualsateverylevelwillhavetocontributeandacceptsomeresponsibilityforcarryingoutthepolicy;

n describethesystemsandproceduresinplaceforensuringthehealthandsafetyofyouremployees.Youcanlinkthistootherdocumentssuchasriskassessments,fireprecautionsandyourCOSHHassessment(seeChapter4),inwhichyouwillhaveconsideredtherisksthatariseinyourworkplaceandtheactiontocontrolthem.Yourpolicyshouldbeclearlysetout;

n bebroughttothenoticeofyouremployees,egbygivingthemacopy;n bereviewedandifnecessaryrevisediftheorganisationchangesornew

hazardsarise;n besupportedbysufficientresources,egenoughfinance,peopleandtimeto

translatethepolicyintoaction.



Organising your staff

Thefour‘Cs’ofapositivehealthandsafetycultureare:

n competence-inrecruitment,trainingandadvisorysupport;n control-byallocatingresponsibilitiesandsecuringcommitment;n co-operation-betweenindividualsandgroups;n communication-includingoral,writtenandvisibleforms.

Askyourself:

n Dopeopleknowwhattheyshouldbedoingandhowtodoit?n Doyouconsultandinvolveyourstaffandthesafetyrepresentativeseffectively?

(See‘Consultingemployeesonhealthandsafety’laterinthischapter.)n Doyourstaffhaveenoughinformationabouttheriskstheymaybeexposedto,

thecontrolsprovidedandhowtousethem?n Doyouhavetherightlevelsofexpertise?Areyourpeopleproperlytrained?

(SeeChapter2.)n Doyouneedspecialistadvicefromoutsidetheorganisationandhaveyou

arrangedtoobtainit?

Planning and risk assessment

Systematicplanningforhealthandsafetyisneededsothathazardscanbeidentified,risksassessed,controlmeasuresandprioritiesdeterminedandthenecessaryresourcesallocated.Askyourself:

n Doyouhaveahealthandsafetyplan?n Ishealthandsafetyalwaysconsideredbeforeanynewworkisstarted?n Haveyouidentifiedhazardsandassessedriskstoyourstaffandthepublic,

andsetcontrolstandardsforpremises,plant,substances,procedures,peopleandproducts?

n Doyouhaveaplantodealwithseriousorimminentdangers,egfires,orchemicalspills?

n Arethestandardsimplementedandriskseffectivelycontrolled?

TheManagementofHealthandSafetyatWorkRegulations1999setoutbroadgeneraldutiesaimedatimprovinghealthandsafetymanagement.Amongotherthings,theyrequireprecautionstobeidentifiedbymeansofriskassessmentscarriedoutintheworkplaceandacompetentpersontobeappointedtohelpemployerscarryouttheirduties.

Risk assessmentThepurposeofriskassessmentistohelpemployersorself-employedpeopledeterminewhatmeasuresshouldbetakentocomplywithlegalduties.ThisincludesgeneraldutiesundertheHSWActandthemorespecificdutiesinotherActsandregulations.Oncedetermined,actionwillneedtobetakentoputthenecessarypreventiveandprotectivemeasuresinplace.

Formostcommonchemicals,PIAChasalreadydonemostoftheworkforyou.(SeeCOSHH essentials for printersandChapter4fordetails.)

Theriskassessmentneedstoconsider:

n thelevelofrisk;n whomightbeharmed;n whethersignificantrisksarebeingadequatelycontrolled.



Ahazardisanythingwiththepotentialtocauseharm,andriskisthechanceofharmactuallybeingdone.Forexample,acanofhighlyflammableliquidstoredinaclosedmetalcabinetinaworkroommaybeaflammablehazardbecauseofitsnaturebutthereislittleriskasitisstoredsafely.Theriskincreasesiftheliquidispouredintoanopencontainerbecausethereisthenadangerofspillage.Therisksignificantlyincreasesifpeoplearesmokinginthearea.

Thefollowingfivestepsneedtobefollowedwhencarryingoutariskassessment:

Step 1 Identify the hazards

n Takeacarefullookatwhatyoudoandhowyoudoit.Remembertoincludeeverythingliketransport,solventstorage,housekeepingandworkequipment.Youwillidentifynumeroushealthandsafetyhazardswiththehelpofthisbook.

n Thinkaboutwhatcangowrong,howpeoplecanbeharmedandwhereitmighthappen.Forexamplepeoplebeinghitbyavehicle,trappedinamachineorexposedtohazardouschemicals.

n Considertheworst.Couldtheybekilled,willtheylosealimborsimplybebruised?Thiswillhelpyoulaterwhenyouneedtoworkoutwhatactionyouneedtotakefirst.

Step 2 Decide who might be harmed and how

n Considerwhocouldbehurtifthingsgowrong.Includeyouremployees,contractorsandnewuntrained,unskilledoperativesandothervulnerablegroupssuchastheyoung.

n Donotforgetvisitors,maintenancestaffandmembersofthepublic.

Step 3 Evaluate the risks arising from the hazards and take the necessary remedial action

n Askwhetherexistingprecautionsareenoughtoprotectpeopleand,iftheyarenot,whatmoreneedstobedone.Donotassumepeoplecanconcentrateallofthetime.Checkexistingsafeguardsdowhatthey’reintendedtodo.Remember,badlydesignedguardscanbedefeatedand,ifnotproperlymaintained,willfail.(SeeChapter5formoredetail.)

n Userecognisedindustrystandards,suchaspublicationsfromtheHealthandSafetyExecutive(HSE),PIAC,theBritishPrintingIndustriesFederation(BPIF)orothertradeassociationsasabenchmark.

n ForchemicalsrefertoCOSHHessentials for printersandmanufacturers’datasheets.Forfurtheradvice,seeChapter4.Youneedtokeepuptodatewithdevelopmentssuchassafersolventsornewtypesofmachineryguarding.Refertosuppliers’instructionsanddatasheets.Askyourselfwhethertheprecautionsyouhaveinplacecomplywiththelaw,representgoodpracticeandreducerisksofarasisreasonablypracticable.

n Prioritiseyouractions.n Allocatenecessaryresources.n Implementprocedurestoensurethenecessaryworkwillbedone.

Step 4 Record your findings

n Ifyouhavefiveormoreemployeesyoumustrecordthesignificantfindingsofyourassessment.(AnexampleriskassessmentformisgiveninAppendix2.AschematicdiagramofhazardstoconsiderinanoverallassessmentofasmallprintingpremisesisgiveninAppendix3.)



Step 5 Review your assessment

n Youwillalsoneedtoreviseyourassessmentwhennecessary.Youmayfindthatyouneedtomakechangestoyourarrangementsafteryouhaveinvestigatedthecausesofanaccident.Onceimprovementshavebeenmade,rememberthatthingschangeandyouneedtocheckregularlythatprecautionsremaininplaceandareeffective.

Monitoring

Monitoringisamanagementresponsibilityandshouldtakeplaceatalllevels.YoursafetypolicyshouldincludearrangementsformonitoringanditisarequirementundertheManagementofHealthandSafetyatWorkRegulations1999.Monitoringshouldincludespotchecksandmoredetailedinspections.Reportsofallaccidents,nearmissesandillhealthcausedbyworkshouldbestudiedtoidentifyemergingtrendsorpatterns.Informationfrommonitoringhelpsyoutodecide:

n whatneedsimprovement;n whatprogressisnecessaryandreasonableinthecircumstances;n howthatprogressmightbeachievedagainstparticularrestraints(egresources

ortime).

Inspection and checksMonitoringcanbecarriedoutbyseveraldifferentmethods,eg:

n routinechecksbymanagers,supervisorsandmaintenancestaff,egtoursofinspection;

n statutorytestsandexaminationsbycompetentpersons,egoflifttruckchains,liftingequipment,andpressuresystemsbyengineeringsurveyors;

n reportingofdefectsbyemployees,egoperatordaily/weeklyinspectionofmachinerysafeguards;

n healthsurveillancebyaresponsibleperson,eginspectinghandsofprinterswhoworkwithUV-curedinksforsignsofdermatitis;

n investigationofincidentsandmonitoringofreportstoidentifyreasonsforfailuresincontrolsandthestepsneededtopreventarecurrence.

Evaluation of accidents, ill health and near missesAneffectivesystemforrecordingallrelevantincidentsisimportant.Recordsofaccidents/illhealthandnearmissescanbeusedtoidentifyproblemareasandtakerelevantaction.Alackofaccidentsdoesnotnecessarilymeanalliswell-goodluckmayhavebeenplayingarole.

Detailedinvestigationofincidentswillhelpyouidentifytheunderlyingcausesofallincidents.Itwillhelpyouhighlightweaknessesoromissionsinyourpolicyormanagementsystems.Thefindingscanbeusedtohelppreventrecurrenceandinitiatethenecessaryremedialaction(whichshouldbecarriedoutpromptly).See‘Accidentsandemergencies’.

Auditing and review

Healthandsafetyauditingaimstoprovideacomprehensive,independentcheckofworkactivities.Itwillreviewexistingarrangementsformanagingandmonitoringhealthandsafetyandidentifyanyshortcomings.Itprovidesfeedbacktomanagersonhowwellrisksarebeingcontrolled.Auditingisusuallymosteffectivewhenitiscarriedoutbypeopleindependentoftheareasbeingaudited,egfromanotherdepartmentorsite.



Auditingschemescanbedevelopedin-houseorcommerciallyavailableschemescanbeused.Anumberofconsultantsoperateschemesbutprintingfirmsneedtosatisfythemselvesthataconsultantisappropriate,sufficientlyqualifiedandcompetenttohelpintheirparticularoperation.

Theinformationobtainedfrommeasuringsafetyperformanceandauditingcanbeusedtoreviewhowwellyouaredoingandwhatmightneedimprovement.

Home working

Healthandsafetylegislationalsoappliestothoseemployeeswhoworkathome.Ifyouhaveemployeeswhodothis,youstillneedtoensuretheyarenotexposedtorisksfromtheworktheydo.SeetheleafletHomeworking: Guidance for employers and employees on health and safety(INDG226)forfurtheradvice.

Lone working

Solitaryworkersmayfaceparticularproblems.Withoutsupervisorsorco-workerspresent,theyarevulnerabletothenormalworkplacehazardsanddonothaveaccesstotheassistancetheycannormallycallon.Incertaincircumstancestheymaybemoreexposed.Forexample,staffleavinglaterthannormalmaybeunabletogethelpifthreatenedinthecarpark.Solitaryworkersshouldnotbeexposedtosignificantlymoreriskthanemployeeswhoworktogether.Precautionsshouldtakeaccountofnormalworkingconditionsandforeseeableemergenciesincluding,fire,illnessandaccident.ForfurtheradviceseetheleafletWorking alone in safety: Controlling the risks of solitary work(INDG73).

Accidents and emergencies

Asanemployeryouneedtoputinplacesuitablearrangementsforidentifying,recordingandinvestigatingallrelevantaccidentsandincidents.Certainaccidents,dangerousoccurrencesandincidencesofillhealtharealsoreportable.

The law and reporting accidentsTheReportingofInjuries,DiseasesandDangerousOccurrencesRegulations1995(RIDDOR)requireyoutoreportcertainaccidents,incidentsandoccupationaldiseasestoyourenforcingauthority.From1April2001therehasbeenanIncidentContactCentre(ICC)torecordthedetailsyousupply.ReportsnolongerneedtobemadetoyourHSEorlocalauthorityoffice.

RIDDORrequiresyoutodothefollowing:

n Keepdetailsoftheincident(eginyouraccidentbook).n Notifytheenforcingauthorityimmediately(viatheICC)ifanyofthefollowing

happenasaresultofwork:

– anybodydies;– anemployeereceivesamajorinjury(suchasabrokenarmorlegoran

amputationinjury)oranyotherpersonistakentohospitalimmediatelyasaresultofaninjurycausedbyyourworkactivities;

– anyoneisseriouslyaffectedbyanelectricshockorpoisoning;– ifthereisadangerousoccurrence,egafireorexplosionwhichstopswork

formorethan24hours,oracraneoverturns.



n Reportwithintendaysaccidentsatworkwhichresultinanemployeebeingabsentfromwork(orunabletodotheirnormaljob)formorethanthreedays.

n Reportcertaindiseasessufferedbyworkerswhodospecifiedtypesofworkassoonaspossibleonreceivingawrittendiagnosisabouttheillnessfromamedicalpractitioner.

Youcanreportincidentsbytelephone(08453009923),fax(08453009924),e-mail([email protected])orbyposttoICC,CaerphillyBusinessPark,CaerphillyCF833GG.

Investigating accidents and emergenciesAtthetimeofwriting,theHealthandSafetyCommissionwasconsultingonanewlegaldutytoinvestigateaccidents.Whatevertheoutcome,investigationofaccidentsandincidentsin-houseisimportanttoestablishthecausesandpreventivemeasuresneededtominimisetheriskoffurtheraccidents.Youshouldalsolookatnearmisses,minoraccidentsandpropertydamage.Itisoftenonlybygoodfortunethatsomeoneisnotinjured.Employersneedtoputproceduresinplacetoensurethefollowingstagesarefollowedifthereisanaccidentordangerousoccurrence:

n Takeanyactionrequiredtodealwiththeimmediaterisks,egprovidefirstaid,putoutthefire,isolateanydanger,fenceoffthearea,calltheemergencyservices.

n Iftheincidentisonethatmustbeimmediatelynotifiedtoyourenforcingauthority,consultthembeforedisturbingthesite.Eveniftheincidentisnotreportable,itissensibletotakephotographsandmeasurementsbeforedisturbingthesite.

n Obtainbasicfacts,egwitnessnames,plantcondition,substancesinuse,place,time,extentofinjury.

n Establishthecircumstances,egwhatwasbeingdoneatthetime.n Trytounderstandthesequenceofeventsleadingupto,duringand

immediatelyfollowingtheaccident.n Fromtheaccidentsequencewritedowntheimmediatecausesoftheaccident.n Fromthislistidentifytheunderlyingcausesoftheaccident.(Youmayhaveto

repeatthisstepseveraltimestogettotherootcausesoftheaccident.)Forexampleifanindividualdidnotfollowaprocedure,trytoidentifywhytheydidnot-itcouldbeduetolackoftraining,anunrealisticprocedureorlackofsupervision.

n Foreachoftheunderlyingcausesidentifiedconsiderwhatstepsneedtobetakentopreventarecurrence.AtthispointconsulttheguidanceissuedbyPIACandHSEforspecificinformationonhowtocontrolhazards.

n Thinkalsoiftheinitialresponsetotheaccidentwasadequate,egwhethertherewasaneffectivefirst-aidresponseorwhethercorrectspillagearrangementswereused.

n Considerifanyofthelessonslearnedapplyelsewherewithintheorganisation.n Consideriftheriskassessmentsneedtobereviewedinthelightofyour

findings.n Throughouttheinvestigation,itisimportantnottojumptoconclusions,and

involveyourtradeunionappointedsafetyrepresentativesoremployeesasappropriate.Thinkabouteachstep,andifnecessaryplanwhatyouaregoingtodoBEFOREithappens.Thefollowinginvestigationchecklistmaybeuseful.Althoughitisnotanexhaustivelist,itgivesexamplesofquestionsthatmightberelevant.



Investigation checklist

As a result of this assessment you should then take action to stop the accident happening in future

Factors involved in the accident

Why this occurred Action to be taken

Machineryorequipmentfailure,eglackofguards,interlocksormaintenance

Workingpracticeorprocedure,eglackofsupervision,customandpracticeornoprocedure

Theworkingenvironment,egstateofthefloor,fumesornoise

Theindividual,eglackoftraining,poorinstructionsorbadlylabelledcontrols

Substancesused,egsolventsorinkshavechanged

Do you need to: Yes No

Improvephysicalsafeguards,egprovideaninterlockedguard?

Provideanduselocalexhaustventilation?

Usemechanicalhandlingaids,egpileturnersormobilelifts?

Introducebettertestandmaintenancearrangements?

Improveworkmethods?

Provideandusepersonalprotectiveequipment?

Makechangestosupervisionandtrainingarrangements?

Reviewsimilarrisksinotherdepartments?

Setupsystemstoriskassessnewplantandchemicalsbeforeuse?

Reviewproceduresforcontractors?

Updatestandardsandpolicies?

Introducemonitoringandauditingsystems?

Givetraininginmanualhandlingtechniques?

Substitutechemicalswithsomethinglesshazardous?



Dealing with emergenciesWhenthingsgowrongpeoplemaybeexposedtoseriousandimmediatedanger.Specialproceduresarenecessarytodealwithemergenciessuchasseriousinjuries,explosion,fire,electrocution,powerfailuresandchemicalspills.

Youshouldprepareanemergencyplanespeciallyifamajorincidentatyourworkplacecouldinvolveriskstothepublic,theneedtorescueemployeesorco-ordinationoftheemergencyservices.

Todothisyoushouldcarryoutariskassessmentandconsider:

n theworstthatcouldhappen;n howpeople-thoseinchargeandothers-areinstructedandequippedtodeal

withtheproblems;n howtheemergencyservicesshouldgetaccessontothesite;n howthealarmwillberaised(don’tforgetnightandshiftworking,weekends

andholidays);n howandwhentocalltheemergencyservicesandhowtohelpthemwith

informationwhentheyarrive;n thatyouwillneedtonotifythefireauthorityifyouhaveover25tonnesof

certaindangeroussubstancesonsite;n wheretogotoreachaplaceofsafetyortogetrescueequipment;n providingemergencylighting;n whetheryouhaveenoughemergencyexitstoalloweveryonetoescapequickly

(andsuitablearrangementstoensurethatemergencydoorsandescaperoutesarekeptunobstructedandclearlymarked);

n nominatingcompetentemployeestotakecontrol;n pre-planningandpractisingemergencyplantshutdownsormakingprocesses

safe.Importantitemssuchasshut-offvalves,electricalisolatorsetcshouldbeclearlylabelledtoavoidconfusion;

n ensuringyouhaveadequatefirst-aidprovisionandfirstaiders;n trainingpeopleinemergencyandevacuationproceduresandrememberingthe

needsofpeoplewithdisabilities.

First aidTheHealthandSafety(First-Aid)Regulations1981requireyoutohaveadequatearrangementsforfirstaid.Theminimumfirst-aidprovisionforeachworksiteis:

n apersonappointedtotakechargeoffirst-aidarrangementsincludinglookingaftertheequipmentandfacilitiesandcallingtheemergencyserviceswhenrequired.Anappointedpersonwillneedtobeavailablewheneverpeopleareatwork;

n asuitablystockedfirst-aidcontainer(easilyaccessibleincasesofemergency);

n informationforemployeesonfirst-aidarrangements(includingnoticestellingpeoplewherethefirst-aidequipment,facilitiesandpersonnelcanbefound).

Do you need to: Yes No

Changemake-readyproceduresorothersystemsofwork?

Institutehealthsurveillance,egforUVinkusers?



Additionalprovisionwillbeappropriateinmanycases,forexample:

n Iftherisksofinjuryandillhealtharisingfromtheworkasidentifiedinyourriskassessmentaresignificant,trainedfirstaidersmaybeneeded.Theymayalsobeneededwherelargenumbersofpeopleareemployed.Theymustbegiventherighttrainingandholdacertificate(whichwillbevalidforthreeyears).Refreshercoursesandre-examinationwillberequiredwhenoldcertificatesexpire.InformationontrainingcoursesandorganisationscanbeobtainedfromyourlocalEmploymentMedicalAdvisoryService(whocanbecontactedviayourlocalHSEoffice).

n Wheretherearespecificrisksfromworkingwithhazardoussubstances,dangerousmachineryandloads,considerspecifictrainingforfirstaiders,extrafirst-aidequipment,sitingoffirst-aidequipment,informingemergencyservicesandfirst-aidrooms.

n Whereworkplacesareremotefromemergencymedicalservices,informlocalmedicalservicesofyourlocationandconsiderspecialarrangementswiththem.

n Whereyouhaveinexperiencedworkers,disabledworkersorpersonnelwithspecialhealthproblems,considertheneedsforspecialequipmentandlocalsitingofequipment.

n Formobilepeople,egsalesstaff,afirst-aidkitneedstobeprovided.

Ifyouhaveasmallcompanywithfewemployeesitmaybemoreappropriatetohaveapersontrainedinemergencyfirstaid.Asyourcompanygrowsyouwillneedtomakesureyourfirst-aidprovisionremainsadequate.

Permits to work

Somehigh-riskactivitiessuchasentryintoconfinedspacesorworkinglargemachinerywillrequireapermittowork.Thisisaformalwrittensystemusedtocontrolcertaintypesofpotentiallyhazardouswork.Thepermitdetailstheworktobedoneandthenecessaryprecautionstobetaken,andformsanessentialpartofmanysafesystemsofworkformaintenanceactivities.SeeChapter8formoredetails.

Working time

ThemainaimoftheWorkingTimeRegulations(WTR)istoensurethatworkersareprotectedagainstadverseeffectsontheirhealthandsafetycausedbyworkingexcessivelylonghoursorhavinginadequaterest.Atthetimeofpublication,proposalsforchangeswereunderconsideration,howeverfurtherguidancecanbefoundinthebookletYour guide to the Working Time RegulationsandA short guide to the Working Time Regulations(availablefromDTI,Tel:08456000925orfromtheDTIwebsite:www.dti.gov.uk).

The problemWorkinglonghourscanhaveamajoreffectonthehealthandsafetyofemployees-thosewhoaretiredaremorepronetomakemistakes,whichcouldresultinaccidents-ortheycoulddeveloplong-termadversehealtheffects.Forhistoricalorproductionreasonsthereisacultureoflonghoursinsomepartsoftheprintingindustry,butinmanycompaniescarefulmanagementofproductionpressuresandplannedpreventivemaintenanceprogrammescanresolvemostoftheproblemsthatcanarise.

Application of WTRIfyouemployworkers,nightworkersoryoungpeopleyouarecoveredbythe



WorkingTimeRegulations.Youneedtotakeparticularcaretoknowtherulesaboutyoungpeople(betweenschoolleavingageand18yearsold)andpeoplewhoworkatnight,sincespecialrequirementsapplytothem.Mostpeopleworkinginprintingarecoveredbythelaw.

Working time limitsForadultworkersthelimitis48hoursperweekaveragedovera17week‘referenceperiod’.Theaveragecanbecalculatedoverdifferentperiodsdependingonthecircumstances.Whereatradeunionisrecognised,employerswhowanttoextendthereferenceperiodwillneedtomakeanagreementwiththattradeunion.Workforceagreementsapplyintheabsenceofarecognisedtradeunion.

Currentprovisionswhichallowforindividual‘opt-out’fromtheaverage48hourslimitareexpectedtoendwithinthenexttwoyears.Companieswillneedtotakeaccountoftheendingofthe‘opt-out’andmakearrangementstocoverthis.

Nobodyshouldworkforlongperiodswithoutabreak.Theseareneededtobreakupmonotonousorcontinuousprocessesandtherearespecialentitlementsforyoungworkers.

Health assessmentWorkinglonghours,especiallyatnight,candisruptthe‘bodyclock’.Workerswhoaretoworkatnightmustbeofferedafreehealthassessmentbytheircompanybeforetheystartnightworkandthenatsuitableintervals,forexamplebeforetheintroductionofanewshiftpattern.Takeadvicefromanoccupationalhealthprofessionalwhenyoudesigntheassessment.

Night shift risk assessmentTheWTRrequireariskassessmentforthespecialrisksassociatedwithnightworkwhichisinadditiontotherequirementslaiddownbytheManagementofHealthandSafetyatWorkRegulationsforageneralriskassessmentandtheControlofSubstancesHazardoustoHealthRegulations(COSHH)forariskassessmentforharmfulsubstances.ForadviceonmakingtheseassessmentsseeearlierinthischapterandCOSHH essentials for printers.

AWTRriskassessmentisneededbecausetasksmaybecomemoredifficult:

n whenperformedatnightindarkness;n whenthefullrangeofdaytimeservicesmaynotbeavailable;n whereworkersfinddifficultyadjustingtodifferentworkingpatterns;n wherethereisincreasedriskofviolencetostaff;n whereworkersaresubjecttoincreasedstressbecauseofreducedsupervision

ormanagement.

Theassessmentmay,forexample,identifytheneedforemergencyorsupplementarylightingtobeinstalled.Actontheassessmentandprovidewhatevercontrolmeasuresmightbeneededsuchasmorelighting,additionaltraininginfirstaid,additionalsecuritymeasures,orperhapsadjustthefrequencyofbreaks.

RecordsYoudonotneedtokeepspecialrecords.Mostcompaniesfindthattherecordstheyalreadykeepofhoursworkedforotherpurposes,likepay,aremorethanadequateforWTR.However,ifyouhavenotpreviouslykeptrecordsofanysortthenWTRdoesrequireyoutokeepsufficientrecordsofthehoursyouremployeeswork.



People with more than one jobSomepeoplehavetwooreventhreejobs,forexampleworkingatnightinapub.Wherethisisthecasethenthetotalhoursworkedshouldbeaddedtogetherwhencalculatingworkingtime.Itisuptoyoutomakereasonableenquiriesaboutanysecondjobsdonebyyourstaffandtoco-operatewithotheremployerstocalculatetotalworkingtime.

Good time management is good businessPromotionofgoodtimemanagementresultsinbetterhealthandsafetymanagement.Itallowsemployerstoplanproperlyforpeaksandtroughs,workerstoplanaproperregimeofworkandfamilylifeandresultsinaworkforcethatis‘happy,healthyandhere’,increasingproductionefficiencies.

Figure 1 Contractedworkcanbesmall-orlarge-scale

Control of contractors

Contractorsareemployedtoworkintheprintingindustryformachineryorbuildingsmaintenanceandmodifications,installationofplantandotherequipment.However,nowadayscontractorscanalsobefoundthroughouttheindustry,asfreelancedesigners,cleaners,caterersandinlogistics,doingarangeoftasksthatwerepreviouslydonebyemployees.Everyoneworkingonyourpremisesorforyouneedstoknowwhathealthandsafetystandardstheyhavetoachieve,includingnotionallyself-employedlabour-onlycontractors.

The law and managing contractorsTheHSWActplacesdutiesonyouandyourcontractortoprotect,sofarasisreasonablypracticable,thehealthandsafetyofemployeesandotherpeoplewhomaybeaffectedbyyourworkactivities.Allpartieswillneedtoco-operatewitheachotherandco-ordinatetheirworktoensureeveryoneiscomplyingwiththeirlegalduties.

InadditiontotheHSWActandtheManagementofHealthandSafetyatWorkRegulations1999,youshouldbeawareoftheConstruction(DesignandManagement)Regulations1994.TheseRegulationsplacedutiesonclients,clients’agents,designersandcontractorstoplantheirapproachandtakehealthandsafetyintoaccount.Healthandsafetyneedstobeco-ordinatedandmanagedeffectivelythroughoutallstagesofaconstructionproject,fromconceptionthroughtosubsequentmaintenanceandrepairarrangements.

Clientsmustbereasonablysatisfiedthattheyonlyusecompetentpeopleasplanningsupervisors,designersandprincipalcontractors.Theyneedtobesatisfiedthatenoughresources,includingtime,havebeenorwillbeallocatedtoenabletheprojecttobecarriedout.Theyalsorequireclientstoproviderelevantinformation-goodexamplesarethelocationofservicesandasbestos-containingproductswithinbuildings.(SeeChapters3and4forfurtherinformationonmanagingasbestosinworkplacebuildings.)



TheConstructionDesignandManagementRegulationsapplywhereconstructionworkisexpectedtolastmorethan30daysorinvolvefiveormorepeopleon-siteatanyonetime.Thiswillincludetheinstallationoffixedplantwherepeopleareliabletofallmorethan2m,suchasinstallationoflargerweb-fedpresses.Wheredemolitionordismantlingofastructureistakingplace,theRegulationsapplyregardlessofthelengthoftimeorthenumberofpeoplecarryingoutthework.

ForfurtherinformationseeA guide to the Construction (Health, Safety and Welfare) Regulations 1996(INDG220)andtheApprovedCodeofPracticeontheConstruction(DesignandManagement)Regulations1994(HSG224).

Ifyouhavepeopleworkingunderyourcontrolanddirectionwhoareself-employedfortaxand/orNIpurposes,theyarelikelytobetreatedasyouremployeesforhealthandsafetypurposes.Youmaythereforeneedtotakeappropriateactiontoprotectthem.Ifyouareinanydoubtaboutwhoisresponsibleforthehealthandsafetyofapersonworkingforyouthiscouldbeclarifiedandincludedinthetermsofthecontract.However,remember,youcannotpassonalegaldutythatfallstoyouundertheHSWActbymeansofacontractandyouwillstillretaindutiestowardsothersbyvirtueofsection3oftheAct.

n Makecontractorsawareofyourcompanysafetyculture.

Stage 2: Choosing a contractor

Contractorsshouldbechosencarefully.Beforeyouchooseacontractor:

n DecidewhatareyourcriteriaforselectingcontractorsandplacingthemonanApprovedList?Assesstheircompetenceinhealthandsafetymatters.Thisappliestoseniorpeopleaswellasthosewhowillbeworkingonyoursite.

n Decidewhatsafetyandtechnicalcompetenceisneeded.Hasthecontractorgotit?n Askquestionsabouttheirsafetyperformance.Howdotheymanagetheirperformance?Asktoseethe

writtenproceduresforsimilarpreviouswork-theiraccidentrecordmaybeagoodplacetostart.n Getevidence.Examinetheirtrainingandrelevantcertificates.Safetypassportschemesareagoodway

ofdemonstratingthetrainingofindividualworkers.

Five practical stages for working with contractors

As with all things a few simple precautions will save time and prevent accidents in the future. Just like managing your own employees, working with contractors will be made so much easier (and safer) if you follow these five practical stages:

Stage 1: Plan before you start

Decideafewgroundrulesbeforeyouevenstarttousecontractors.Ifthecontractorsaregoingtobeworkingwithyouforalongtimeitisespeciallyimportanttomakeplansaboutwhatyouareaskingthemtodoandhowyourownstaffwillbeworkingwiththem.

n Ensurethatyouhaveagoodplanningframeworktopulltogetheralltheseparateelementsofwhatyouareaskingthecontractortodo.Writeplansdown,meetandconsulteveryoneinvolved.

n Definethejob.n Identifythehazards.Considertheindividualelementsofthejobandtheeffectofeachpieceof

contractedworkonthewholeproject.n Assesstherisks.n Eliminateandreducetherisksthatyoucontrol.n Specifythehealthandsafetyconditionsthatyouwantthecontractortofollow.n Discussthesewiththecontractor/s.



n Gothroughinformationaboutthejobandthesite,includingsiterulesandemergencyprocedures.n Agreerespectiveresponsibilitiesforriskassessmentsandprecautions.n Askforasafetymethodstatement,riskassessmentorsafetypolicy.n Decidewhethersubcontractingisacceptableandusetheinformationgatheredtohelpyoumakeyour

decision.Ifitis,howwillhealthandsafetybeensured?n Ifyouhaven’tusedthecontractorbefore,asktotalktosomeoftheirpreviousclients.n Considerhowyouwillmonitortheirhealthandsafetyperformance.

Stage 3: Contractors working on site

Whentheyarriveonsiteyouneedtohavethegroundrulesinplace.TheseshouldbeagreedBEFOREthecontractorstartswork.Theycanincludethefollowing:

n Howdoyoucontrolaccesstoyoursite?Doeseveryonesigninandout?n Nameasitecontactforday-to-daycommunication-don’tjustwaitforsitemeetingstodiscussand

resolveproblems.Makesurethepersonappointediscompetentandtrained.n Reinforcehealthandsafetyinformationandsiteruleswithasimpleinductioncourseorasafetycheck

cardsettingoutyourrulesforeveryvisitor.Makesureemergencyproceduresarecovered.n Implementsafesystemsofwork,suchasforhotworkorworkonfragileroofs.n Howwillyourownoperationsaffectthecontractor’swork?n Whattools,plant,substancesandequipmentwillbeused?n Whatwillthearrangementsforpropersupervisionbe?n Checkthateveryoneunderstandsthejobbeforeyouallowworktobegin.n Don’tforgettoprovidefacilitiesforcontractors,iewashroom,toilets,canteenetc.

Stage 4: Keeping a check

Don’tjustleavethecontractortoit.Notonlycancostsspiraloutofcontrol,butsafetycantoo.

n Decidehowoftenyouoryourmanagersneedtomakecontactwithyourcontractors.n Isthejobgoingasplanned?Isthecontractorworkingsafelyandinthewaythattheyagreed?Checkif

therehavebeenanyincidentsorchangesinpersonnel?n Areanychangesorspecialarrangementsrequired?

Stage 5: Reviewing the work

Learnlessonsfromcontractingsothateveryone,includingyouremployeesandthecontractorcanimprovethewaytheywork.Beforeyoustart,plantoreview.

n Howdoyouplantoreviewthejobandthecontractor’sperformancewithallthoseinvolved,includingthecontractor?

n Duringthereview,askyourselfhoweffectiveyourplanningwas,howthecontractorperformed,andhowthejobwent.

n Recordthelessons,reviewandlinkthesetoyourselectionprocedures.



Contractors and your employeesAttimessuchasmajorrebuildingworkstheremaybelargenumbersofcontractorsonsite,oftenworkinginproximitytoyourownemployeesandeachotherandtoatightdeadline.Youneedtothinkabouthowtheirworkmayaffecteachotherandhowtheyinteractwithyourownmaintenanceorproductionactivities.Themoreactivitiesthataregoingon,thegreaterthechancethereisofsomethingbeingoverlooked.Thekeyisgoodcommunication,planningandcontrol.Withoutthese,chaoscanresultandaccidentswillhappen.

Consulting employees on health and safety

Employersmustconsultalloftheiremployeesonhealthandsafetymatters.Whereemployershaverecognisedunions,theSafetyRepresentativesandSafetyCommitteesRegulations1977willapply.Whereemployeesarenotmembersofaunion,ortheunionisnotrecognised,theHealthandSafety(ConsultationwithEmployees)Regulations1996(HSCER)willapply.

Consultationshouldinclude:n anychangethatmaysubstantiallyaffecttheirhealthandsafetyatwork,egin

procedures,equipmentorwaysofworkingsuchassafesystemsofworkforcleaningprintingcylinders;

n theemployer’sarrangementsforgettingcompetentpeopletohelphimorhersatisfyhealthandsafetylaws;

n theinformationthatemployeesmustbegivenonthelikelyrisksanddangersarisingfromtheirwork.Thiswouldincludefireandexplosionhazardswhenusinghighlyflammableinksandmeasurestoreduceorgetridoftheserisks;

n theplanningofhealthandsafetytraining;n thehealthandsafetyconsequencesofintroducingnewtechnology,for

exampleuseofUVinks.

FurtherinformationonconsultingemployeesisavailableinthefreeleafletConsulting employees on health and safety: A guide to the law(INDG232).

UndertheSafetyRepresentativesandSafetyCommitteesRegulations1977,tradeunionappointedsafetyrepresentativeshavetherightto:

n investigatepotentialhazardsanddangerousoccurrences;n examinethecausesofaccidents;n investigatecomplaintsbyemployeesrelatingtohealthandsafety;n makerepresentationstotheiremployeronhealthandsafetymatters;n carryoutinspectionsoftheworkplace;n receivetimeoffwithpaytoperformthesefunctionsandundergotraining.

Employershaveageneraldutytoconsultsafetyrepresentativesonallaspectsofhealthandsafetyintheworkplace,andprovidethemwiththenecessaryinformation,facilitiesandhelptoallowthemtocarryouttheirfunctions.Thisiswithaviewtomakingandmaintainingarrangementsfortheirjointco-operationinthepromotionanddevelopmentofmeasurestoensureemployees’healthandsafetyatwork,andtochecktheeffectivenessofsuchmeasures.

Asafetycommitteemustbeestablishedifrequestedinwritingbytwosafetyrepresentatives.Theemployershouldthenconsultwiththesafetyrepresentativesandestablishthesafetycommitteenolaterthanthreemonthsaftertherequestwasmade.Anoticeshouldbepostedforemployeesstatingthecompositionofthecommittee.



FurtherinformationcanbefoundinthepricedpublicationSafety representatives and safety committees(L87),knownasthe‘BrownBook’.

Inspectors and enforcement

EnforcementforhealthandsafetyatworklieswitheitherinspectorsfromHSEorfromyourlocalauthority.HealthandsafetyinprintingandmanyalliedtradesisnormallyenforcedbyHSEinspectors.Aninspector’sprimaryfunctionistoensurerelevantlegalstandardsofhealthandsafetyintheworkplacehavebeenachieved.Tohelpenforcingauthoritiescarryouttheirduties,youarerequiredbylawtonotifyyourenforcingauthority(normallyyourlocalHSEoffice)thatyouareoccupyingafactoryoroffice.

Powers of inspectorsFollowingavisit,inspectorswillprovideadviceandmayconfirmthisinwriting.Inspectorshavepowersofenforcementwhichmightinclude:

n servingimprovementnoticesthatrequireimprovementstobemadewithinacertaintime;

n servingprohibitionnoticesthatstopaprocessortheuseofapieceofequipmentwhereariskofseriouspersonalinjuryexists;

n prosecutionofabusiness,orundercertaincircumstancesanindividual,forbreachesofhealthandsafetylaw.

Theymayvisittoinspecttheworkplaceortoinvestigateaccidentsorcomplaints.Theyoftenvisitworkplaceswithoutgivingnoticebutyouareentitledtoseetheiridentificationbeforelettingthemin.Theirpowersincluderightofentryintoyourpremises,therighttotalktoemployeesandsafetyrepresentativesandtotakephotographsandsamples.Theyareentitledtoyourco-operationandanswerstoquestions.

Inspectorswillenforcethelawwhentheyjudgeitnecessary,buttheyareconcernedtohelpyoudowhatisreasonableandpracticabletocontrolriskstohealthandsafety.Theywillgiveadviceandyoumayturntothemforguidance.Theyarehappytoanswerquestionsandgiveyouinformation,muchofwhichisfree.YoucanalsocontactyourlocalHSEofficeorHSE’swebsite:www.hse.gov.ukorHSEBooks:www.hsebooks.co.ukor,forgeneralenquiries,contactHSE’sInfoLine Tel:08701545500.



Chapter 2 TrainingSee the ‘References’ section at the back of the book for details of publications which relate to Training


TrainingrequirementsareidentifiedinseveralActsandregulationsincludingthefollowing:

n HealthandSafetyatWorketcAct1974(HSWAct)n ManagementofHealthandSafetyatWorkRegulations1999n ProvisionandUseofWorkEquipmentRegulations1998(PUWER98)n ControlofSubstancesHazardoustoHealthRegulations1999(COSHH)n ElectricityatWorkRegulations1989

Itiscrucialthatallemployees,includingsupervisorsandmanagers,haveadequatehealthandsafetytraining.

Training methods

Thesewillvaryfordifferentpeopleandjobsdependingonexistingabilitiesandtherisksofthejob.Anytrainingproviderneedstobecompetent.

Trainingcanbecarriedoutbyoneormoreofthefollowing:

n in-housetrainingpersonnel(thismightincludesupervisors);n externaltrainers(thiscanbedoneonthepremisesorbysendingemployees

awayonshortcoursesorday-releasecourses);n distanceandopen-learningtechniques;n trainingprovidedbysuppliersandmanufacturersfollowinginstallationofnewor

refurbishedmachinery,ortheintroductionofnewconsumablessuchasblanketwashes;

n ‘sittingwithNellie’-youshouldbeconfidentthatthepersongivingthetrainingiscompetentbothinthejobanditshealthandsafetyaspectstoavoidpassingonbadhabits.

TrainingmaterialsareavailablefromanumberofsourcesincludingthePrintingIndustryAdvisoryCommittee(PIAC),tradeorganisations,safetyorganisationssuchastheBritishSafetyCouncil(BSC)andtheRoyalSocietyforthePreventionofAccidents(RoSPA),andindependenttrainingandhealthandsafetyconsultants.

ThePIACPrinting industry:Health and safety training packagepublishedbyHSEisacomprehensiveopen-learningcoursedesignedforuseinmediumandlargerprintemployersandprintingcolleges.Itcontainstargetedmodulescoveringarangeofsubjectsincludingnoiseandriskassessments,assessingmachineryguardingandconductingaccidentinvestigation.

Foreachactivityastructuredtrainingsessionisprovidedincludingsubjectsfordiscussionandcasestudies,supportedbyhand-outsandvisualaids.Thepackagehasbeendesignedtobeusedanddeliveredbycompetentin-housestaff.

SectorSkillsCouncils(SSCs)(UK-wide),LearningandSkillsCouncils(LSCs)inEngland,EducationandLearningWales(ELWa)inWalesandLocalEnterpriseCompanies(LECs)inScotlandareabletoprovidepracticalhelpontraining.They



canalsoprovideinformationonNationalandScottishVocationalQualifications(NVQsandSVQs)whichmeetstandardsofcompetencelaiddownforparticularjobs.Manyofthesequalificationscanbeobtainedbyattendanceatvariousprintingcollegesaroundthecountry.

TheInstituteofOccupationalSafetyandHealth(IOSH)providestrainingandexaminationintechnical,legalandhealthandsafetymanagement.

OrganisationssuchastheBritishPrintingIndustriesFederation(BPIF)andtheGraphical,PaperandMediaUnion(GPMU)alsoprovidearangeofprint-specifichealthandsafetytrainingcoursesforalllevelswithincompanies.

Seethe‘Furtherinformation’sectionforthefullcontactdetailsoftheseorganisations.

Induction training

Inductiontrainingfornewemployeeswillhelpthemsettleintotheirwork.Thistypeoftrainingusuallyincludesinformationaboutthecompany,theorganisationformanaginghealthandsafety,thehazardsoftheworkplace,theprinciplesofsafeworkingpracticeandthesafetyresponsibilitiesofindividuals.

Managersandsupervisorshavealegalresponsibilitytomaintainasafeworkingenvironment.Theyareaccountableforthesafetyofthoseundertheircontrol.Theyareresponsibleforspottinghazardsorpoorworkingpracticesandcorrectingthem.Theyarealsoresponsibleforinvestigatingaccidentsandnearmissesandmayhavefurtherspecificdutiesallocatedtothemunderthesafetypolicy.

Seniormanagersneedtoknowenoughabouthealthandsafetytodetermineprioritiesandtoassesstheperformanceofpeoplefurtherdownthemanagementline.Theyshouldexaminethehealthandsafetytrainingneedsofindividualsatregularintervals.Thecommitmenttotrainingshouldbespeltoutinthecompanysafetypolicy.

Afterinduction,thehealthandsafetytrainingneedsforeachindividualshouldbeidentifiedandtrainingprovidedsothatnooneisaskedtoperformataskforwhichtheyhavenotbeentrained.

Thefollowingareexamplesofthetopicsappropriateforinclusionininductiontrainingatdifferentlevelswithinacompany:

Thefollowingareexamplesofthetopicsappropriateforinclusionininductiontrainingatdifferentlevelswithinacompany:

Training for all employees - example topics

n Companystructuren Companysafetypolicyn Safetycommitteesn Safetyrepresentativesn Occupationalhealtharrangementsn Responsibilitiesofindividualsn Companyrulesn Hazardsandsafeworkingstandards,including:



– Safesystemsofwork– Housekeeping– Machinerysafety– Visualdisplayunits(VDUs)– Fire– Chemicalsandsolvents– Materialshandling– Electricity– Noise– Firstaid

Training for all supervisors/managers - example topics

n Responsibilities-includingtheirownresponsibilitiesandthoseofothersinthecompany

n Monitoringofhealthandsafetystandardsn Hazardidentificationn Accidentinvestigationandreportingn Riskassessmentn Relevantlegalrequirementsn Safesystemsofworkandothermethodsusedtocontrolriskn Sourcesofinformationn Controlofcontractors

Training for senior managers - example topics

n Purposeofcompanyhealthandsafetypolicyn Causesofaccidents/illhealthandtheircostsn Planningforhealthandsafetyn Monitoringaccidents,reportsandstatisticsn Personalresponsibilityandaccountabilityn Functionsofsafetycommitteesandsafetyrepresentativesn Developingasafetyculturen Useofsafetyauditsn Relevantlegalrequirementsn Roleofsafetyadvisern KnowledgeoftheworkofHSEandotherauthoritiesn RoleoftheOccupationalHealthServicen Existenceofrelevantstandardsandguidance

Remembertherearemanyhazardousactivitiesintheprintingindustrywherespecificjobtraininginsafesystemsofworketcisessential,egpresscleaning,webbing-up,guillotineoperating,maintenancework,lifttrucks,andmanualhandling.

Evenexperiencedemployeesmayneedtrainingwhentheyaremovedtonewareasofworkoraskedtooperatenewtypesofmachines.Retrainingshouldbecarriedoutregularly,toreinforceparticularsafetyissues,orwhentherearechangesintheprocessandequipment.Sometimesaccidentinvestigationscanrevealtheneedforretraining.

Trainingneedsshouldberegularlyreviewedtocheckthatthetrainingdeliveredisadequate.Trainingneedscanalsobereviewedwheninvestigatingaccidents,investigatingnearmissesandasaresultofcarryingoutriskassessment.Fromtimetotimeitpaystodorefreshertraining.Everyonecangetstaleandthisavoidsslippingintobadhabits.



Training safety representativesTradeunionappointedsafetyrepresentativeshavetwodistincttrainingneeds.Firstly,theyneedtounderstandtheirfunctionsasatradeunionofficialandtodothistheyareentitledtotimeoffwithpaytoattendaTUCorotherapprovedtradeunioncourse.

Secondly,theymayneedadditionaltrainingintheparticularhazardsoftheindustry-notonlythehazardsintheirownjobsbutalsothehazardsofworkdonebythepeopletheyrepresent.Theemployerhasdutiestowardssafetyrepresentatives(see‘Consultingemployeesonhealthandsafety’inChapter1).Companiesshouldco-operatesothattradeunionappointedsafetyrepresentativesintheircompanycanreceiveadequatetrainingonindustryhazards,rulesandprocedures.

Accidents

Job specific

Theoperatorofanoffsetlithoprintingmachinewasstrangledwhenhispulloverwascaughtbytheinkingrollers.Hewastryingtoretrievemisfedpaperviathegapbeneaththeductkeysbelowtheinkingrollersguard.Theguardwasdeficientandtheoperatordidnotturnthemachineoffbeforetryingtoretrievethepaper.Trainingshouldhavebeengiveninthesafemethodofworkingandtherequiredstandardofmachineryguarding.Proceduresshouldhavebeeninplacetochecktheconditionofguardsregularly.

Amachineoperatorinaprintingworksdamagedhisspinewhenhefellfromaladderwhilecarryingoutmaintenanceworkathigh-levelmachinery.Theladderwasnottiedorfooted.Operatorsregularlycarriedoutminormaintenanceworkbutnoonehadbeentrainedtouseladders.

Training for those moving jobs

Anexperiencedprinterhadpartofhisrightindexfingeramputatedwhilechangingthebladeofaguillotinehehadnotoperatedbeforeandhadnotbeentrainedtouse.

Refresher training

Aprintingshopsupervisortrappedtwofingersinafoldingmachinewhileclearingacreasedpieceofpaperwithoutstoppingthemachine.Hehadbeenfullytrainedsomeyearspreviouslybuthadshort-circuitedthesafeworkproceduressofrequentlywithoutincidentthathenolongerrecognisedtheobviousrisk.



Chapter 3 Workplace and transport safetySee the ‘References’ section at the back of the book for details of publications which relate to Workplace and transport safety


GeneralrequirementsforworkplaceandtransportsafetyarecontainedinanumberofActsandregulationssuchastheHealthandSafetyatWorketcAct1974(HSWAct)andtheManagementofHealthandSafetyatWorkRegulations1999.

TheWorkplace(Health,SafetyandWelfare)Regulations1992arespecificallyaimedatprotectingthehealthandsafetyofeveryoneintheworkplace,andensuringthatadequatewelfarefacilitiesareprovidedforpeopleatwork.EmployershavedutiestoensurethatworkplacesundertheircontrolcomplywiththeseRegulations.MoredetailedinformationcanbefoundinthepublicationWorkplace health, safety and welfare. Workplace (Health, Safety and Welfare) Regulations 1992. Approved Code of Practice(L24).

TheDisabilityDiscriminationAct1995createsarightofnon-discriminationagainstdisabledpeopleinthefieldofemployment,includingadutyonemployerstoprovide‘reasonableadjustment’toworkingconditionsortheworkingenvironmenttoovercomethepracticaleffectsofdisability.Employersarenotexpectedtomakeanychangeswhichwouldbreakhealthandsafetylaws.

TheemploymentpartoftheDisabilityDiscriminationActdoesnotapplytoemployerswhoemployfewerthan20people.However,theyareencouragedtofollowgoodpracticeguidelines.FurtherinformationontheDisabilityDiscriminationActshouldbeobtainedfromtheDepartmentforEducationandSkills.

Fundamentals of workplace health and safety

Someofthebasicrequirementsforemployersare:

Safe place of workYoumusthave:

n buildingsingoodrepair;n precautionsthatstoppeopleormaterialsfallingfromopenedges,eg

mezzaninefloors,rackingareasandrunningboards;n spaceforsafemovementandaccess,egaroundreelstandsandonmezzanine

floors;n floors,corridorsandstairsetcfreefromobstructions,egtrailingcablesand

pallets;n gooddrainageinwetprocesses,egscreencleaninginscreenprintingor

flexographicprintingusingwater-basedinks;n windowsthatcanbeopenedandcleanedsafelyincludingrooflights.Youmay

needtofitanchorpointsifwindowcleanersneedtouseharnesses;n weatherprotectionforthoseworkingoutdoors,eglifttruckdrivers,security

guards,trafficcontrollers(banksmen)anddeliveryworkers;n outdoorrouteskeptsafeduringicyconditions,egsalted,sandedandswept.



Alsothinkabout:

n machineryandfurniturebeingsitedsothatprojectingpartsdonotcauseariskofinjury,egatbuckle-folders;

n notoverloadingfloors-presses,particularlyoldones,areveryheavy;n spaceforstoringtoolsandmaterials.

LightingYoumustprovide:

n enoughlight.Usenaturallightwherepossiblebuttrytoavoidglare;n agoodleveloflocallightingatworkstations;n suitableformsoflighting.Somefluorescenttubesflickerandcanbe

dangerous,givingsomerotatingmachinerytheappearanceofbeingstationary;n well-litoutsideareas-thiswillhelpsecurity.

Youwillneedspecialfittingsforflammableorexplosiveatmospheres,egatheat-setovens,flexographicandgravurepresses(see‘Explosionrisksinflexographicandgravure’inChapter7).

Light-colouredwallshelptomakethemostofnaturalandartificiallight.FurtherguidanceaboutlightingisgiveninthebookletLighting at work(HSG38).

Moving around the premisesYoumusthave:

n safepassageforpedestriansandvehicles.Youmayneedclearlymarkedseparateroutes(see‘Safemovementofvehicles’laterinthischapter);

n level,evensurfaceswithoutholesorbrokenboards;n hand-railsonstairsandrampswherenecessary;n safedoors,egvisionpanelsinswingdoorsandsensitiveedgesonpower

doors;n surfaceswhicharenotslippery.

Thinkaboutmarkingsteps,kerbsandfixedobstacles,egbyblackandyellowdiagonalstripes.

Designing workstationsWhendesigningworkstationsandseatingarrangements,considercomfortandsafety.ErgonomicprinciplesshouldbefollowedandadequateaccounttakenofresponsibilitiesundertheManualHandlingOperationsRegulations1992andtheHealthandSafety(DisplayScreenEquipment)Regulations1992.Thisadviceappliestothehand-workingandinsertionsectorsinparticular.

Workstationsandseatingmustsuittheworkerandthework.Seatingmustbeprovidedwheretheworkoperations(orsubstantialpartsoftheoperations)canormustbedonesitting.Seatingshouldalsobeprovidedforemployeeswhoseworknecessitatesthemhavingtostandforlongperiods.

Insomecircumstancesmanualhandlingrisksmaybebettercontrolledbypeoplestandinguptocarryoutatask.Othermeasurestoreducetherisksandproviderelieffromstanding,suchasregularjobrotation,canalsobetaken.FurtherinformationisgiveninthebookletSeating at work(HSG57).



Figure 2 Modernguillotineandhandlingsystem

CleanlinessYoumust:

n providecleanfloorsandstairswhicharenotslippery;n providecleanpremises,furnitureandfittings(eglights);n providecontainersforwastematerials,egmetal-liddedbinsforwash-upcloths;n removedirt,refuseandtradewasteregularly-remembertonotifylaundriesif

theyarereceivingsolventoruncuredUVink-ladencloths/wipes;n clearupspillagespromptlyandarrangeproperdisposal,egthroughalicensed

contractor;n keepinternalwallsorceilingsclean.Theymayneedpaintingtohelpeasy

cleaning.

Hygiene and welfareYoumustprovide:

n clean,well-ventilatedtoilets(separateformenandwomenunlesseachtoilethasitsownlockabledoor);

n washbasinswithhotandcold(orwarm)runningwater;n soapandtowels(orahanddryer);n skincleansers,withnailbrusheswherenecessary;n pre-orafter-workcreamsandskinconditioningormoisturisingcreamswhere

necessary;n dryingfacilitiesforwetclothes;n facilitiesforworkersworkingawayfrombase;n lockersorhangingspaceforclothing;n changingfacilitieswherespecialclothingisworn;n acleandrinkingwatersupply(markedifnecessarytodistinguishitfromthe

non-drinkablesupply);n restfacilities,suchasrestroomsorrestareas,includingsuitablefacilities

toeatmealswherefoodeatenintheworkplacewouldotherwisebecomecontaminated.TheWorkplace (Health, Safety and Welfare) Regulations 1992. Approved Code of Practice(L24)outlinesadditionalarrangements,egforheatingfood;

n arrangementstoprotectnon-smokersfromdiscomfortcausedbytobaccosmoke,egprovideseparateareasorroomsforsmokersandnon-smokersorprohibitsmokinginrestareasandrestrooms;

n restfacilitiesforpregnantwomenandnursingmothers;



n acomfortabletemperatureandadequateventilationincludingfreshair.TheWorkplace (Health, Safety and Welfare) Regulations 1992. Approved Code of Practice(L24)referstoaminimumtemperatureof16°Cunlesstheworkinvolvesalotofseverephysicaleffort,inwhichcasethetemperatureshouldbeatleast13°C.

Safe movement of vehicles

Manyaccidentseachyearinvolvepoweredvehiclesincludinglorries,vansandlifttrucks.Injuriesmaybesevere,andevenfatal.Transportmovementsinandaroundtheworkplaceneedtobecontrolledtoprotectpedestrians,andtopreventdamagetoplantandequipmentsuchasrackingsystems.Riskassessmentsneedtotakeaccountofanycontractorswhomayworkon,orvisitthesite,suchascontractloadersinthenewspaperindustry.

Lookatthemovementofgoodsaround,intoandoffthesite.Forexample,checkthat:

n vehiclesandpedestriansareseparatedasmuchaspossible.Trafficroutesusedbybothneedtobewideenoughtoenablevehiclestopasspedestrianssafely.Barriersorrailsmaybeneededinparticularlyvulnerableplaces,suchasdoorways,gateways,tunnels,bridgesorotherenclosedroutes;

n pedestrianaccesstoloadingbaysanddeliverypointsiscontrolled;n theneedforvehiclestoreverseiskepttoaminimumandthat,wherepossible,

reversingisrestrictedtodesignatedareas;n areasinwhichvehiclesaremovedarewelllit;n workstations,vulnerableplant,gascontainersandchemicalstoragefacilities

arenotlikelytobestruckduringvehiclemovements;n trafficroutes,roadwaysandpedestrianroutesareclearlymarked;n sitespeedlimitsaremarkedandobserved;n speedcontrolmeasures,suchashumps,areprovidedwhereappropriate

(gapsmaybeneededtoallowlifttruckstopasssafely);n safecrossingpointsforpedestriansaremarked;n actionistakentocontroldangeratblindspots,includingopeningswithstrip

curtainswhichvehiclestravelthroughorpast;n visitingdriversknowandfollowyourrules;n ifnecessary,vehiclemovementsaredirectlysupervisedbyproperlytrained

signallers(banksmen),particularlywhenreversingandnearblindcorners;n banksmenarevisibletodriversatalltimes,andareabletostandinasafe

positionwhileguidingthereversingvehicle;n ifnecessary,high-visibilityclothingisprovidedforandwornbybanksmen;n trainingintheuseofrecognisedsignalsisgiventodriversandanyonewho

controlsvehiclemovements;n floorsandroadwaysarekeptingoodcondition.n ForfurtherinformationseethefreeleafletManaging vehicle safety at the

workplace(INDG199).

Loading and unloading of vehicles

Accidentsfrequentlyhappenwhenpeoplefallfromvehicles,ortheloadmovesunexpectedlyandtheyarestruckbyit.Particulardangersexistwherereelsofpaperarebeingunloadedastheyareheavyandgainmomentumoncetheystarttomove.

Unloadingofreelsneedstobedonewithsuitableequipmentsuchasaclamp,boomorpoleattachmentonalifttruck,andinaccordancewithasafesystemofwork.Tiltingclampdevicesareparticularlyuseful,astheypermitreelstobepickedupfromthehorizontalandplacedvertically,orviceversa.



Areputablesupplieroflifttruckattachmentswillbeabletogiveadviceaboutsuitableequipmentforyourjob,andtheeffecttheuseofthedevicewillhaveontheratedcapacityofyourtruck.

Points to check:

n avoidtheneedtoclimbonloadsbyusingcurtain-sidedvehicles,orproprietarysheetingsystems;

n providesafeaccessifworkmustbedoneataheight;n provideanduseagantrysystem,safetylinesandharnessesifworkonhigh

loadscannotbeavoided;n eliminatemanualhandlingofreels;n loadandunloadinasafeplaceandkeepeveryone,includingmembersof

thepublic,wellclearoftheareaduringloadingandunloadingoperations;n avoidmanualhandlingbyusingpallets,alifttruckoraporter’strolley;n deviseasafesystemtodealwithmishaps,suchasstuckloads.Acommon

mistakeistoattempttofreeastuckloadbytyingaropetoitandpullingwiththelifttruck-injuriesoccurwhentheropeoritsfixingbreaksanditrecoilsviolently;

n makesureinstructionsexistfordealingwithanyvehiclethatmightarriveon-sitewithanunsafeload,forexamplepalletisednewspaperbundleswhichhaveshiftedduringtransit,andthattheinstructionsarefollowed;

n makearrangementstosecureloadsbeforevehiclesleavethesite,forexampleusingloadbindersinsidecurtain-sidedvehicles,topreventdangerousmovementoftheloadintransit.

Figure 3 Rackingshouldbesecurelyfixedandhaveaisleswideenoughtoallowmanoeuvring

Safe stacking and storing

General principles

n Storageareasshouldbespecificallydesignated,clearlymarkedandunderthecontrolofaresponsibleperson.

n Considerpermissiblefloorloadings.n Placematerialshandledbycraneorlifttruckonbattensorothersuitable

materialtoensurethataslingorforkscanbeinsertedunderthem.n Goodhousekeepingisessentialatalltimes.n Providesufficientlighting.n Maintainadequateclearancebetweenrowstoensuresafestackingand

withdrawal.



n Maintainadequateheadroomforlifttrucks.Remembertocheckthatlighting,cablingandheatersaremountedhighenoughtopreventthembeingaccidentallystruckbythemast.

n Positionloadscapableofbeingstackeddirectlyontopofeachotheronafirm,levelbase.

n Checkstacksperiodicallyforstabilityandtakecorrectivemeasureswherenecessary.

n Considerfireprecautionsatanearlystage-stackswhicharetoohighmaypreventsprinklersystemsfromworkingcorrectly.

Don’t:

n exceedthesafeloadofracks,shelvesorfloors;n allowitemstostickoutfromstacksintogangways;n climbrackstoreachuppershelves-usealadderorsteps;n leanheavystacksagainstwalls;n de-stackbythrowingdownfromthetoporpullingoutfromthebottom.

Racking installationsRackingshould:

n beinstalledandmaintainedinaccordancewiththemanufacturer’sinstructions;n beerectedonsound,levelfloorscapableofwithstandingthepointloadingof

eachbaseplate;n besecurelyfixedtothefloorwherelifttrucksandmechanicalhandling

equipmentareused.Ifrackshavetobesecuredtothebuilding,calculationsshouldconfirmthebuildingisfitforthispurpose;

n haveaisleswideenoughtoensurethatmechanicalhandlingequipmentcanbeeasilymanoeuvred;

n havethemaximumloadclearlystatedonthem;n neverbealteredwithoutconsultingthemanufacturerfirst;n makekeycomponentshighlyvisibletohelplifttruckdriverspositiontheirforks

correctly.

Use of palletsOperatorsshouldreceiveinstructiononthesafeuseofpallets.Accidentsinvolvingpalletsarecausedby:

n poordesign;n poorconstruction;n usingpalletsunsuitableforparticularloads/rackingsystems(rememberyou

mayreceiveconsignmentswithdifferent-sizedpallets);n continueduseofdamagedpallets;n badhandling.

Precautions to reduce the risk of accidents when working with pallets

n Establishaneffectivepalletdamageinspectionschemeatthegoods-instage.Ifpalletsareregularlyinadamagedcondition,takeactionwiththesupplier.

n Inspectallpalletsagaineachtimebeforere-use(damagedonesshouldbewithdrawn).

n Handleemptypalletscarefullyandmakesuretheyarenotdraggedorthrownabout.

n Toavoiddamagetopallets,andtolifttheloadssafely,makesuretheforksofanyhandlingdeviceextendintothepallettoatleastthree-quartersofitsdepth.

n Forksshouldnotextendbeyondthepalletbeinglifted(egtheycouldoverturnanadjacentload).



n Asageneralguide,theheightoftheloadshouldnotexceedthelongestbasedimensionofthepallet.

n Avoidstackingofpalletisedloadscapableofbeingcrushed.

Reel storage and stackingIdeally,pedestriansshouldbeexcludedfromreelstorageareasinwhichlifttrucksareused.Thisisespeciallyimportantwhenstackingorde-stackingoperationsaretakingplace.

Stackingreelsonendusuallyrequirestheuseofclamptrucksorsimilarequipment.Themaximumheightforanystackwilldependonthereelsizeandwillbelimitedbystability,drivervisionandoverheadobstructions.Thereshouldbegoodlightingwithminimumshadow.Reelsshouldbestackedsafely.Pillarsshouldbeclearlymarked,egwithyellowbanding.

Whereclamptrucksorothersafemeansofstackingonendarenotavailable,reelswillprobablybestoredhorizontally.Itissafesttostorereelswithoutstackingbutiftheyarestackedmorethanonetierhighduetolackofspace,itisvitaltouseproperwedgestopreventaccidentalbreakingdownofthestack.Ifwedgesaretoosmallorincorrectlyshaped,notonlywilltheybeliabletomove,butthepaperwillalsobedamaged.Atleastonewedgeshouldbeplacedateachsideofeveryreelatfloorlevel-largewedgeswithhandlesmaybebest.

Stackingaislesshouldbewideenoughforanyvehiclesdoingthework.

Figure 4 Correctpositioningofwedgesandsafestackingofreels

Reels must be stacked true and vertical and be of equal diameter in any one stack, except that a reel with diameter slightly less than the other may be used as the top reel of a stack

Reels with dished ends or protruding centres must not be stacked on end

Reels must not be placed horizontally against a vertical reel

Correct positioning of wedges

WRONG RIGHT

Height limitedfor this method



Manual breaking down of pyramid stacksReelsmaybedeliveredonlorriesinpyramidstacks,orbestoredthatwayinthewarehouse.Wherepossible,considerchangingthedeliveryandstoragearrangementssoreelsarestoredanddeliveredonend.Itisbesttousemechanicalmethodsofhandlingreelsstackedlikethis,egbyusingalifttruckwithtiltingclamp,liftingboomortinedevices-askaspecialistsupplieroflifttruckattachmentsforadvice.Mechanicalhandlingdeviceswillhelpprotectyouremployeesandalsohelppreventdamagetothereels.

Ifmanualbreakingdownofsuchstackscannotbeeliminated,asafesystemofworkmustbesetdownandimplemented.Thesystemneedstotakeaccountof:

n theneedtode-stackreelsinapredeterminedorder;n theneedtoensurethatpeopleonlyworkfromthesideofthestack,where

theywillnotbehitbyareelifitmovessuddenly;n theneedtoadequatelyandfirmlychockallreelsonthebottomrowofthe

stackuntilitisnecessarytomovethem(chockdesignisimportant-theheightofthechockshouldbeatleastoneeighthofthediameterofthereel);

n theuseofproperlydesignedbatsorpaddlestocontrolunchockedreels.Brakingchocksmaybeused,togetherwithachockpaddleandaleverbat;

n theneedtoprovideenoughpeopleforthejob-unloadingshouldbeconductedbyateamofatleastthreeadequatelytrainedandsupervisedpeople,andthismayincludethedriverofthedeliverylorry.Onepersonwilldrivethelifttruck,whiletheothertwoworkatthesideofthestack,barringdownthereels;

n theneedtoprovideasafesystemofworkfordealingwithreelsdeliveredincontainerswheresideaccessmaynotbepossible.

Therehavebeenfatalaccidentswhenreelsbeingmanuallyde-stackedhaverunoutofcontrol-mechanicalmethodsshouldbeusedifatallpossible.

SeeChapter7forfireprecautionsrelatingtostackedreels.

Lift and clamp trucks

Liftandclamptruckscanbeusedformanymaterialhandlingoperationsintheprintingindustry,particularlyinthemovementofpalletsofpaper,paperreels,chemicalsandwastematerials.Lifttruckaccidentscausemanyseriousinjuriesincludingfatalitieseveryyear-suitableoperatortraining,vehiclemaintenanceandworkingconditionsareessential.

The law and lift trucksInadditiontothegeneralrequirementsoftheHSWAct,thoroughexaminationandtestingofthechainsofalifttruckbyacompetentpersonisrequired.Youwillneedtoobtainandkeepacopyofthesereportsandrectifyanysafetydeficienciesidentifiedinthem.

ThepublicationRider-operated lift trucks: Operator training. Approved Code of Practice and guidance(L117)givespracticalguidanceoncomplyingwiththerequirementsofsection2oftheHSWActinrelationtothebasictrainingofoperatorsofrider-operatedlifttrucks.

TheApprovedCodeofPracticerequires:

n employerstoprovidebasictrainingforoperatorsbyrecognisedinstructors(suchinstructorsmaybeemployeeswhoarecompetenttocarryoutthisrole);



n competencetestingoflifttruckoperators;n authorisationof,andappropriaterecordsfor,allemployeespermittedtodrive

lifttrucks.

Inadditiontotheabove,driver-operatedlifttrucksusedregularlyontheroadforlongperiods,andtheirdrivers,mustbelicensedbytheDrivingStandardsAgency.

Health problemsLifttruckscancreatehealthproblemswhichwillneedtobeconsidered.Thesecaninclude:

n breathingproblemsfromusingdieseltrucksinconfinedworkingenvironments(goodmaintenance,egoffuelinjectors,canreducefumeproblems);

n backandupperlimbdisordersduetopoorseatingand/orcontrols.n Poorroadwayscancauseexcessivetruckvibrationandbackproblems.

Common accidents

Somecommoncausesoflifttruckaccidentsinclude:

n unsafereversing;n speeding;n overloading;n passengercarrying;n untraineddrivers;n poororinadequatevisibility;n poorworkingenvironment,egunevenroadsurfacesorobstacles;n inadequateseparationofpedestriansandlifttrucks;n inadequateseparationofhighwayvehiclesandlifttrucks;n poortruckmaintenanceincludingmaintenanceofchainsandbrakes.

Safety guidelines for lift trucks

n Ensurealloperatorshavereceivedadequatetraining.n Ensureenoughpeoplehavebeentrainedtocoverholidays,weekends,

overtimeandsickness.n Ensuretraininginstructorsarecompetentininstructionaltechniquesandskills

assessment.n Restrictuseoflifttruckstoauthorisedoperatorsonly(authorisationshouldonly

begiventoadequatelytrainedandexperiencedoperators).Itmayhelptopostalistofauthoriseddriversonthetruck.

n Providesuitablerefreshertrainingforoperators.n Ensuremanagersandsupervisorsaretrainedinsafetyaspectsofliftandclamp

trucks.n Managersshouldhaveanappreciationoftherisksandthewaystominimise

them.n Supervisorsshouldhaveenoughknowledgetobeabletorecognise

inadequaciesintheoperationoflifttrucksandthetrainingneedsofoperators.n Screenoperatorsforfitness,egeyesighttesting.n Keepfloorsandroadwaysingoodcondition,freefromobstacles,obstructions

andpotholes.n Allowenoughroomforlifttruckmanoeuvres.n Maintainalllifttrucksonaregularbasistoensuretheyareingoodcondition

(includingexaminationofthemastchains,tyres,brakesandhorns).Introducedailydriverchecksofthesafetyequipment.

n Ensurethatthoroughexaminationandtestingofliftingchainsarebeingcarriedoutbyacompetentpersonasrequired.



n Segregatelifttruckroutesfrompedestrianandworkingareasasmuchaspossibleandmarkthemwithbarriersorlinesonthefloor.

n Ensuregradientsarenottoosteep.n Keepkeyssafewhenthelifttrucksarenotbeingusedbyauthoriseddrivers.n Ensurethatoperatorsuseseatbelts.n Ensuregoodvisibilitywhenmovingloads-wherenecessaryuseabanksman

todirecttrafficsafely.n Rememberthatthefittingofcranejibattachmentsissubjecttoadditionallegal

requirements.

Don’t:

n allowanyonetodrivealifttruckunlesstheyhavebeenselected,trainedandauthorisedtodoso;

n carryreelsstackedontopofeachother(asthetopreelswillbeunsupportedandliabletofall);

n uselifttrucksinareaswhereflammableconcentrationsofvapoursmaybepresent,egclosetogravureorflexographicpressesusinghighlyflammableliquidsorininkstoresunlessthetruckshavebeenspeciallydesignedandprotected;

n leavekeysintheignitionwhentrucksareparkedorleftunsupervised;n allowanyoperatorstoconsumeanyalcoholwhileatwork;n useforks,palletsorbinstoliftpeopletoworkatheights(useproperlydesigned

mobileworkplatforms);n pickuploadsifsomeoneisstandingclosetotheload;n allowpeopletowalkunderraisedloads;n moveunstableloads;n leavealifttruckunattendedonagradientexceptinanemergency(ifyoudo

havetoleavethetruckonaslopeinanemergencyusewheelchocks);n carrypassengersunlessthelifttruckisdesignedtodoso;n runoverelectricalcablesorflexiblepipesonthefloorunlesstheyaresuitably

protected;n operatewiththeloadraisedexceptforstackingandde-stackingmanoeuvres;n allowspeedingorunsafereversingpractices;n fitattachmentstolifttruckswhichcouldaffecttheirliftingcapacitywithout

consultingthemanufacturer,authorisedsupplierorqualifiedlifttruckengineer;n forgettoconsidertheneedforbeacons,mirrors,hornsetc,theprotectionof

driversfromfallingobjectsandlightingwherenecessary;n allowotherpeople,suchasdeliverydrivers,touseyourlifttrucksunlessyou

arecertainthattheyhavereceivedappropriatetrainingetc.

Accident

Aprintworkerwascrushedbetweentwofullpalletsofpaperweighinghalfatonneeachwhenalifttruckreversedandinadvertentlypushedapalletintoherbackasshestoodatherworkstation.Despitehavingaconsultants’reportwarningthattheriskofcollisionbetweenpedestriansandlifttrucksinthecrampedpremiseswashigh,noattempthadbeenmadetosegregatetheactivitiesorprovideaone-waytrafficmanagementsystem.



Safety guidelines for automatic guided vehicles (AGVs)Theseinclude:

n ensuringthatallsafetyfeaturesareoperatingcorrectly;n ensuringthatstoppingperformancesareappropriatetotheriskandload.

Vehicleswillneedtocometoacontrolledstopsotheydonotreleasetheirloadsuddenly;

n ensuringthatappropriatemaximumspeedsareset;n ensuringthatadequateclearanceshavebeenlefttopreventtrappingpeople

betweenmovingvehiclesandfixedstructures.

Figure 6 SafetyfeaturesofanAGV

Asbestos in buildings

Asbestos-relateddiseaseskillanestimated3000peopleeachyearintheUKandthisfigureisexpectedtorise.Manyofthepeoplenowsufferingfromthesediseasesworkedinthebuildingandmaintenancetrades-joiners,plumbers,electricians,engineersetc.

Asaroughguide,ifyourbuildingwasbuiltbeforethe1980sandyoucarryoutanytypeofmaintenance,repairorrefurbishmentwork,youcouldbeexposingpeopletoasbestosdustwithoutrealisingit.Anyindividualexposuremaybesmall-butthesecanbuildupandmayresultinanasbestos-relateddiseaselateroninlife.Thisisparticularlyrelevanttomaintenancepersonnel.Atthetimeofwriting(January2002)theHealthandSafetyCommissionproposestointroduceanewdutytomanageasbestosinbuildings.

Warninglight

Beacon

Emergencystop

Tripbumpers



Theintentionofthe‘dutytomanage’,ascurrentlydrafted,istorequireemployersto:

n takereasonablestepstodeterminethelocationofmaterialslikelytocontainasbestos;

n presumethatmaterialscontainasbestosunlessthereisareasontosupposetheydonot;

n makeawrittenrecordofthelocationofasbestosandpresumedasbestosmaterial,andkeepituptodate;

n keepacheckontheconditionofasbestosandpresumedasbestosmaterials;and

n assesstheriskofexposurefromasbestosandpresumedasbestosmaterialsandrecordtheactionnecessarytoensurethat:

– ifthematerialmaycreateariskofexposurebecauseofitsstateandlocationitisrepairedorifnecessaryremoved;

– anysuchmaterialismaintainedinagoodstateofrepair;– informationaboutthelocationandconditionofthematerialisgivento

anyonelikelytodisturbit,includingmaintenancecontractorsaswellasthosenormallypresentinthebuilding.

AnewApprovedCodeofPracticewillbeproducedfortheduty,togetherwithsupportingguidance.Rememberyourownemployeesmayalsobeexposediftheyworkinofficeorstorageareaswhereasbestosinsulationboardproductshavebeenusedwhichhavebeendamagedbyalterationsorthemovementofmaterials.

Where is asbestos found in buildings?Thefollowingareareaswhereasbestosmightbefoundinolderbuildings:

n inspraycoatingforfireprotectionandinsulationonsteelwork,concretewallsandceilings;

n ininsulationlagging,onpipework,andforboilersandducts;n inasbestosinsulatingboardusedaswallpartitions,firedoors,ceilingtiles

etc;n inasbestoscementproductssuchassheetingonwallsandroofs,tiles,cold

watertanks,gutters,pipesandindecorativeplasterfinishes.

What should you do?

n Identifyanyasbestosmaterialonsite(ifyouareunsure,haveittested).Keeparecordofitslocation.

n Ensureanyrelevantemployeesorcontractorsknowifandwhereasbestosmaybepresentwithinyourworks.

n Ensureanyasbestosyoudofindisinasafecondition,egundamagedand/orsealed(andwillnotaffectexistingemployeesworkinginyourfactory).Carryoutregularcheckstomakesurethatitremainssafe.

n Ifworkisrequiredonorneartheasbestosyoumayneedtocallinlicensedcontractors.Youwillneedtoinformanyonecarryingouttheworkofthedangersandensuretheycarryouttheworksafely.

n Askyourlocalenforcingauthorityforfurtherinformation.Freeandpricedpublicationsareavailable,egManaging asbestos in premises(INDG223rev2).



Chapter 4 Health risksSee the ‘References’ section at the back of the book for details of publications which relate to Health risks

Nationally,over2millionpeopleayearsufferfromillhealthcausedormadeworsebywork.Thirteenmillionworkingdaysarelostaspeopletaketimeoffbecauseworkhasmadethemill.Theprintingindustryisnoexception.Ill-healthproblemsincludemusculoskeletaldisorders,occupationalasthma,deafness,eyedamageanddermatitis.Dermatitisisaparticularprobleminprinting-Europeanreportshaveindicatedthatitaccountsfor65%ofallcasesofillhealthintheindustry.

Themanagementofhealthriskswithintheworkplaceisoftenneglectedorfailsbecause,unlikesafetyissues,healthriskstendtobebothlessobviousandlesswellunderstood.Becausetheonsetofillhealthisoftendelayed,theriskscanbeunderestimateduntilitistoolateandpermanentdamagehasoccurred.

Employershavejustasmuchresponsibilityforsafeguardingthehealthasthesafetyoftheiremployees.Riskassessmentsneedtocoverhealthaswellassafetyhazards(seethegeneraladvicegivenonriskassessmentinChapter1).


n HealthandSafetyatWorketcAct1974(HSWAct)n ControlofSubstancesHazardoustoHealth(COSHH)Regulations1999n ManagementofHealthandSafetyatWorkRegulations1999n Workplace(Health,SafetyandWelfare)Regulations1992n NoiseatWorkRegulations1989n ControlofLeadatWorkRegulations1980(CLAW)n ManualHandlingOperationsRegulations1992n ControlofAsbestosatWorkRegulations1987(ConsolidatedRegulations

areduetobemadein2002)n IonisingRadiationsRegulations1999



Table 1 Examplesofhealthhazardsinprinting

Occupational health and rehabilitation

Inanybusiness,workersarethemostvaluableassetsanditisimportanttolookafterthemproperly.Employersneedtoactivelymanagehealth.Witheffectiveoccupationalhealthsupportandadvice,healthrisksatworkcanbemanagedinwaysthatarenotcostlyordifficult.Manyworkerswhohavealreadybeenmadeill,fromwhatevercause,canbehelpedtoremaininorreturntowork.

Therearelegaldutiestopreventillhealthcausedbywork.ThemainlegalframeworkistheHSWAct,supplementedbyregulationswhichcoverparticularactivities,suchasmanualhandlingandexposuretoharmfulsubstances.Theserequireyoutomakeassessmentsofthehealthriskstoworkersarisingfromworkactivitiesandtotakeactiontopreventorreducethoserisks.

Hazard Health effects Typical processes

Inhalationofsolventvapour(healtheffectsdependonthesolvent,itsconcentrationinairandthelengthofexposure)

Headaches,nausea

Effectsonthecentralnervoussystem

Cleaninglithoandletterpressrollersandcylinders

Screen,flexoandgravureprinting

Contactwithandabsorptionofsolventthroughtheskin

Dermatitis

Inhalationofvapoursandmistsfromisocyanatesorreactiveacrylates

Occupationalasthma Useoflacquers,adhesives,inksetccontainingisocyanatesorreactiveacrylates

Skincontactwithreactivechemicals(healtheffectsdependonthechemical,itsconcentrationandthelengthofexposure)

Dermatitisincludingsensitisation(skinallergy)

UseofUV-curedproducts

Etching,engraving

Platemaking

Screenreclamation

Stereorollerpreparation

Gravurecylinderpreparation

Skincontactwithandinhalationofpotentiallytoxic,verytoxicadditives(egthosewithriskphasesR40‘Possibleirreversibleeffects’,R45‘Maycausecancer’,R46‘Maycauseheritablegeneticdamage’,R61‘Maycauseharmtotheunbornchild’)

Carcinogenic(cancer)

Mutagenic(harmtotheunbornchild)

Screenprintingwithspecialistinksandcoatings

Screenreclamation

Generalprintingandcleaningactivityinvolvingtheuseof,egfontsolutions,biocides,formaldehyde,dichloromethane,N-vinylpyrrolidone(NVP)

Exposuretohighlevelsofnoise Noise-induceddeafness

Tinnitus

Webprinting

Printfinishing

Unsafemanualhandling Backinjuries Handlingofpaperreels,sheetsandbundles

Awkwardorrepetitivemovements Upperlimbdisorders,egtenosynovitisandcarpaltunnelsyndrome

Typesetting

Printfinishing

Exposuretomicro-organismsfromcontaminatedwater

Humidifierfever

Legionnaires’disease

Paperstorageorprintingwherehumidifiersareused

Anyprintingprocessinbuildingswithcoolingtowersorotherwatersystemsthatcanbecomecontaminated



Occupational health servicesEmployersmayneedexpertandspecialistadviceonhowtohelpthemwithissuessuchas:

n identifyinghealthhazards,assessingrisksandchoosingthenecessarycontrolmeasures;

n checkingtheeffectivenessofthecontrolmeasuresand,whererequired,measuringtheexposureofemployees,forexamplebyatmosphericsampling;

n advisingonplacementandrehabilitationofemployees;n provisionofappropriateon-sitefirst-aidandtreatmentfacilities;n identificationofcausesofillhealthwithintheworkforce;n promotionofgoodgeneralhealthamongemployees.

Occupationalhealthservicesmaybeabletohelpwiththesematters.HSE’sEmploymentMedicalAdvisoryServicecanadviseyouandtheleafletNeed help on health and safety?(INDG322)providesmoreinformation.(SeealsoNHSPlus:www.nhsplus.nhs.uk)Health surveillanceHealthsurveillanceisonecomponentoftheoverallmanagementofhealthrisks.Itinvolvesobtaininginformationaboutanemployee’shealthandhelpstoprotectthatemployeefromhealthrisksatwork.Itmaybenecessary:

n undertheControlofSubstancesHazardoustoHealth(COSHH)Regulations1999,forexampletoprotectagainstdermatitisoroccupationalasthma;

n undertheManagementofHealthandSafetyatWorkRegulations1999,wherepeopleworkinnoisyprocesses;

n wherethereissignificantexposuretoleadinpremisessuchastraditionalcraftprintersandtheControlofLeadatWorkRegulations1980apply.

TheneedforhealthsurveillanceshouldbedecidedaspartoftheassessmentsrequiredbytheseRegulations.Healthsurveillancecannotreplacepropercontrolmeasuresbutisanessentialpartofahealthconservationprogramme.

Healthsurveillanceisrequiredwhere:

n anidentifiablediseaseoradverseeffectmayberelatedtoexposure;n thereisareasonablelikelihoodofthatdiseaseoreffectoccurringunderthe

particularworkconditions;n therearevalidtechniquesfordetectingsignsofthediseaseoradverseeffect

andsurveillanceislikelytoimprovetheprotectionofemployees’health.

Themainobjectiveofhealthsurveillanceistoprotectthehealthofindividualemployeesbycheckingforearlysignsofwork-relatedillness.Italsoprovidesinformationaboutandearlydetectionofadversechanges,whichmaybecaused,forexample,byexposuretonoiseorasubstancehazardoustohealth.

FurtherguidanceabouthealthsurveillanceisgivenintheHSEbookletHealth surveillance at work(HSG61).

Allemployeeswillneedtobegiveninformation,instructionandtrainingaboutanyriskstotheirhealththatmightarisefromtheirwork.Wherehealthsurveillanceisappropriatetheyalsoneedtoknow:

n whatsymptomsandsignstolookoutfor,andwhereappropriate,howtoself-examine(egfordermatitis);

n howthehealthsurveillanceschemeworksandwhotoreporttoiftheyareconcerned;



n whatthearrangementsareforseeingtheirownhealthrecordsandcollectiveresultsofthehealthsurveillanceprogramme.

RecordsmustbekeptwherehealthsurveillanceiscarriedouttocomplywiththeCOSHHRegulations.TheinformationthatshouldbeheldintherecordsisdetailedintheAppendixoftheCOSHHGeneralApprovedCodeofPractice(L5).Recordsshouldberetainedfor40years.

RehabilitationEarlydetectionofillnessgivesyouachancetodealwiththeproblempromptly,andprovidestheopportunityforyoutohelpworkersremainatwork,perhapsbyarrangingforlightdutiesormodifyingworkforalimitedperiod.Ifaworkerexperiencesdifficultiesinreturningtotheirnormaldutieswithinafewweeksthenyoushouldspeaktoahealthprofessionalaboutsettingupanactiverehabilitationprogramme.

Largerorganisationsmayhavetheirownspecialistsandanoccupationalhealthservice,butallbusinessescanobtainaccesstotreatmentandrehabilitation.Somemakearrangementsthroughtheiremployer’sliabilityinsurer,somehave‘goodneighbours’(largercompaniesthatoffersmallbusinessesintheirsupplychainaccesstotheirsupportservices),andothersgoitalone.Somesmallbusinessesfinditworthwhiletomakelocalpartnershiparrangementswithhealthprofessionals.

Anumberofpeoplecanadviseyouaboutwhatisavailabletoyoulocally.Atradeassociation,chamberofcommerceortradeunionrepresentative,ifyouhaveone,willprobablyknowifthereareany‘goodneighbour’businessesyoucouldcontact.YourlocalHealthandSafetyExecutiveofficemightalsobeabletoadvise.

Hazardous substances

Manychemicalsubstancescancauseharmiftheyareinhaledorabsorbedthroughtheskin.Manyalsocausedermatitisordamagetotheeyes.Exposurecanhaveanimmediateeffectormaybedelayed.Repeatedexposuretosomesubstancesmaycausedamagetothelungs,liverorotherorgans.Theycanbetakenintothebodybybreathingthemin,passingthroughtheskinorbyeatingfoodwhichhasbeentouchedbycontaminatedhands.

Somesubstancescancausebothlocalandinternaleffects,forexampletheymightdamagetheskinandcauseliverdamage.Themosteffectivewaytoprotectemployeesfromanyharmfulsubstanceistoseeiftheuseofthesubstancecanbeavoidedcompletely,perhapsbyfindingasafersubstituteorbychangingtheprocessinsomeway.

ManyofthehealthhazardslistedinTable1relatetotheuseofhazardoussubstances.Withtheexceptionsofasbestosandlead(forwhichtherearespecialisedregulations),theuseofhazardoussubstancesatworkissubjecttotheControlofSubstancesHazardoustoHealth(COSHH)Regulations1999.ThissectionsummarisestherequirementsofthoseRegulationsandgivesadviceonthecontrolmeasuresforparticularprintingprocesses.

Foreverydaytasksinvolvingcommonlyusedprintingchemicals,thePrintingIndustryAdvisoryCommittee(PIAC)hasproducedCOSHH essentials for printers.ThisguidancegivesyouagoodheadstartwithyourCOSHHassessments,andcomprisesaseriesofsummarysheetscoveringtypicaltasks,whichexplainthestepsyouneedtotaketocontrolemployees’exposure.Thefirststagesoftheassessmentprocesshavebeendoneforyouusinginformationfromsuppliers.UndertheCOSHHRegulationsyoumust:



n assesstheriskstohealtharisingfromtheuseofhazardoussubstancesatwork(andreviewyourassessmentifchangesoccur);

n preventorcontroltherisk,egbyusingasafersubstitute,orbysuitablecontrolmeasures;

n ensurethatcontrolmeasuresareusedandmaintained;n monitorexposureandcarryouthealthsurveillancewhennecessary;n inform,instructandtrainyouremployeesabouttherisksandtheprecautions

needed;n keeprecordswhererequired.

Figure 7 TheuseofhazardoussubstancesatworkissubjectedtotheCOSHHRegulations

Exposure limitsForcertainsubstances,wherethereisariskofinhalation,occupationalexposurelimitshavebeenset.Therearetwokinds-maximumexposurelimits(MELs)andoccupationalexposurestandards(OESs).Youmayneedtorefertothesewhenassessingtherisksinyourworkplace.Furtherinformation,includinganexplanationofthedifferencebetweenthetypesofexposurelimits,isgivenintheguidancebookletOccupational exposure limits(EH40),whichispublishedyearly.



Assessment under COSHH

Firstgatherinformationonthesubstancesusedinyourworkplace.Usemanufacturers’labelsandsafetydatasheetstohelpyoudecidewhichonesarehazardous.Anysubstancewhichcarriestheclassification‘verytoxic’,‘toxic’,‘harmful’,‘corrosive’,or‘irritant’,orwhichhasbeenassignedamaximumexposurelimitoroccupationalexposurestandardbecauseofrisksfollowinginhalation,issubjecttotheCOSHHRegulations.Thisalsoappliestobiologicalagents,substantialquantitiesofdusts,andothersubstanceswhichpresentcomparablehazards.

Suppliersofchemicalsforuseatworkarelegallyobligedtoprovidesafetydatasheetscontaininginformationunder16headings,specifiedintheChemicals(HazardInformationandPackagingforSupply)Regulations.ThisinformationwillhelpyoutocarryoutyourCOSHHassessment,butsimplycollectinginformationisnotenough-youneedtousetheinformationtodecidewhetherornotthereisarisk,andwhetherornotyourowncontrolsandworkingproceduresaresufficient.Contactyoursupplierforadviceifyouareinanydoubtabouttheinformationprovidedinsafetydatasheets.

Consider:

n howthesubstanceisused,handledorstored;n whomightbeaffected;n thelikelyroutesofexposure-inhalation,ingestion,skinabsorption;n thelikelihoodandeffectsofspillsorleaks;n whatcontrolmeasuresarecurrentlyused;n anyrisksduringcleaningormaintenanceactivities.

Itisimportanttofindouthowsubstancesareactuallyusedintheworkplace,andwhoisexposedtothem-don’tforgetcontractorsandmaintenanceworkers.Thinkaboutthehandlingofsubstancesfromdelivery,touseanddisposal.Thinkalsoaboutwhatcangowrong,forexamplehowyouwoulddealwithspillageorleakingcontainersofsolvent,orcarryoutrepairsonmachineswherethereisuncuredUVink.Drawconclusionsabouttherisksanddecideifyouneedtotakeactiontoreducethem.Specialisthelpmayberequiredtohelpyoumakethesedecisions,forexamplefromanoccupationalhealthprofessional.Recordyourconclusions.

Prevention or control of exposureIfyourassessmentconcludesthatthereareriskstohealth,thenyouneedtodecidewhatelseyouneedtodotocomplywiththeCOSHHRegulations.

Ifpossible,preventexposurebyusingalesshazardoussubstanceoradifferentprocess.AgoodexampleofthisisthePrintingSolventSubstitutionSchemefortheoffsetandUV-curablesectorintroducedinthiscountryinOctober2000.Thisisavoluntaryscheme,basedonaverysuccessfulapproachinGermany,toreducevolatileorganiccompounds(VOCs)intheprocess,byreplacingrollerandblanket



washeswithahighboilingpointsolvent/vegetablecleaningagent(VCA)andtakingstepstoreduceoreliminateisopropylalcohol(IPA)fromthefountsolution.Theprinciplesoftheschemeareshownintheboxinsertlaterinthischapter.Anotherexampleistheuseofwater-basedinksforflexiblepackaging.Askyoursupplierforalternativeproductsthatmaybesafertouse.RememberifyouchangeyourproductyouwillstillneedtocarryoutaCOSHHassessmentforthenewsubstanceandensurethatyouprovideappropriatecontrols.

Wherepreventionofexposureisnotpossible,youneedtoconsidercontrolmeasures.Thisusuallymeansacombinationofsomeofthefollowing:

n Enclosingtheprocess.n Partialenclosureand/orlocalexhaustventilation(LEV).n Generalventilation.n Asystemofworkandhandlingprocedurestominimiseleaksandspills.n If,andonlyif,youcannotadequatelycontrolexposurebyacombinationofthe

measuresabove,thenyoushouldalsoprovidepersonalprotectiveequipment(PPE)suchasrespiratoryprotectiveequipment,glovesandeyeprotection.See‘Personalprotectiveequipment(PPE)’towardstheendofthischapterforfurtherinformation.



Chemical hazards in printing

Table 2 Printingprocesseswhichmaygiverisetoskinoreyecontacthazards

Note: The examples here are only illustrative and are not exhaustive

Process or activity Type/name of substance Potential health hazard

Etching,engraving,platemaking,certainphotographicreproductionsystems,correctionoflithoplates(hydrofluoricacid)

Corrosiveacids,egconcentratednitricandsulphuricacids,hydrofluoricacid

Skinburnsandblisters

Burnswithconcentratedhydrofluoricacidareverysevere

Eyedamage

Cleaningofscreensinscreenprinting Strongalkalis,egconcentratedsodiumorpotassiumhydroxide

Corrosivetoskin,eyesandmucousmembrane

Concentratedphotographicdevelopersolutions

Hydroquinone Irritanttoeyesbutmaycausepermanentdamage

Irritantandsensitisingtotheskin,maycausedermatitis

UVandelectronbeamcurableinks,varnishesandlacquers

Reactiveacrylatesormethacrylates Corrosivetoskin,eyesandmucousmembranes

Potentialforskinsensitisation

Photographicfixersolutions Aceticacid,acidicsaltsolutions(egsodiumthiosulphate)

Irritant

Hardeneraddedtophotographicfixersolutions

Diluteformaldehydesolution Irritant

Frequentcontactmayleadtoskinsensitisation

Lithoplatemaking,gravurecylinderpreparation,photoengraving,photographicbleaches

Dichromates,egammonium,potassiumandsodiumdichromates

Verycorrosive

Inhighconcentrationscancausedeepulcers

Potentialforskinsensitisation

Lithoprinting:fountsolution,blanketrestorers,cleaningsolvents

Isopropylalcohol(IPA),methylethylketone(MEK),whitespirit

Dermatitis

Gravureandflexographicprinting:variousinks

MEK

Alcohols,egindustrialmethylatedspirits(IMS),IPA

Esters,egethylacetate

Aromatichydrocarbons,egtoluene,xylene

Dermatitis

Screenprinting:UV-curedinks N-vinylpyrrolidone(NVP)andMichler’sKetone

Cancer,harmtotheunbornchild

Screenprinting:inks Ketones,egcyclohexanone

Aromatichydrocarbons,egtoluene,xylene

Dermatitis



Table 3 Printingprocesseswhichmaygiverisetoinhalationhazards

Examples of processes or activity Type/name of substance Potential health hazard

Makingflexographicandletterpressplates

Perchloroethylene Dizziness,drowsinessandothereffectsonthecentralnervoussystem

Cleaningrollers,cylindersandblanketrestoring

Chlorinatedhydrocarbons,egdichloromethane

Ketones,egmethylethylketone(MEK)

Dizziness,drowsinessandothereffectsonthecentralnervoussystem

Cardiacarrhythmia(highconcentration)

Affectsliverandkidneysonlong-termexposure

Lithoprinting-fountsolution Alcoholssuchasisopropylalcohol(IPA) Dizziness,drowsinessandothereffectsonthecentralnervoussystem

Gravureandflexographicprinting Inkscontainingketones(egcyclohexanone),alcohols(asinIMS),esters(egethylacetate,isopropylacetate)oraromatichydrocarbons,egtoluene,xylene

Asabove

Screenprinting Inkscontainingketonesoraromatichydrocarbons

Asabove

Screenprinting:UV-curedinks N-vinylpyrrolidone(NVP)andMichler’sKetone

Cancerandharmtotheunbornchild

Adhesivelaminating

Useofpolyurethanelacquers

Isocyanateprepolymers Irritationofrespiratorytract(highconcentration)

Occupationalasthmacouldoccurevenatlowlevels

Handling,cutting,grindingleadtype,hotmetalwork

Leaddust/fume Leadabsorbedinbloodstreamleadstoheadaches,tiredness,stomachpains,constipationandlossofweight

Dyelineprinting Ammoniumhydroxide Irritationofrespiratorytract(asammoniavapour)

High-speedprintingusingUVink-leadingtoinkmisting

ReactiveacrylatescontainedinUVinksetc Irritationofrespiratorytract

Potentialforoccupationalasthma

Laserengraving(gravurecylinders)

Maintenanceinvolvingwelding

Metalfume Irritationofrespiratorytract,‘flu-like’illness(metalfumefeverdependingonthemetal)

Poisoningfromsubstancesinthefume

UseofUVlampsforphotoprocessing,UVcuring,coronadischarge

Ozone Irritationoftheupperrespiratorytract

Headachesandnausea

Digital(ink-jet)printing Methylethylketone

Propanol

Cardiacarrhythmia(highconcentration)

Affectsliverandkidneysonlong-termexposure

Dizziness,drowsinessandothereffectsonthecentralnervoussystem

Dusts

Saw/knifemillinginbindery Paper

Dustofanykindcanirritatetherespiratorytractandblockthenose

Useofanti-set-offpowder Sugar/starch

Thermography Plasticisers

Bronzingmachines,mixingaluminiumpastes

Metal

Manufactureofformes Softwooddust Respiratorydisordersincludingoccupationalasthma

Maintenanceinvolvingcutting,sawing,drillingetc

Hardwood Occupationalasthmaandcancers

Maintenancework,particularlytobuildings

Asbestos Cancersandasbestosis



Specific process health hazards

Design and artworkRiskstohealthfromdesignandartworkcanbereducedby:

n usingnon-flammableadhesives-preferablywax;n removingwaxfromglasssurfacesbyscrapingratherthanusingsolvent;n usingalternativestoaerosolswheretheseareavailableandonlyusingaerosols

ifthereisgoodventilation;n notsmokingwhereaerosolsareused-manywillbeflammable.

Graphic reproductionDarkroomswithautomaticfilmprocessorsneedmechanicalventilationtoensurehealthyandcomfortableworkingconditions.Tentofifteenairchangesperhouristhestandardnormallyachievedintheindustry.Asuitableextractorfanmountedinanoutsidewallwilldo,butitisimportanttoprovideanairinlet.Carefullydesignedlouvrecoverswillensurethatunwantedlightdoesnotentertheroom.

PlatemakingAutomaticprocessingeffectivelyreducesthelikelihoodofskincontactwithchemicalsduringnormaloperation.Somedeveloperscancauseaggressiveskinreactions,sonitrileorbutylrubbergauntletsandprotectiveclothingareneededwhenmanipulatingthechemicalcontainers.Suitablegogglesorfaceshieldsshouldbeprovidedandwornifthereisariskofsplashing.

Keepdrumsofreplenishersolutionfeedingprocessequipmentinshallowtrays,soastocontainspillage(andprotectthefloor).

Deletion fluidsDeletionfluidscontaininghydrofluoricacidintoxicandcorrosiveconcentrationsmaybeusedtomakeminoralterationstoprintingplates.Theseproductsareparticularlyharmfulifskinoreyecontactoccurs-theaffectedareashouldbewashedimmediatelyunderrunningwater,andmedicaladviceobtained.

Checkthesafetydatasheetsfortheseproductstoensurethatappropriatefirstaidisavailable.Antidotecream(calciumgluconategel)willpreventseriousburnsrightdowntothebone.Ifitisneeded,keepfreshstockonthepremises.Makesurepeopleknowwhyitisneededandhowtouseit.

Wherepossible,usedeletionpensasanalternativetosmalljarsorpotsofdeletionfluidtoreducethedangerofskincontact.Iflarge-scaledeletionworkisessential,keepthecontainersofdeletionfluidsinsecurestoragewhennotinuse.

Lithographic printingWash-upsolventshavecommonlyincludedwhitespiritandsimilarmixturesofpetroleumdistillates.Vegetableoilderivativesandhighboilingpointsolventsarenowavailableforuseasrollerandblanketcleaners,andtheseproductsusuallyreducerisktohealthbyinhalation.Skincontactmayremainahazardsothataskincareregimemaybenecessary.TryusingtheseproductsaspartofthesubstitutionapproachunderCOSHH.SeetheboxinsertoverleaffordetailsoftheUKPrintingSolventSubstitutionScheme.



Figure 8 Usedriptraysandautomaticpumpingtoreduceskincontactwithchemicals

UK Printing Solvent Substitution Scheme

Principles of the scheme:

n All‘new’machines(suppliedafter11October2000)willbecapableofbeingusedthroughouttheirnormalworkinglifeandacrossthenormalrangeofproductioncapabilitieswithcleaningsolventshavingaflashpointof55°Cormore(‘AIIIsolvents’).

n Cleaningsolventswithaflashpointoflessthan21°Cwillnotbesuppliedorusedforroutinerollerandblanketwashing(‘AIsolvents’).

n Cleaningsolventswithaflashpointofbetween21°Cand55°Cwillexceptionallyberestrictedtomachinesinusebeforethedateofthisagreementwhere,fortechnicalreasons,thereisnootherpossibleoption.Theywillnotbeusedonnewmachines(‘AIIsolvents’).

n Manufacturers,suppliers,printersandemployeesandtheauthoritieswillworktogethertopromotetheuseofalternativestotheabovesolvents,includinghighboilingpointsolvents(flashpoint>100°C)andvegetablecleaningagents.

n Solventsinblanketreviverandinkstripperproductswhichhavebeenintentionallyformulatedtoincludehalogenatedhydrocarbons,terpenes(assignedtheriskphrasesR38‘Irritatingtotheskin’,R43‘Maycausesensitisationbyskincontact’),n-hexaneandsecondaryaminesoramideswillnotbesuppliedorused.

n Thebenzenecontentofsolventssuppliedorusedwillbelessthan0.1%.n Thetolueneandxylenecontentofsolventssuppliedorusedwillbelessthan

1%.n Thearomaticcontent(C9)ofsolventssuppliedorusedwillbelessthan10%.n Thepercentageofisopropylalcoholoralternativelowboilingorganic

substancesusedinfountsolutionswillbereduced(immediatelyto5-10%)andprogressivelyto5%orless.

n Smallamountsoflowboilingpointmaterialsthatareinfrequentlyused-suchasblanketreviversordriedinkremoverscontainingmethylethylketone-maycontinuetobeusedprovidedappropriatespecialprecautionsareobservedandtraininggiventothoseusingthem.

SupplierswillindicateconformancewiththeschemebyinsertionofthePIACsymbol(availablefromthePIACSecretariat)withthephrase‘UKPrintingSolventSubstitutionScheme’-andtheAI,AIIorAIIIdesignationontheproductlabel.Thephrase‘ConformstoUKPrintingSolventSubstitutionScheme’,theAI/AII/AIII



designationtogetherwiththewords‘ItistheaimoftheschemetoreducetheuseoflowboilingpointorganicsolventsintheprintingindustryinaccordancewiththeprinciplesoftheControlofSubstancesHazardoustoHealth(COSHH)Regulations1999andpromoteimprovedcontrolofsolventexposureinlinewiththeguidancegiveninthebooklet COSHH essentials for printers’shallbeinsertedintoSection16‘Otherinformation’ofthematerialsafetydatasheet(MSDS).

Press,presscomponentandconsumablesuppliersanduserswillworktogetherthroughPICON,theAssociationofPrintingMachineryImporters,theScreenPrintersAssociation,theFlexiblePackagingAssociation,theCorrugatedPackagingAssociation,theNewspaperPublishersAssociation,theNewspaperSociety,theBritishPrintingIndustriesFederation,theScottishPrintEmployersFederationandtheGraphical,PaperandMediaUniontoprovidetechnicalsupportandtrainingonnewcleaningmethodstouserswhomakethechangetohigherboilingpointsolventsandwho,wherenecessary,replaceblanketsandinkingrollers.

Morevolatileandaggressiveorganicsolventsaresometimesusedforremovalofdriedinkortoswelllowareasoftheblanket.Checkwiththesupplierstomakesurethattheleasthazardousproducthasbeenchosen.Whateversolventisselected,useasafesystemofworktocontrolitandreduceexposure.Useoftheseproductsshouldbekepttoaminimum.

Isopropylalcohol(IPA)isamajorcontributortothetotalsolventcontentofpressroomair.Makesurethatthepercentageconcentrationinthefountdoesnotexceed5%andconsidersuitablealternatives.

Humidifiersmaybeusedtomaintainsuitableenvironmentalconditionsforlithoprinting.(Seeunder‘Humidifierfever’inthe‘Otherhealthissues’sectionlaterinthischapter.Thisneedstobeconsideredifhumidifierswithwaterreservoirsareused.)

Ultraviolet (UV) curable materialsParticularcareisneededwhenhandlingultraviolet(UV)andelectronbeamcurablematerials(inks,varnishesandlacquers).Theyareusedinalltypesofprintingandpackagingapplicationswheretheirfastdryinganddurablefilm-formingpropertiesallowimmediateprocessingoftheprint,suchascartonprinting,labels,plasticsubstrates,pharmaceuticalpackaging,printingoftheoutersurfaceoffoodandconfectionerywrappersandmetaldecorating.ClearUV-curablevarnishesandlacquersgiveaprotectiveandhighglossfinishandareusedforgeneraloverprintingwork.

UVlightcuresfreshlyprintedmaterialalmostinstantaneouslybyinitiatingarapidpolymerisationprocess.Beforetheinkorvarnishiscuredtheapplicationviscosityisdependentonthemixtureofreactiveacrylateschosen.MostUV-curableinkscanbeconsideredsolventfree.

However,thehandlinganduseofuncuredmaterialandassociatedwash-upsolventsgiverisetoanumberofrisks.

BurnsTheinitiatorsandsomeconsituentsincludedinUV-curableinksarepowerfulUVabsorbersandcancausesevereburningifinkorvanishcontaminatestheskinandisthenexposedtosunlight.Itisimportanttoensurethatinkandvarnishdoesnotgetontotheskin.Youshouldensurethatappropriatepersonalprotectiveequipmentisprovidedandused.



Skin irritancyPolyfunctionalacrylatesandmethacrylatescancauseskinirritationandsomecanalsocauseskinsensitisation.Thefirstsignsofirritation-reddeningoftheskinandappearanceofarash-maynotdevelopuntiladayafterexposure,andmayworsenoverthefollowingtwotothreedays.Itisgenerallyatemporaryeffectanddisappearsonceexposurestops.

TheUKPrintingIndustryhasagreedaschemeknownasAcrylatePreferenceCriteria,summarisedintheboxinsert,tocontroltheuseofacrylateswithahighpotentialtoirritate.Reactiveacrylatesmeetingthepreferencecriteriastillhavethepotentialforirritancyandsensitisation,buttoalesserextent,andtheirpreferreduseshouldbeconsideredundertheCOSHHsubstitutionduty.

Acrylate Preference Criteria

Preferreduseofacrylatesfulfillingthefollowingcriteria:

n Skinirritancyrating(OECDtest404)lessthan2.n Organicsolventcontentlessthan0.2%.n Acrylicacidcontentlessthan0.1%.n MembersoftheacrylatesuppliersCEFICUV-curableacrylatessectorgroup

willprovideinformationinsafetydatasheetsandskinirritationratingstoinkmanufacturers.

n PrintinginkmembersoftheBCFwillpreferentiallyformulateproductswithacrylatesmeetingthecriteriaandindicatethisonsafetydatasheets.

n Printersadvisedtouseproductsconformingwiththecriteria.n GPMUmembersadvisedingeneralonlytouseproductsconformingwith

thecriteria.n DetailedCOSHHassessmentandadditionalcontrolmeasuresneededif

non-conformingacrylatesused.n Thephrase‘ThisproductconformstotheBCFguidelinesonAcrylatePreference

Criteria’tobeaddedtoSection16oftheproductsafetydatasheet.ThefollowinginformationonglovestobeaddedtoSection8oftheproductsafetydatasheet:

‘Glovesofalengthtooverlapthesleevesofoverallsshouldbeused.Thefollowingisrecommended:

n Single-usedisposableunpowderednitrilegloves(short-durationexposurenotexceeding30minutesorwhereonlysplashesarelikely).Nottobeusedwheremechanicalresistanceisrequired,orwherepunchingortearingoftheglovesislikelytooccur.Nottobereusedwhenremoved.

n Minimum0.45mmthickness,unlined,unpowdered,naturalrubber,latex-free,nitrilegloves(longerdurationexposure,upto4hours,ormechanicalhandlingactivities).Tobereplacedimmediatelywhenpuncturedordegradedorwhenachangeofappearance(colour,elasticity,shape)occurs.

n Heavyduty,unlined,naturalrubber,latex-free,nitrilegloves(whenusingsolvents).Notethatcontactwithketonesorchlorinatedsolventsmayaccelerateglovedeterioration.Tobereplacedimmediatelywhenpuncturedordegradedorwhenachangeofappearance(colour,elasticity,shape)occurs.’

Someacrylatesthatarelesswellused,butmayberequiredtomeetthedemandsofparticularapplications,donotcurrentlyconformtotheAcrylatePreferenceCriteria.Typically,commercialgradesoftheseacrylateshaveskinirritationratingsof2ormore.Particularcareshouldbetakenintherareexceptionswhereitisnecessarytousesuchproducts.



Skin sensitisationSkinsensitisationisapowerfulallergicreactionthatcanoccuratanytime,causingsensitivitytofurthercontact,evenatlowlevels-wellbelowthoseassociatedwithirritancy.Theskincanbecomeredandswollen,notalwaysatthesiteofcontact,forexample,aroundtheeyes.Sensitisationisnormallyirreversibleandmaybecausedbybothnaturalandsyntheticproducts.

HavingselectedtheleasthazardousUV-curableproductpossible,thefollowingfactorsshouldbetakenintoaccounttoreducetheriskofinjuryfromhandlinginksandcoatingsandfromcleaningpresses:

Handling inks and coatings

n Automaticinkdispensersreducetheneedtohandleink,andwherethequantityhandledislarge,considerpumpapplicationfromadrumorstoragearea.Wherethisisnotpossibleandinksareappliedtoductsbyhand,appropriateglovesshouldbeworn.

n Poweredmixingandstirringetcwhichgivesrisetoairborneemissionsshouldtakeplaceindesignatedareaswithsuitableandeffectiveexhaustventilation.

n Keepcontainersforuncuredmaterialsclosedwhennotinuse.n IdentifyprocedurestodealwithwebbreaksorrandomfailureofaUVsource

whichcanproducelargequantitiesofwebcoatedwithuncuredmaterial,alongwithsuitabledisposalarrangements(seeunder‘Cleaningandspillages’).

n Personalprotectiveequipmentshouldbecleanedordisposedofasspecialwasteafteranyobviouscontaminationasitmayotherwisebeamethodoftransferringuncuredmaterial.Sendcontaminatedclothingforspecialistlaunderinginlabelledbags.Suchclothingshouldneverbetakenhomebyemployeesforlaundering.

n Ifuncuredmaterialenterstheeye,rinsewithplentyofcleanwaterandseekmedicalassistance.Dealwithskincontactbywashingwithsoapandwater.Adequatefacilitiesarebestlocatedclosetothepointofuse.

Cleaning and spillages

n Cleaningofmachineryandassociatedequipment,inkducts,rollersetcwillbeneededregularly,forexampleatchangeofcolour,endofshiftortheworkingday,orchangetootherinks.

n Provideimperviousaprons(includingabib),longgauntletglovesandeyeprotectionsuchasaclearplasticfaceshield.SeeAcrylatePreferenceCriteriaforadviceonglovetype.

n Makesureallthelocalexhaustventilationandpersonalprotectiveequipmentprovidedisused.Rememberthatmaintenancepersonnelarealsoatriskfromcontactwithuncuredmaterialsthatcaninadvertentlyaccumulateinnormallyinaccessiblepartsofplantandmachinery.

n Providesuitableliddedcontainerslabelledtoindicatethatskincontactshouldbeavoidedforthesafedisposalofcontaminatedclothsetc.Theseshouldberemovedfromtheworkroomattheendoftheshift.

n Ifcleaningsolventsareintendedtobeusedseveraltimesbeforeeventualdisposal,keepthemonlyforcleaningmachinesusingUV-curablematerials,andstoreinclosedcontainersthatareclearlyidentifiedandlabelled.

n Clothsdampenedwithsolventforcleaningwillbecomecontaminatedwithuncuredmaterial.Skincontactwiththeseclothsislikelytobeaseriouscauseofskinirritationowingtothe‘defatting’actionofthesolventandthedepositionofuncuredmaterialontheunprotectedskin.Disposeofcleaningclothsimmediatelyanddonotputtheminoverallpocketsorleaveonbencheswhereothersmayhandlethem.



n Removepermeableclothingthatbecomesaccidentallysplashedwithcleaningsolventsand/oruncuredmaterialsatonce.Cleanordisposeofsuchclothingasspecialwaste.Sendcontaminatedclothingforspecialistlaunderinginlabelledbags.

Ink mistInkmistorflycanbesignificantaspressspeedsincrease,particularlyinoffsetandletterpressprocesses,andthemistformedcanirritatetheskinandrespiratorytract,withthepotentialforrespiratorysensitisation.

n Whereinkmistgenerationisidentified,androller/plate/blanketpressuresarecorrectandproperlymaintained,trytoreduceexposurebyinkreformulation.Coolingofrollersandcylinderswillhelptoreduceflybymaintainingthecorrectinkviscosity.Otherfactors,apartfrompressspeed,thatmayhaveabearingincludetheamountofmaterialontherollers,thesizeoftheroller,airtemperatureandtherelativehumidity.Askforadvicefromyoursuppliers.

n Ifinkflypersists,considerfittingshroudsatrelevantrollersonthepressandtheprovisionoflocalexhaustventilation.Inallcasesworkroomsshouldbewellventilated,forexamplebymechanicalventilationsystems.

OzoneUVcuringlampsgiveoffconsiderableheatandconvertsomeoftheoxygenpresentintheairintoozone.Mechanicalextractioncoolstheair,butalsoleadstocontinuousgenerationofozonebytheconversionofoxygenpresentinthefreshlysuppliedairaroundtheUVlamp.Ozonegasisharmfulevenatrelativelylowconcentrations.Levelsabouttheoccupationalexposurestandard(currently0.2ppm,15minutetime-weightedaverage(TWA))canleadtoeye,noseandthroatirritation.Higherlevelsofexposuresometimescauseheadacheandnausea.Atlevelsabout15timestheoccupationalexposurestandard,chestpainandcoughingmayoccur.

n Provideextractiontocontrolozoneandductthisoutsidethebuildingtoasafeplacewhereitcannotreturntotheworkroom.Monitortoensurethatthesystemisworkingsatisfactorilyandmakearrangementsfor14-monthlyexaminationbyacompetentperson.

n Unitsusingwatercooling,fedthroughspeciallydesignedquartztubes,allowcuringand,aswellasremovingheat,blockorfiltersomeofthehigherenergy(UV-C)lightresponsibleforozonegeneration.Thesewater-cooledor‘cold-cure’UVlampsdonotrequireair-coolingandthereforethereisnobulkairmovementaroundtheUVlampandozoneisnotlikelytobecontinuouslygeneratedinsignificantamounts.Thisshouldbeconfirmedduringinstallation.

FurtherinformationisgiveninGuidanceNoteEH38Ozone: Health hazards and precautionary measures.

UV lightExposuretoUVlightfromcuringunitscancauseparticularlyacuteeffectsastheyaremuchmorepowerfulthanthoseusedinplatemaking.See‘Radiation’laterinthischapter.

ProvidefixedorinterlockingscreenstopreventdirectorreflectedUVlightbeingemittedintotheworkroom.ThereflectivesubstratescommoninlabelandscreenprintingcreateagreaterhazardiftheUVlampcowlingisnotkeptproperlyadjustedtominimiseescapeoflight.Insomecases,atunnelextensionmayberequired.Noattemptshouldbemadetoinspectprintedsheetsunderthelampbecauseofthehighlevelsofreflectedlight;sheetsshouldberemovedfromthepressforinspection.Screensshouldberegularlychecked,andbrokenordamagedscreensorfilterglassesshouldbereplaced.

AsummaryofthepotentialhealthhazardsandtheprecautionstobetakenintheuseofUV-curablematerialsisgiveninTable4.



Table 4 UV-curablematerials-healthhazardsandprecautions

Health surveillanceHealthsurveillanceofthoseusingUV-curablematerialisrequiredandshouldincludeinspectionofallexposedareasofskinbyaresponsiblepersonwhohasbeeninstructedtorecognisetheskindisordersdescribed.Anypersoncanbenominatedandtrainedastheresponsiblepersonbutoftenafirst-aiderorsupervisorisbest.Thereshouldbeinspectionsatleastonceamonthandemployeesshouldbeencouragedtocheckthemselvesforsignsofskindisease.Casesofsuspecteddermatitisshouldbereferredtoadoctorornurseforfurtherinvestigation.

Wherethemainriskisfrominkfly,promoteawarenessofpossiblerespiratoryproblemsusingpre-employmentenquiriesandinformationaboutsymptoms,andencourageemployeestoreportsymptomstotheresponsibleperson.Wherepre-employmentenquiriesandinformationaboutexistingrespiratoryconditionsandsymptomsoftightnessandpainsinthechest,breathlessnessetcareused,rememberthattheyaresimplyabaselineagainstwhichanyfuturehealthproblemscanbeassessed.Suchenquiriesarenotasubstituteforpropercontrolofexposure.

Healthrecordsforeachemployeesubjecttohealthsurveillanceshouldbekept.Thefirstsignsofharmfuleffect-reddeningoftheskinandarash-maynotappearuntil24hoursafterexposure,andmaygetworseovertwoorthreedays.Asystemofskininspectionwillidentifyanyprinterswhodevelopproblems.

Wash-upsolventswithtracesofUV-curablematerialsareaparticulardanger.Organicsolventsde-fatanddamagetheskin,makingiteasierforallorganicmaterialstopenetratethesurfaceoftheskinandreachthevulnerablelayersbeneath.Keepsuchsolventsoffskinandclothing.

Ifcontactdoesoccur,washoffimmediatelywithplentyofsoapandwater.Removecontaminatedclothingimmediately.Senditforlaundering,butmakesureitisproperlypackagedtopreventinadvertentcontactandlabelled,indicatingthehazard,toprotectotherpeoplewhomayhandleit.Ifeyesareaffected,cleanwithplentyofwaterandgetmedicalhelp.

Screen printing and cleaningScreenprintingisaprocessusinginksandauxiliaryproducts(includingsurfacecoatings)thataresolvent-orwater-based,orcuredbyultra-violetlight(UV).Printing

Type of exposure Health hazards Precautionary measures

ContactwithUV-curablematerials Skinirritation

Skinsensitisation

Considerpossibilitiesforlessirritantsubstitutes,andenclosedhandlingsystemsorautomaticdispensers.Useimperviousaprons,glovesandeyeprotection

InhalationofUVinkmistorinkfly

Upperandlowerrespiratorytractirritation

Potentialforsensitisation

Reformulationofinks,cylindercoolingetc

Shroudingofrollers,andlocalexhaustventilation

Contactwithwash-upsolvents Skinirritation

Upperandlowerrespiratorytractirritation

Consideruseoflocalexhaustventilation.DeviseandusesafesystemsofworkincludinguseofPPEwherenecessary(egspillageandleakage)

Inhalationofozone Eye,noseandthroatirritation

Headachesandnausea

Localexhaustventilation

UVlight Occularirritationtovaryingdegreeswhichmaytemporarilycausedifficultywithvision

Skinburns(ieerythema)

Fixedorinterlockingscreening

Suitablegogglesandskinprotectionduringcertainmaintenancework



maybedonemanuallyorbyusingmachinerywithvaryingdegreesofautomation.Screenprintinginksandsolventsmaycontainglycolethersandtheiresters.Likemanyothersolvents,glycoletherscancausedizziness,headaches,lossofco-ordinationandnausea.Somearemorehazardousthanothers,astheycanalsoaffectthebonemarrowandcauseaplasticanaemiaandoughtnottobeused.ParticularcareandaveryhighstandardofcontrolarerequiredwhereinkscontainingN-vinylpyrrolidone(NVP)andMichler’sKetoneareused.Checkwithyoursupplierifindoubtandsubstitutesaferalternatives.

Screen preparationAdhesivesusedtoattachthemeshtothescreenframeoftencontainisocyanates(seethesectionontheuseofisocyanateslaterinthischapter).Useimperviousprotectiveglovesandafacevisorwhendegreasingorpreparingthemeshbeforeapplyingthestencil,especiallywhenusingcorrosivedegreasants.

UVlampsusedtopreparethestencilscangiverisetoanumberofrisks(seethesectiononUV-curablematerialsearlierinthischapter).Imperviousglovesshouldbewornduringthepreparationofdirectandindirectstencils,andfortheuseoffillerstoblankouttheremainderofascreennotcoveredbyanindirectstencil.Thepreparationshouldbecarriedoutinawell-ventilatedarea.

Printing and dryingScreenprintingareasneedlocalexhaustventilationorextractionthatpreventsoradequatelycontrolstheriskofinhalation.Asaminimumtheventilationsystemshouldcomplywiththeoccupationalexposurelevelsforthesubstancesused.Positionmechanicalventilationsothatitdrawsfumesawayfromtheprinters.Arrangetheworkflowsothatdryingracksarepositionedinanareaofforcedventilation,sotheairflowacrossthemdrawsthefumeawayfromtheworkingarea.Ventdryingtunnelsandovenstoasafeplaceoutside.

Screen cleaning and reclamationAfterprintingalwaysremoveasmuchwetinkaspossiblefromthescreen,wearingsuitableimperviousglovestopreventskincontact(seekadvicefromyourglovesupplierifindoubt).Cleanscreensinamechanicallyventilatedareasuchasabooth.Donotusehigh-pressurewaterjetstocleanscreensdousedwithsolvents,asthiswillresultinunnecessarilyhighlevelsofairbornesolvent.Jetthemwhentheyarefreefrominkandsolvent.

Ifthequantityofworkallows,enclosedautomaticsystemsprovidethebestmethodofscreencleaningandreclamation.

Figure 9 Screenprintingareasneedverygoodventilationtokeeptheairclearoffumes



Operatorsshouldweareyeprotection(gogglesorvisors),aprons,glovesorgauntletsandwaterproofbootswhenusinghigh-pressurewater/steamcleaners.Ventilation,electricalsafety,hearingprotectionanddrainageneedtobeplannedwhenthewetcleaningareaissetout.FurtherinformationisavailableinGuidanceNotePM29Electrical risks from steam/water pressure cleaners.

Use of isocyanateslsocyanatesmaybefoundinadhesivesusedinlaminating,polyurethanelacquers,primersandcertainspecialisedinks.Theyarerespiratorysensitisersandhavethepotentialtocauseasthmaticattacks,whichmayoccurimmediatelyonexposureorafteradelayofseveralhours.Healthsurveillancewillbenecessaryinmostcircumstances-seekspecialistadvicefromanoccupationalhealthprofessionalaboutthis.

Trytochooseproductsthatdonotcontainisocyanatesifpossible,butiftheyareunavoidable,choosethosethathavetheminimumisocyanatecontentnecessaryandaretheleastvolatiletofulfilproductionrequirements.Rememberthereisalwaysariskofrespiratorysensitisationwhenisocyanatesareused,eveniftheyarepresentinproductsatverylowlevelsandappropriatecontrolsshouldbeprovided.

Careisneededtoensurethatcontrolmeasuresareselectedandimplementedtopreventinhalationofisocyanates.Localexhaustventilationthatpreventstheriskofinhalationwillbeappropriateinmanysituations.Asaminimumtheventilationsystemshouldensurecompliancewiththerelevantoccupationalexposurelevelforthesubstancebeingused.Riskislikelytobegreaterinsituationsinwhichthesubstanceisheated,orwhenmistingoraerosolformationmayoccur(theoperatingspeedofthemachinewillaffectthis).

Figure 10 Providefacilitiesfordealingwithspillagessuchasaspillkit

Airmonitoringshouldbecarriedout.Therecanbeseriousriskstohealthifthelocalexhaustventilationorothercontrolmeasuresfail,deteriorateordonotworkproperly.Youshouldkeeparecordofanyexposuremonitoringyoucarryoutforatleastfiveyears.YoucanfindmoreinformationonmonitoringintheguidancebookletMonitoring strategies for toxic substances(HSG173)andMethods for the determination of hazardous substances: Organic isocyanates in air(MDHS25/3).

Generalprotectiveclothing,includingglovesandeyeprotection,willbenecessaryandincertainsituationsrespiratoryprotectiveequipmentwillbeneeded-thiswillbedeterminedbytheCOSHHassessment.



Providefacilitiesforfirstaidandfordealingwithspillages,skinandeyecontaminationandotheremergencies.SeethebookletSafe use of isocyanates in printing and laminatingforfurtherguidance.

Disposal of wasteRememberthatthedisposalofwastematerialsandnominallyemptycontainersaresubjecttoenvironmentalregulations.Takeadvicefromyourwastemanagementcontractorandthewasteregulatoryauthority(EnvironmentAgencyetc).

Noise

Loudnoiseatworkcancauseirreversiblehearingdamage.Itacceleratesthenormalhearinglossthatoccursaswegrowolder.Itcancauseotherproblemssuchastinnitus(troublesomenoisesintheear),interferencewithcommunication,andstress.

Civilclaimsagainstemployersarecommon,andmanyaresuccessfulbecausenotenoughhasbeendoneinthepasttoprotectthehearingofpeopleatwork.

Do you have a noise problem?Asaruleofthumb,ifyoucannothearanormalconversationinyourworkplaceclearlywhenyouare2mawayfromthespeaker,thenoiselevelislikelytobearound85dB(A)orhigher.Ifyoucannothearsomeoneclearlywhenyouareabout1maway,thelevelislikelytobearound90dB(A)orhigher.

Ifyouthinkyoumayhaveaproblem,findoutwhatthenoiselevelsareinyourworkplacebytakingmeasurements.

Measuring noise levelsNoiseismeasuredindecibels-youwillusuallyseeitwrittenasdB(A).Thenoiselevel(soundpressure)ismeasuredlogarithmicallysothatevery3dB(A)increasemeansadoublingofthenoiseenergy,forexample93dB(A)istwiceashazardousas90dB(A).

Inmostjobs,theriskdependsnotjustonthenoiselevels,butalsohowlongpeopleareexposed,includinganyovertime.FormoreinformationseethebookletReducing noise at work(L108).

Noise and the lawTheNoiseatWorkRegulations1989areintendedtoreducehearingdamagecausedbyloudnoiseandtheylaydownthreeactionlevels.TheRegulationsrequireemployerstoassesstherisksandtakeactionwhenworkers’dailyexposuretonoisereachesthe85dB(A)(LEP,d)*‘firstactionlevel’andfurtheractionifitreachesthe90dB(A)(LEP,d)secondor140dB(A)‘peak’actionlevels.Whenmeasuringnoiseexposurenoaccountistakenoftheeffectofanypersonalearprotectorsworn.

* Dailypersonalnoiseexposure:theworker’snoiseexposureaveragedoveraneight-hourworking

period



Figure 11 Doyouhaveanoiseproblem?Loudnoiseatworkcancauseirreversiblehearingdamage

Ifyoufindthatthenoiselevelisatthefirstactionleveloraboveyoumust:

n havetheriskassessedbyacompetentperson;n tellyourworkersabouttherisksandprecautions;n makehearingprotectionfreelyavailabletothosewhowantitwherelevels

exceed85dB(A).

Ifyoufindthatthenoiselevelsareatthesecondactionlevelorabove,inadditiontotheaboveactions,youmustalso:

n doallthatisreasonablypracticabletoreduceexposurewithoutrelyingonhearingprotection,eguseengineeringcontrols;

n userecognisedsafetysignstoidentifyandrestrictentrytozoneswherenoisereaches(orexceeds)thesecondorpeakactionlevels.Employees,includingmanagersandsupervisors,mustnotenterthesezonesunlesswearingsuitableandeffectivehearingprotection.

Noise reductionConsider:

n choosingquietmachinesorprocessesfornewwork.Makersmustreducenoisebygooddesignandconstructionandalsoprovidenoisedatawiththeirequipmentiflevelsarelikelytoreachorexceedthefirstactionlevel.Ifyouarebuyingmachinery,insistonthisinformation.Oncethemachineryisinstalled,checkthenoiselevelsandtakeanystepsnecessarytoreducenoise.Noiseemissionlevelscanbelimitedaspartofthecontractwithsuppliersandcheckedafterinstallation;

n changingthemachineandprocesstoproducelessnoise.Don’tforgetthatotherchangesyoumakemightaffectnoiselevels;

n enclosingnoisymachinesbyprovidingacousticenclosures.Thesehavetobemadeofappropriatenoise-reducingmaterialsandbecorrectlyinstalled.Iftheyarenotproperlydesigned,noiseescapingfromholes,feedopeningsorpoorlyfittingpanelsmaysignificantlyreduceperformance.Specialistadvicewillprobablybenecessary;

n puttingnoisymachinesandprocessesinseparaterooms,awayfromemployees’workareas;

n fittingsilencerstoallexhaustsandmakingsuretheyarekeptinplaceandmaintained.



Reducing exposureThinkaboutreducingthelengthofexposurebyrotatingjobsorprovidinganoiserefuge,egatmachinecontrolpoints.

Remember-hearingdamageiscumulative.Makesurethatyoungpeopleinparticulargetintothehabitofavoidingnoiseexposure,beforetheirhearingispermanentlydamaged.

Providing hearing protectionEnsurethatworkerswearhearingprotectionwheredailypersonalnoiselevelsexceed90dB(A).Rememberthisisnotasubstitutefornoisereductionatsource.

Donotrelytooheavilyonhearingprotectors.Inpracticetheyreducenoiseexposurelessthanisclaimedbecausethey:

n havenotbeencorrectlyselected;n arenotfittedandworncorrectly;n arenotproperlymaintained;n areuncomfortableorinconvenienttowear.

Plasticfoamormineralfibre/waxedplugs,ifproperlychosenandcorrectlyworn,canbeasgoodasearmuffs.Towork,hearingprotectorsneedtobewornallthetimethatpeopleareinnoisyareas.Iftheyareleftoffforevenshortperiods,eventhebestprotectorscannotgreatlyreducenoiseexposure.Supervisorsshouldcheckthis.

Protectorsshould:

n besuitablefortheconditionsinwhichtheyaretobeused;n provideenoughattenuationtoreducethenoiseexposureleveltobelow

90dB(A)andpreferablytobelow85dB(A);

n onlybeissuedonapersonalbasis;n neverberemovedinanoisyenvironment;n becompatiblewithotherformsofnecessaryPPE;n preferablybemarkedtoindicateconformitywithBSEN352:1993Hearing

protectors - safety requirements and testingPart1:Ear-muffs.Part2:Ear-plugs.Part3:1997Ear-muffs attached to an industrial safety helmet.

Itwillbebeneficialforemployeestohaveachoiceofhearingprotectionfromarangeoftypesidentifiedassuitable.SeethefreeleafletsNoise at work: A guide for employees(INDG99),Ear protection: Employers’ duties explained(INDG298),andProtect your hearing!(INDG299)pocketcard.

Workersneedtobeadequatelytrainedintheproperfitting,useandcareofhearingprotection.Thiswillhelptoensurethatprotectorsmaintaintheirefficiencyandarecorrectlyworn.

Common problems and solutions for printersExperiencehasshownthattherearecertainareasthatcanusefullybetargetedtoreducenoiseinaprintingworkplace.

Sheet-fedbuckle-foldingmachinesinthefinishingdepartmentcreatehighnoiselevels.Thesemachinesshouldbefittedwithacoustichoodsatallbuckleplatestoreducethenoise.GuidanceisgiveninthepublicationNoise reduction at buckle-folding machines.



n Web-fedpresseshaveseveralnoisesources(inparticularthefolder),andvariousnoisecontrolmeasuresmaybeappropriate.GuidanceisgiveninthebookletNoisereductionatweb-fedpresses.

n Vacuumpumpsandcompressors,suchasthoseassociatedwithsheet-fedprintingmachines,gatherer-stitcher-trimmersandbuckle-foldingmachines,canproducehighnoiselevelsanditisimportanttositesuchequipmentawayfromtheworkroomorshielditinasuitableenclosure,asthesecanmakealargecontributiontotheoverallnoiselevel.

n Sheet-fedprintingmachines(ingeneral)donotcreateexcessivelevelsofnoiseiftheyareproperlyspacedandhoused,aslongasnoisefromvacuumpumpsandcompressorsiscontrolled.

n Regularpreventivemaintenanceofmachinescanbeimportantinavoidingthegenerationofexcessivelevelsofnoise.Wornbearingsinbuckle-foldingmachinesarefrequentlyfoundtobeasignificantsourceofnoise.

n Itisgoodpracticetocarryoutregularhearingchecksonallemployeeswhosedailypersonalnoiseexposuresequalorexceed90dB(A),andsuchchecksshouldbecarriedoutwhennoiselevelsreachorexceed95dB(A).RefertotheleafletHealth surveillance in noisy industries(INDG193)andtheparagraphsunder‘Hearingprotection’inthe‘Personalprotectiveequipment(PPE)’sectionattheendofthischapter.

Hearing lossUndertheManagementofHealthandSafetyatWorkRegulations1999,employeesexposedtocertaintypesofrisk,suchashighnoiselevels,shouldbeprovidedwithappropriatehealthsurveillance.Suchconditionsarelikely,forexample,atlargeweb-fedpressesandassociatedfolders.Healthsurveillanceforhearinglossusuallyinvolveshearingcheckscalledaudiometry.

Thereisnosimpleformulatoshowwhenaudiometryisnecessary.Thestartingpointistoassesstheriskofemployeesbecomingdeafbecausetheyarebeingexposedtoloudnoise.

Thisriskdependsonthenoiselevelandthelengthofexposure.Employersshouldarrangeforacompetentpersontocarryoutanassessmentoftheiremployees’noiseexposures,asrequiredbytheNoiseatWorkRegulations1989.

Programmesforhearingchecksneedtobeunderthecontrolofsomeonewhocanmakesenseofaudiometricdataandadviseindividualsonthestateoftheirhearingandonfollow-upaction.Thismightbeanoccupationalphysician,anursewithappropriatetrainingandexperience,anaudiologicalscientistoratrainedaudiometricianabletoreferemployeestoamorequalifiedpersonwhentheyneedmoreadvice.

Healthsurveillanceforemployeesinnoisyjobsnormallymeans:

n regularhearingchecksincontrolledconditionstomeasurethesensitivityofhearingoverarangeofsoundfrequencies;

n informingthemabouttheresultsoftheirhearingchecks;n keepingrecords;andn encouragingthemtoseekfurtheradvicefromadoctorwherehearing

damageissuspected.

Formoreinformation,seeGuidanceNoteMS26A guide to audiometric testing programmes.



Manual handling

The law and manual handlingTheManualHandlingOperationsRegulations1992requireallemployersto:

n avoidtheneedforhazardousmanualliftingandhandlingifitisreasonablypracticabletodoso,egbyredesigningthetaskand/orworkplacelayout,eliminatingtheneedtomoveloadsmanually,usingmechanicalhandlingequipmentetc;

n assesstheriskofinjuryfromanyhazardousmanualliftingandhandlingwhichcannotbeavoided;

n takestepstoreducetheriskofinjuryfrommanualhandling,egbyprovidingmechanicalassistance,improvementstothetask,loadorworkingenvironment;

n provideemployeeswithinformationontheweightoftheloadandanindicationoftheheaviestsidewherealoadhasacentreofgravitythatisnotcentrallypositioned.

Risk assessment filterAdetailedassessmentofeveryriskcouldbeamajorundertakingandinvolvewastedeffort,soHSEhasdevelopedafiltertoscreenoutstraightforwardcases.Thefilterisbasedonasetofnumericalguidelinesdevelopedfrompublishedscientificliterature,anditsapplicationwillprovideareasonablelevelofprotectiontoaround95%ofworkingmenandwomenalthoughitshouldnotbeseenasprovidingsafeweightlimitsforlifting.

Theguidelinesassumethattheloadiseasytograspwithbothhandswiththehandlerinastablebodyposition,andtakeintoaccounttheverticalandhorizontalpositionofthehandsastheymovetheloadduringthehandlingoperation,aswellastheheightandreachofthehandler.

Figure12givesaboundarymappedoutbytheguidelines.Ifthehandler’shandsentermorethanoneoftheboxzonesduringtheoperation,thesmallestweightfiguresapply.Ifthetaskrequiresliftingorloweringofthehandsoutsidetheboxzones,amoredetailedassessmentshouldbemade.

Figure 12 Liftingandlowering

3 kg 7 kg

7 kg 13 kg

10 kg 16 kg

7 kg 13 kg

3 kg 7 kg

10 kg 5 kgshoulder height

elbow height

knuckle height

mid lower leg height

shoulder height

elbow height

knuckle height

mid lower leg height

20 kg 10 kg

25 kg 15 kg

20 kg 10 kg

10 kg 5 kg

women men



What are the risks?Althoughsomepeoplearemoreatrisk,everyonecansufferinjuriesasaresultofmanualhandling-thisiswhyhazardousmanualhandlingactivitiesshouldbeavoidedifpossible.Ifitisimpossibletoavoidsuchactivitythenitshouldbeassessedandriskreductionmeasuresconsidered.Whenmakinganassessment,youmayhavetogiveparticularattentiontothefollowinggroupsofpeople:

n younger,moreinexperiencedemployees;n olderand/orlessphysicallyfitemployees;n thosewithexistinginjuriesorconditionssuchasasthma;n pregnantemployees.

Manual/materialshandlingcanleadtoinjuriesandmusculoskeletaldisordersinvariouspartsofthebodyincludingtheback,abdomen,neck,upperlimbsandevenlowerlimbs.

Thecumulativeeffectsofevenminorinjuriescanbecomemorepronouncedoveraperiodoftime.Seriousandlastingdamagetothespineandotherpartsofthebodycanresult.Carefuljobdesigncanavoidtheproblemsofrestrictingparticulartaskstoparticularworkersorthedisruptionthatcanfollowifpeopleareinjured.

Poorliftingandcarrying,pushingandpullingcausesmorethan25%ofthework-relatedinjuriesreportedintheprintingindustryeachyear.

Figure 13 Reelandcylindertrolleysreducetheamountofmanualliftingandcarrying



Reducing the risksWhenmanualhandlingisunavoidable,lookatthejobandthinkaboutreducingtheriskbyprovidingmechanicalhelp,forexample:

n scissorliftsandelevatingtablesatfoldersandguillotines;n pileturnersandjoggerstoreducetheneedforhandturningand‘knockingup’;n mechanicalorfree-runningconveyorstoreduceliftingandcarrying;n hoistsandslingsatreelstandstoreducemanualliftingofpaperreels,especially

thosemountedonswingarms;n reelconveyortrolleysforlocalisedmovementofpaperreelsintoandoutof

reelstands;n cylinderandrollertrolleys;n reelshafttrolley;n sacktrucks.

Otherwaysofreducingtheriskinclude:

n makingtheloadsmaller/lighteroreasiertograsp,egbybuyinginsmallerpaperbundlesorchemicalcontainers;

n reorganisingorredesigningthetaskstoreducetheeffortrequired;n alteringworkstationheightstosuittheworker;n improvingthelayoutoftheworkplacetomaketheworkmoreefficient;n ensuringreasonableworkingtemperatures;n ensuringadequatemanoeuvringspacehasbeenprovided.

Handling newspaper and magazine bundlesSpecificguidanceisavailableonthecontrolofriskfromhandlingbundles,comprisingtwofreeleaflets(IACL105Handling the news: Advice for employers on manual handling of bundlesandIACL106Handling the news: Advice for newsagents and employees on safe handling of bundles)andatrainingvideoWhatthepapersweigh.Theindustryhasagreedamaximumbundleweightof18kg,withatargettoreducethisfurtherto17kgtohelpreducetheriskstoallthoseinvolvedinthedistributionchain-includingdeliveryboysandgirls,andnewsagents.

TrainingConsiderprovidingeveryemployeewithbasictraininginmanualhandlingtechniquesappropriatetothetypeofworktheydo.Youwillalsohavetoconsiderothermoredirectwaystoreducerisk.

Trainingshouldcover:

n howmanualhandlingcancauseinjury;n theessentialsoftheManualHandlingOperationsRegulations1992;n howtorecognisepotentiallyharmfulmanualhandlingtasks/operations;n appropriatesystemsofwork;n correctuseofmechanicalaids;n appropriatehandlingtechniques.

FurtherinformationonmanualhandlingcanbefoundinthebookletManual handling.Manual Handling Operations Regulations 1992.Guidance on Regulations(L23)andtheleafletBack in work: Managing back pain in the workplace(INDG333).



Accidents

Aprinterliftingamagazinebundleweighing12kgontoapalletinjuredhislowerback.Hehadnotbeengivenanyhandlingaidsortrainingincorrectliftingtechniques.

Anemployeeattemptingtoclearajammednewspaperbundleonaconveyorinjuredherback.Shehadnotbeengivenanytrainingorinformationonmanualhandlingtechniquesorbundleclearingtechniques.

Amaintenancefittersufferedbackpainafterliftingpressinkingrollersweighing23kg.Hehadreceivednotrainingorinformationonmanualhandling.Useofmechanicalliftingequipmentorassistancefromasecondpersonwouldhavereducedtheriskofinjury.



Assessing and reducing risks

JobDoesthejobrequire:

n liftingorloweringtoofar?n rushing?n carryingoverlongdistances?n lotsofrepetitions?n twistingandturning?

Work areaIstheworkarea:

n toodark?n tooslippery?n toocongested/obstructed?

LoadIstheload:

n tooheavy?n toolarge?n toounstable?n toosharp?n toodifficulttograsp?

IndividualsAreindividuals:

n fit?n inneedofspecialconsideration?n trained?

Example tasks

Loadingandunloadingdeliveriesbyhand

Movingmaterialstoandfrommachines

Loadingandunloadingmachines

Assemblingandpacking

Preparing,maintaining,movingandrepairingpressesandotherequipment

Short-term action

Providehelpforheavyloads.Reducetheloadsize.

Breakdowntheloadsintoeasilyhandledunits.Foldorwrapoverlargesheetsofpaper.

Raisepalletsetctotherightheightandposition.

Useappropriate,fit,trainedpersonnel.Rotatetheworktoreducerepetition.

Useappropriate,fit,trainedpersonnel.Ensureadequateworkingspace.

Long-term solution

Palletiseloads.Uselifttrucks,pallettrucks,boomconveyors,vehicleswithtailliftsetc.

Useconveyors/hoists/lifttrucks/pallettrucksetc.Useairtables,egatguillotines.

Automateloading/unloadingoperations.Usemechanicalaids,egscissorliftsandpilehoists.

Provideawell-litworkingenvironmentwithsuitableseatingwhereappropriate.Automate.Providemechanicalaids.

Providemechanicalaids,eghoistsforremovingcylindersetc.



Repetitive handlingRepetitivehandlingcanpresentparticularproblemsandgiverisetoconditionscalledwork-relatedupperlimbdisorders(WRULDs)orupperlimbdisorders(ULDs).Sometimestheconditioniscalledrepetitivestraininjury(RSI).

Themusculoskeletalsystem(iethemuscles,bones,ligaments,tendons)inourhands,arms,shouldersandneckcanbeharmedbystaticorawkwardpostures,excessiveforcelevelsandrepeatedexertions.Thisisespeciallysowhenthesearecombinedwithlittleopportunityforvarietyorothermeansofrecovery.

Work-relatedupperlimbdisorders(WRULD)cancauseallofthefollowing:

n pain;n softtissueswelling;n restrictionofjointmovement;n reducedsenseoftouchandmanualdexterity;n permanentdisabilityifothersymptomsgountreated.

Failuretotakepromptactioncanresultin:

n seriousillhealth.Well-motivatedandproductivepeoplehavehadtogiveupworkbecauseofpainanddisablementfromWRULDs;othershavebeensobadlyaffectedthatsimplehouseholdtasksbecomedifficult;

n lostproductionduetoemployeestakingsickleave;n compensationclaimsfromemployeesthathavehadtostopworkingbecause

ofWRULDs;n employeescomplainingof,orseekingmedicalattentionfor,persistentpainor

actualinjury;n hiddencosts,egtrainingnewstafforprovidingextrastaffwheresickness

absenceishigh.Substantialcostsavingscanoccurwhenapreventivestrategyisadopted.

AdditionalinformationaboutupperlimbdisordersisgiveninWork-related upper limb disorders in the printing industry(IACL91).

Toprotectyouremployeesfromupperlimbdisordersyouneedtobeabletoidentifytheoperationsthatgiverisetotheriskandtakestepstoreducethatrisk.

How to assess and tackle ULDsIdentify the hazardsThefollowingareexamplesofoperationswhichcangiverisetoupperlimbdisorders(ULDs):

n Usingpoweredhandtools.n Usingpliersorscissors.n Sealingboxeswithtape.n Handfeeding/unloadingofmachines.n Assemblywork.n Counting,sorting,checking.n Stripping,breaking,knocking-out,knocking-up.n Flatpackwrapping.n Manualhandlingofbundles.n Handinsertionwork.n Jacketingofcasedbooks.

Hazardsmayalsoexistiftheworkinvolvesfrequent,forcefulorawkwardgripping,squeezing,twisting,andrepitition,pulling,pushingorlifting.



Warningsignsofupperlimbdisorderscanincludecomplaintsbyworkersandimprovisedchangestoworkstationsortools.

Ifanyoftheabovearecharacteristicofyourworkplaceyoushoulddoafullergonomicriskassessment.Don’tforgettoconsidertherisksarisingfromtheuseofdisplayscreenequipment(seeChapter3forfurtheradvice).Asystematicandergonomicapproachwillhelptoassessrisksandprovidesolutions.

Reduce the riskApplyergonomicprinciplestomachines,workstationsandworkmethodssothatthejobfitstheperson.Forexample:

n reducehighforcelevels(maintainequipmentproperly,spreadforcelevels,usetoolswithappropriatelydesignedhandles);

n reducehighlyrepetitivemovements(balancefrequentrepetitionwithnon-repetitivework,carryouttaskswiththeotherhand,introducehandlingaids,useautomation,providemorevariedtasks);

n providerest/recoverytimebybreaksoractivitychangesbeforefatiguestarts;n changepostures(modifyoperation,redesignworksothewristcanbestraight);n changetheoperator’spositioninrelationtowork;n wherepeopleremaininthesameposition,provideamixofworkrequiring

movement.

Otherstepsinclude:

n makingsureoperatorsreceiveadequateinformation,instructionandtraining;n beingawareofthemaincauses/symptomsandpreventivemeasures;n reportingproblemsearlybeforetheybecomeserious;n ensuringnewemployeesstartatslowerworkratesbeforegradualupgrading;n rotatingjobs(variationoftasks);n ensuringthatanyincentiveschemesdonotadverselyaffecthowtheworkis

done(egensuresufficientbreaksaretaken).

Future control measures

n Examinerisksfromupperlimbdisorderswhenplanningchangestoworkmethodsorpurchasingnewmachinery.Checkthatergonomicprincipleshavebeenincorporatedinthedesign.

n Considerhealthsurveillance,egrecordkeepingandpromptmedicalassessmentwhenproblemsarereported.

n Thinkaboutwaystoencourageearlyreportingofsymptoms.n Lookatsicknessrecordsandstaffturnover.n Considerthepossibilityofalternativeworkifapersoncannotcontinueina

particularjoborwhereitwillassistareturntowork.n Introduceasystemtomonitortheeffectivenessofcurrentcontrolmeasures.n BealerttoanyincreaseinULDsintheworkplace,egafterachangein

process,andtakeappropriateaction.n Ensurethattherearearrangementsforeffectiverehabilitation(see

‘Occupationalhealthandrehabilitation’earlierinthischapter).



Radiation

LasersLaseruseintheprintingindustryisincreasing.Applicationsincludelaserprintersandcopiers,scanners,platemakers,engravers(inprintingcylindermanufacture),packagedatemarking,diecuttingandtypesetting.

Radiation hazardsAlaserisasourceofintenselight.Laseremissionscanbedangerouswhenviewedeitherdirectlyorwhenreflectedfromasmoothsurface.Thegreatesthazardistotheeye,becauseitfocusesvisiblelaseremissionstoformaverysmallimageontheretina.Powerintensitiescanbeincreasedbyafactorof100000sothatevenafewmilliwattsoflaseremissioncancauseseriousandpermanentdamagetotheretina,andthereforevisionintheaffectedeye.

Itisimportanttogetaneyeexaminationimmediatelyfollowinghazardouspersonalexposure,butroutineeyeexaminationaspartofhealthsurveillanceisnotrecommended.Sometypesoflaserproduceinvisiblebeamsthatmaystillbefocusedbytheeyetoproduceaharmfulimageontheretina.Skinburnsmayalsobeariskthatneedsassessment.

Fume hazardsLasercopiersandcomputerprintersmaygiveoffozone,dustandfume-thisisseldomexcessiveandnotnormallyaproblemiftheequipmentisbothwellmaintainedandsitedinaplacethatiseffectivelyventilated.Othertypesofequipmentmayneedlocalexhaustventilation(LEV)-yourCOSHHassessmentwillhelpyoutodecidetheneedforthis,andyoursuppliershouldbeabletoadvise.

Mechanical and electrical hazardsAswithanymachinery,dangersfrommovingpartsandfromelectricalinstallationsexist-thesehazardsshouldbeevaluatedaspartofyourriskassessment.

Safeguarding standardsLaserproductsareclassifiedinaccordancewiththeirlevelofhazard.BSEN60825-1:1994Safety of laser products Part 1: Equipment classification, requirements and user’s guidegivesinformationonclassdefinitions.LaserproductsusedintheprintingindustrywillgenerallybeClass1(safebyengineeringdesign).Thismeansthelaserandworkpiecewillbefullyenclosedduringnormaluse.

Lasersaregenerallyclassifiedaccordingtotheiroutputpower,butrememberthataClass1laserproductmaycontainahigh-poweredClass4laserinsideitscasing.TamperingwithorremovalofshieldingorenclosurefromaClass1productmayresultinexposuretoahigh-poweredlaseremission.Alsorememberthatharmfulexposurecanresultfromreflectedlaserbeamsaswellasthosethatarevieweddirectly.Avoiduseofmirrorsorreflectiveglassnearlasersources.

Whenyouacquirelaserequipmentthesupplierhasadutytoprovideadequateinformationtoyou(see‘Acquiringmachineryandotherworkequipment’inChapter5).Theinformationprovidedbythesupplierwillhelpyoudevelopsuitablesystemsofworkforthesafeoperationofyourequipment.



Onlyacompetentperson(usuallyaserviceengineer)shouldcarryoutanyservicingorotherworkonyourlaserequipment.Acompetentpersonissomeonewhoisproperlytrainedinlasersafetyandwhoisabletofollowasafesystemofworkwhichinmanycaseswillincludewearingsuitableeyeprotection.Itisyourresponsibilitytoassesseyeprotectionneedsandtoensureyourworkerswearit(see‘Personalprotectiveequipment(PPE)’laterinthischapter).

ForfurtherinformationonlasersseethebookletLaser safety in printing.

Ultraviolet (UV) lightUVlightisusedinphotoengravingandlithographicplatemakingandtocurecertaininks,vanishesandlacquers,eginlithographic,flexographicandlabelprinting(see‘Hazardoussubstances’earlierinthischapterforhazardsofUV-curableinksetc).

UVlightistypicallygeneratedbyacarbonarc,xenondischargetubeormercuryvapourdischargetube.Nowadays,carbonarcsareseldomusedbecauseofthefumetheygenerate(primarilycarbonmonoxideandtoxicoxidesofnitrogen).

Accidents

Anemployeewasdealingwithafilmmisfeedonanimagesetter.Heturnedoffthecomputerbutforgotabouttherasterimageprocessor(RIP).Heopenedthecovertothefilmandlaser,andusedanoverridekeytorunthefilmthroughmanuallysothathecouldfindthemisfeed.ButstoredinformationintheRIPcausedthelasertostartupunexpectedly,andtheemployeesufferedeyedamagefromthereflectedlaseremission.

Radiation hazardsExcessiveUVexposurecancauseacuteeffectssuchasrednessandburningoftheskinanddamagetotheeyes(possiblycausingpainfulconjunctivitis).Theonsetofsymptomsmaybedelayedforseveralhoursafterexposure.Peoplewhohavehadthelensoftheeyeremoved(aphakes)maysufferretinaldamagefromexposuretoUVlight.

SomepeoplemayhaveanabnormallyincreasedsensitivitytotheeffectsofUVlightwhichmaybeaconsequenceofoneofanumberofuncommonmedicalconditionsormayresultfromexposuretoasensitisingchemicalsuchasaprescribeddrug,forexamplesomeantibioticsincludingtetracyclinesandsulphonamides,thiazidediuretics,tricyclicantidepressants,phenothiazinesandsomeothercategoriesofdrugs.Suchsensitisationmayresultinanexaggeratedsunburnresponseorinmorevariedandlesswelllocalisedskinchanges.Anyonewhodevelopsanabnormalconditionaffectingmainlythelight-exposedareasofthebodymayhavebecomephotosensitised.FurtheroccupationalexposuretoUVlightshouldstopandtheindividualshouldbereferredtoadoctor.

UVexposurealsoincreasestheriskofdevelopingvarioustypesofskincancerandisassociatedwithacceleratedskinageingandcataracts.Skincancerriskincreaseswithexposurelevelandwithexposuretimeandisnotthoughttohaveanexposurethresholdbelowwhichthereisnorisk.

Whenconsideringacuteeffects,asageneralrule,UVBsources(thoseemittingatwavelengthsbetween280and320nm(nanometres))aremorehazardousthanUVAsources(thoseemittingatwavelengthsbetween320and400nm).UVCsourcesemitbelow280nmandarepotentiallythemostharmful.UVCradiation



is,however,easytoremoveasevenglassisaheavyabsorber.Thisisatechnicallycomplexarea,andusersmayneedtotakeadvicefromtheirsuppliersabouttheadequacyoftheirprecautions.

Fume hazardsUVlightsourcesusedforcuringareusuallymuchmorepowerfulthanthoseusedinplatemaking.Itisimportanttoensurethatwheretheselampsareaircooledtheyarewellventilatedsothatfumeandozoneisremoved.

Safeguarding standardsFixedorinterlockedscreeningatUVlightunitspreventsdirectorreflectedUVemissionfrombeingemittedtotheworkroomwhereitwouldpresentarisktotheskinandeyes.Itisimportantthatthescreens,shuttersandsealingbrushesonprint-downframesarewellmaintained,sothatemissionleakageisprevented.ItisparticularlyimportanttocheckthatlampcowlingsareadjustedsothatUVescape,especiallywherereflectivesubstratesareinuse,isminimised.Acommonfailureisthesplittingofinfillcanvasscreens.Theseshouldberegularlyinspectedandreplacedasnecessary.

Figure 14 ScreenallUVlightsourcesadequately,preferablywithautomaticcurtainsorblinds

PrintedsheetsshouldnotbevisuallyinspectedunderaUVlampbecauselevelsofreflectedradiationmaybehigh:removesheetsfromthepressbeforeinspection.

ForsomeunusualmaintenanceworkitmaybenecessarytorunaUVlampwithoutscreening.Insuchcases,suitableeyeprotectionagainstUVemissionwillbenecessary,togetherwithclothingtocoverexposedareasofskin.

Forfurtherinformationsee‘Screenprinting’and‘Basicrulesofmachinerysafety’inChapter5.

Infrared sourcesInfraredunitsareusedtypicallyfordryingprintedmaterialatoffsetlithopresses,asanalternativetotheuseofanti-set-offpowderandforaccelerateddrying.Theequipmentmaybefittedretrospectivelytoexistingmachines.

Radiation hazardsInfraredlightmaycauseeyeinjury(especiallytothelensoftheeye).Intheprintingindustry,however,itisunlikelythatsourceswillbeofsufficientoutputforthisrisktobeaseriousproblem.Exposuremayalsocausereddeningandburnstotheskin.



Fume hazardsTheinksusedonlithopresseshavealowsolventcontent.Therearegenerallynofire,explosionorfumehazardsarisingfromtheirevaporation,howeveryouwillneedtoassessthefumehazardsandintroducecontrolmeasuresifnecessary.

Safeguarding standardsInterlockingoflampunitswithpressespreventstheriskoffirewhenmachinesarestoppedduringaprintrun,orwhenthereisamisfeed.

Dryersshouldbeelectricallyisolatedduringwash-upatmachinesandusingflammablesolventsshouldbeavoidedontheinfraredunititself.Lampenclosuremaybenecessarytoshieldoperatorsfromexcessiveexposureandtoreducelevelsofglarethatmightotherwiseinterferewithwork.

Static eliminatorsStaticelectricitymaybeaprobleminsomeplants.Aswellasthepossibilityofoperatorsexperiencingpainfulstaticshocks,thereisalsotheriskofstaticignitionofflammablevapours,forexamplewherevolatile,flammablesolventsareusedinprocessessuchasweb-fedgravureandflexographicprinting.Polythene,PVCandotherinsulatingsubstratesareparticularlylikelytogeneratestatic.

Staticeliminatorsareusedtopreventthebuild-upofunwantedelectrostaticchargesandsoavoidthepotentialforstaticignitionofflammablevapours.Staticeliminatorsneedtobedesignedsothattheycannotproduceincendiarysparks,andwhererelevantneedtobeconstructedtoasuitableexplosionprotectionstandard.Staticeliminatorsmaybeusedinconjunctionwith‘staticassist’devices,ormaybeusedtocontrolstaticgeneratedbythemovementoftheweb.

Somestaticeliminatorscontainsmallamountsofsealedradioactivematerial,whichionisestheair.Itisalsopossibletousestaticeliminatorssuchascarbonfibrebrushes,andhighvoltagetypes,whichdonotcontainradioactivematerial.

Itisimportantthatstaticeliminatorsarekeptcleanandproperlymaintained.

Thecorrectfittingofanystaticeliminatorsisaskilledtaskanditisrecommendedthatadvicebetakenfromthesuppliers.Staticeliminatorscontainingradioactivematerialshouldnotbetamperedwithordismantled.Ifyoususpecttheyarenotworkingcorrectly,callthesupplier.

Skin disease (dermatitis)

Adetailedstudyintheprintingindustryhasidentifiedthatabout40%ofprintingworkersarelikelytohavesufferedfromaskincomplaintatsomestageandover10%arelikelytohaveacurrentproblem.Thishighlightsthefactthatskinproblemsareanimportantproblemintheprintingindustry,whichwerepreviouslyunderestimated.Peopleworkingintheprintingareaandinvolvedincleaningprintingmachineryshowedthegreatesttendencytowardsskinproblems,buttheevidencesuggeststhatsomeproblemscanexistinallareasofprinting.

What is dermatitis?Dermatitisisacommonskincondition,whichisreportedtoaffectbetween15to20%oftheUKpopulation.Thecausesarevaried.Itisoftenquitesimplyaninflammationoftheskin,andcanariseasaresultof:



n aninheritedsensitivitytoeczema(atopy);n contactwithirritantssuchassoaps,solventsandwetwork;n anallergycausedbycontactwithcertainsubstancessuchasnickelorrubber.

Intheworkplaceallthesefactorsmaybeinvolved.Theprintingindustryusesdevelopers,etchingsolutions,solvents,inks,glues,gums,oilsandgreasesthatcanallcauseskinirritation.

Printingprocesseswithahighoccurrenceofskinproblemsare:

n platemaking;n correctionoflithoplates;n solventuse;n UV-curedinkuse;n materialscontainingisocyanates;n cleaningoflithorollersandcylinders;n guillotining;n handlingpressroomconsumables.

Fiftypercentofworkersinvolvedinthecorrectionoflithoplatesorcleaningoflithorollersandcylindersarelikelytohavehadaskincomplaintatsometime.

Affected areasThemostcommonlyaffectedpartsofthebodyarethefingersandthewebsbetweenthefingers,closelyfollowedbythebackofthehands,particularlythoseofprintingpressworkers.Theseworkersgenerallyalsohavemoreproblemsonthewrist,forearmandelbowsthanotherworkers.Somethinglikethree-quartersofthosewhohaveeverhadaskincomplaintfindtheproblemclearsupawayfromwork.Amajorityofskinproblemsfirstoccuraftertheageof16.

SymptomsThemostfrequentlyreportedsymptomsbyprintworkers,andwhichareconsistentwithirritantcontactdermatitisare:

n itching;n roughskin;n dryskin;n redness.

Work-related substancesThemostcommonwork-relatedsubstanceswhichgenerallyaggravateskinconditionsare:

n wash-upsolutions;n inksandcleaningsolvents;n UVvarnishes;n UVinks;n developers;n thinners;n handcleansers.

Washingpowders,cleaningagentsandpersonalsoapsbothatworkandinthehomecanalsocauseproblems.Handlingofpaper,constantwashingandcontactwithwatercanallleadtodryness,anditchyandsoreskinconditions.

Thedisappearanceofsymptomsawayfromwork,foundinaboutthree-quartersofallprinterswithaskincomplaint,reinforcestheneedforbetterskincareprovisionintheindustryandmoreawareness.



Why employers should take action TheManagementofHealthandSafetyatWorkRegulations1999andtheControlofSubstancesHazardoustoHealth(COSHH)Regulations1999requireemployerstoassessriskstohealthaswellassafety,suchasdermatitis,andtakeactiontopreventit.Also,dermatitiscostsmoney-fromsicknessabsence,lossofproduction,staffturnover,retrainingetc.

AspartoftheiroverallCOSHHassessmentsemployersneedtoassesstherisksofdermatitisfromthematerialsandprocessestheyuse.Health surveillance should be carried out and employees properly informed, trained and supervised(seeearlierinthischapterunder‘Healthsurveillance’).

Wherethereisexposuretosubstancesthatmaycausedermatitisandthehandsandforearmsarelikelytobeaffected(forexamplewhereUV-curableinks,lacquersandvarnishesareused)thefollowingmeasureswillhelpprotectemployees.

n Arrangeforaresponsiblepersonsuchasasupervisororfirstaidertobegiventrainingbyanoccupationalhealthprofessionalonthesymptomsandsignsofdermatitis,andsetupasystemofperiodicskininspections.Thefrequencyoftheinspectionswilldependontheindividualcircumstances,egthelikelyseverityofthedermatitisthatmightdevelop,butwouldnormallybeatleastmonthly.

n Arrangefornewemployeestohavetheirhandsandforearmsinspectedbeforetheystartworkwiththesubstancethatmightcauseaskinreaction.

n Referanyemployeefoundtohaverelevantsymptomsorsignstoasuitablemedicalpractitioner(normallyanoccupationalhealthphysician)whoisfamiliarwiththerisksoftheprocessandtheprinciplesofhealthsurveillance.

n Trainemployeessotheycanrecogniseandreportrelevantsymptomsandsignsofillnesstotheresponsibleperson.

FurtherguidanceisgiveninthebookletAssessing and managing risks at work from skin exposure to chemical agents(HSG205)andSkin problems in the printing industry(IACL101rev1).

Other health issues

Workplace stressStressisthesecondbiggestoccupationalhealthproblemintheUK,afterbackpain.About5millionworkerssufferfromhighlevelsofstressatwork.Howemployersdesignandmanagejobsaffectsthementalandphysicalhealthoftheiremployees.

What are the effects of stress?Stressispeople’snaturalreactiontoexcessivepressure-itisn’tadisease.Butifthestressisintenseorgoesonforsometime,itcanleadtomentalandphysicalillhealth,suchasdepression,nervousbreakdownorheartdisease.Thesymptomsofstresscanalsoincludeindecision,anxiety,alteredappetite,changesinweight,headaches,backache,skinrashesanddifficultyinsleeping.

What must employers do?Itisthedutyofallemployerstomakesurethattheiremployeesarenotmadeillbytheirwork.Wherestresscausedormadeworsebyworkcouldbe,oris,leadingtoillhealth,employersmustassesstherisk.

Ariskassessmentforstressinvolves:

n lookingforpressuresatworkwhichcouldcausehighandlong-lastinglevelsofstress;



n decidingwhomightbeharmedbythese;andn decidingwhethertheemployerisdoingenoughtopreventthatharm.

Ifnecessary,employersmustthentakereasonablestepstodealwiththosepressures.Simplyrelyingonemployeestomanagetheirownstress,forexamplebytrainingtheminrelaxationtechniques,orjustprovidingcounsellingwhentheyexperiencehighorsustainedlevelsofstressisnotenough.Referalsotothesectiononoccupationalhealthservicesatthebeginningofthischapter.

Managing stressMostofthe‘thingstodo’onstressboildowntogoodmanagement,includinggoodmanagementofhealthandsafety.Theyareongoingprocessesthatneedtobebuiltintothewayacompanyisrun.

n Takingstressseriously,andbeingunderstandingtowardspeoplewhoadmittobeingundertoomuchpressure.

n Encouragingmanagerstohaveanopenandunderstandingattitudetowhatpeoplesaytothemaboutthepressuresoftheirwork,andlookingforsignsofstressintheirstaff.

n Ensuringthatstaffhavetheskills,trainingandresourcestheyneed,sothattheyknowwhattodo,areconfidentthattheycandoitandreceivecreditforit.

n Ifpossible,providingsomescopeforvaryingworkingconditionsandflexibility,andforpeopletoinfluencethewaytheirjobsaredone.Thiswillincreasetheirinterestandsenseofownership.

n Ensuringthatpeoplearetreatedfairlyandwithconsistencyandthatbullyingandharassmentarenottolerated.

n Ensuringgoodtwo-waycommunication,especiallyattimesofchange,andnotbeingafraidtolisten.

Workplace stress and mental healthWorkplacepressurecankeepstaffmotivatedandbethekeytoasenseofjobsatisfaction,butpeople’sabilitytodealwithpressureisnotlimitless.Excessiveworkplacepressureandresultingstresscanbeharmfulanddamagingtobothyouremployees’healthandtoyourbusinessperformance.

EmployershavearesponsibilityundertheHSWActtotakereasonablecaretoensurethathealthisnotputatriskthroughsustainedlevelsofstressarisingfromthewaytheworkisorganised,thewaypeopledealwitheachotherorfromday-to-daydemands.

Itisknownthattoolittlepersonalcontroloverthework,notbeingallowedtouseskillsfully,beingoverworkedorunderworked,andboringworkcanallcontributetostress.

Learntorecognisesignsofstressandencourageemployeestodiscussproblemsopenly-arepeopledistracted,tenseorworried?

Givehelp,besympatheticand,ifappropriate,adviseemployeestoseetheirdoctor.Delaycanmakemattersmuchworse.

Furtherinformationonstressatworkcanbefoundintheemployer’sguideTackling work-related stress: A manager’s guide to improving and maintaining employee health and well-being(HSG218)andtheleafletWork-related stress: A short guide(INDG281).

New and expectant mothers at workEmployersarerequiredtotakeparticularaccountofriskstonewandexpectantmotherswhencarryingoutriskassessments.Particularattentionshouldbegivento



liftingandcarrying,hoursofworkincludingnightwork,workrequiringlongperiodsofstandingandworkinvolvingexposuretochemicals,egexposuretolead.Employersneedtoensurethatexposuretocarcinogenic,mutagenicorteratogenicsubstancesisprevented,assuchexposuremaycreatearisktotheunbornchild.

Ifariskisidentifiedthensuitablealternativeworkshouldbeoffered.Ifthisisnotpossibletheworkershouldbegivenpaidleaveforaslongaspossibletoprotectherhealthandsafetyandthatofherchild.

FurtherinformationcanbefoundinthebookletNew and expectant mothers at work. A guide for employers(HSG122).

Drugs and alcoholThemisuseofalcoholanddrugscanaffectworkperformanceandpotentiallyposeathreattohealthandsafety.Employerscanbenefitbydevelopinganalcoholanddrugspolicy.Thispolicyshouldformpartoftheoverallhealthandsafetypolicy.Itshouldhelpemployersidentifyproblemsatanearlystage,encourageaffectedpeopletocomeforwardforhelpandtreatmentandensureappropriatecontrols.

Worksuchasoperatingmachineryordrivingdemandsclearthinkingandsoundjudgement.Whereperformanceisimpaired,peopleshouldnotbeallowedtoundertakesuchduties.Allactivitiesofemployeeswhoareinaplaceofworkwhileundertheinfluenceofdrugsoralcoholshouldbestrictlycontrolled.

HSE’sEmploymentMedicalAdvisoryServicecanadviseonallaspectsofoccupationalillhealthincludingdrugabuse.FurtherinformationforemployersisavailableintheleafletDrug misuse at work(INDG91).

Passive smokingPassivesmokingisthebreathinginofotherpeople’stobaccosmoke.Itcancausedamagetohealth,makeasthmaworseandcauselungcancer.

Thinkaboutagreeingruleswiththeworkforcetoprotectnon-smokersandencouragingandhelpingsmokerstogiveup.AdviceisgiveninthebookletPassive smoking at work(INDG63).

TheWorkplace(Health,SafetyandWelfare)Regulations1992requirethatrestroomsandrestareasincludesuitablearrangementstoprotectnon-smokersfromdiscomfortcausedbytobaccosmoke.Thiscanbeachievedbyprovidingseparaterestareasorroomsforsmokersandnon-smokersorbyprohibitingsmokinginrestareasandrestrooms.

Humidifier feverHumidifierfeverisaflu-likeillnesscausedbyinhalationoffinedropletsofwaterfromhumidifiersthathavebecomecontaminatedbymicro-organisms.ItshouldnotbeconfusedwithLegionnaires’disease(see‘Legionellosis’).

Thesymptomsofhumidifierfevervaryfrommildfeverwithheadache,malaiseandmuscleweakness,toacuteillnesswithhighfever,cough,chesttightnessandbreathlessnessonexertion.Theonsetofsymptomsisdelayed,beginningfourtoeighthoursafterthestartoftheworkingshift.Thesymptomsusuallyoccuronthefirstdaybackatworkafteraweekendorotherbreakandtendtoresolveover12to16hours.

Humidifiersaresometimesusedinprintcompaniestostabilisepapersizeandcondition.Theyarealsopresentinbuildingair-conditioningsystems.



Contaminationofhumidifiersystemsismostlikelytooccurininternalreservoirswithinthehumidifiersandinholdingtanks,especiallyifthewaterisrecirculated.Paperdustoranti-set-offpowdersmayactasanutrientforthegrowthofmicro-organismsifallowedtoaccumulate.Exposurethenresultsfromsprayemittedfromthecontaminatedsystem.

Sofar,casesofhumidifierfeverintheprintingindustryhavebeenassociatedwithspinningdiscandspray-typehumidifiersincorporatingholdingreservoirs.

Prevention and controlChoosethehumidificationequipmentthatisleastlikelytobecomecontaminated,egsteamhumidifiers,compressedairatomisersthattakewaterdirectlyfromthemains,orevaporativetypehumidifiersthatdonotcreatewaterspray.

Maintaincleanliness-weeklycleaningmaybenecessaryinprocessenvironments,everytwotothreemonthsmaybeacceptableforoffices.Ensurethathumidifiersaredrainedandkeptdryduringperiodswhentheyarenotinuse,andarethoroughlycleanedanddisinfectedbeforetheyareusedagain.

Ifhumidifierfeverissuspected,turnoffthehumidifiersandseekadvicefrombothamedicalpractitionerandacompetentventilationengineerwiththenecessaryspecialisedknowledgeofhumidifiers.

LegionellosisLegionnaires’diseaseisapneumoniathatprincipallyaffectsthosewhoaresusceptibleduetoage,illness,immunosuppression,smokingetcandmaybefatal.Legionellaecanalsocauselessseriousillnessesthatarenotfatalorpermanentlydebilitatingbutwhichcanaffectalltypesofpeople.

Infectionisattributedtoinhalinglegionellae.Thesebacteriaarewidespreadinnaturalwatersourcesbutmaymultiplyundercertainconditionsiftheyenterman-madesystemsorwaterservices.Mostcasesandoutbreaksoflegionellosishavebeenattributedtowaterservicesinbuildingsandcoolingtowers;othersourcesmayincludehumidificationsystemsandindustrialcoolants.Plantandsystemscontainingwaterwhichislikelytohaveatemperatureintherange20-45°C,andwhichmayreleaseasprayoraerosolduringoperationorwhenbeingmaintained,mayalsopresentarisk.

The lawTheNotificationofCoolingTowersandEvaporativeCondensersRegulations1992requirethenotificationtolocalauthoritiesofwetcoolingtowersandevaporativecondensers.Legionnaires’ disease: Control of legionella in water systems. Approved Code of Practice(L8)givesguidanceoncomplyingwiththerequirementsoftheHealthandSafetyatWorketcAct1974andtheControlofSubstancesHazardoustoHealthRegulations1999inrespectofthisrisk.

AsbestosAsaroughguide,ifyourbuildingwasbuiltbeforethe1980sandyoucarryoutanytypeofmaintenance,repairorrefurbishmentwork,eveninstallationofnewcablinginanoffice,youcouldbeexposingpeopletoasbestosdustwithoutrealisingit.Anyindividualexposuremaybesmall-butthesecanbuildupandmayresultinanasbestos-relateddiseaselateroninlife.Thisisparticularlyrelevanttomaintenancepersonnelandcontractorswhocouldunknowinglydisturbasbestosinpremisesbuiltbefore1985iftherearenorecordsofwhatmaterialisinthebuilding.

SeethesectioninChapter1dealingwiththecontrolofcontractorsandChapter3aboutthemanagementofasbestosinworkplacebuildings.



Local exhaust ventilation (LEV)

Maintenance, examination, testing and the lawUnderregulation9oftheControlofSubstancesHazardoustoHealthRegulations1999,controlmeasuresmustbemaintainedinanefficientstate,inefficientworkingorderandingoodrepair.Regularmaintenancewillensurethisisachieved.EmployersmustalsoensurethatthoroughexaminationsandtestsofLEVarecarriedoutevery14months,andappropriaterecordsmustbekeptforatleastfiveyears.

Someonewhohasthenecessarytraining,knowledge,skillsandexperienceshouldcarryoutmaintenance,examinationandtestingofLEV.Yourinsurancecompanymayhavethecompetencerequired.

Selection and useLEVisfrequentlyusedandcanbeaneffectivewayofcontrollingexposuretohazardoussubstances.Itworksbydrawinghazardousemissionsawayfromthebreathingzonesofworkersintoahoodorboothandductworkconnectedtoanextractorfan.LEVmayalsobeusedonmachinesforcontrollinghazardoussubstancesatthepointatwhichtheyaregenerated.

ExamplesofsituationswhereLEVmightbenecessaryinclude:

n screenprintingandscreencleaningwork;n gravureprintingusingvolatilesolvents;n UVunitswhereozoneorinkflyisgenerated;n hotmeltgluestationsandpapermillingatadhesivebinders.

InmanycircumstancesLEVmaybecheaperandmoreeffectivethangeneralventilation.(Generaldilutionventilationworksbyintroducingfreshairintotheworkplacetolowerthegenerallevelofhazardoussubstancesintheair.)

HeatlossesfromLEVmaybeminimisedbyheatrecoverysystemsorrecirculationoffilteredair.Recirculationshouldonlybeemployedafterspecialistadvicetopreventtherecirculationofhazardousmaterialsinharmfulquantities.

Making the most of LEVGetanexperttodesignandinstallthemostappropriatesystem,withtherighthoods/enclosures,ductwork,airvelocitiesandcleaningandfiltrationsystems.Itissensibletoinvolveemployeesindiscussionsaboutthedesignofthesystems,astheyhavetousetheplantandwillhaveviewsaboutwhatisworkable.Ingeneral:

n Keeptheextractionasclosetothesourceofcontaminationaspossible.n Makesurethefandrawsairawayfromtheoperator.n Extractatthesamelevelorbelowthesourceofcontaminantunlessthereis

needtocontrolfumerisingfromaheatedsource.Extractionpositionedabovetheoperator’sheadwilldrawharmfulsubstancesintotheirbreathingzone.

Check,cleanoutandmaintainthesystemregularly,particularlyflexibleductwork.Ifnecessary,provideenoughheatingandlighting(suitablyprotected)withintheenclosuretoencourageworktobedoneinsidetheextractedarea.

Common causes of LEV failureThefollowingarecommoncausesofLEVfailureandareeasilycheckedbyyou.Ithelpstokeeparecordofthesechecks:



n physicaldamagetoandpoorpositioningofhoodsandbooths;n damagedand/orblockedductwork;n blocked,damaged,unsuitableorincorrectlyinstalledfilters;n toohigh/lowwaterlevelsinwetcollectors;n wear,corrosionorbuild-upofcontaminantonfanblades;n slippingorbrokendrivebeltstofans;n poorlubricationoffanbearings;n poorfitmentoftheductwork.

Figure 15 Makesurefansdrawairawayfromtheoperator

Personal protective equipment (PPE)

Ifyouarethinkingofusingpersonalprotectiveequipment(PPE)tocontrolemployees’exposuretosubstanceshazardoustohealth,rememberthatCOSHHlimitsitsusetosituationswhereitisnotreasonablypracticabletouseothercontrolmeasuressuchaslocalexhaustventilation.

PPE and the lawThePersonalProtectiveEquipmentatWorkRegulations1992requireemployersto:

n assessriskstohealthandsafetywhichhavenotbeenavoidedbeforeprovidingPPE;

n providesuitablePPEfreeofchargetoprotectemployeesagainstriskswhichhavenotbeencontrolledbyothermeans;

n takeallreasonablestepstoensureitisproperlyused;n maintainPPEprovidedincleanandefficientworkingorderwithappropriatestorage

accommodationforitwhenitisnotinuse;n giveinformation,instructionandtraininginitsuse.

EmployeesmustusethePPEprovidedandreportanylossorobviousdefecttotheemployer.

GoodBad

GoodBad



Figure 16 Someprinciplesofgoodductingdesign

Respiratory protective equipment (RPE)ChoosingWhenchoosingrespiratoryprotectionconsiderthejobtobedoneindetail.Identifythecontaminantandthelikelylevelofexposureagainstwhichprotectionisrequiredandtakeintoaccounttheworkingenvironmentinwhichitwillbeworn.

DifferenttypesofRPEofferdifferentlevelsofprotectionandthecorrecttypehastobematchedagainstthejob,includingthepotentiallevelsofexposure,andthewearer.Assesstheworkcarefullyandconsultthesuppliersofthesubstanceinuseandtheprotectiveequipment.British(BS)andEuropean(EN)Standardssetoutthespecificationsforrespiratoryprotectivedevicesandfilters.Checkthatequipmentismarkedtoindicateconformitywithastandard.Unlessitisagoodfitandproperlyworn,RPEwillnotoffereffectiveprotectionandwillnotperformasdesigned.

MaintainingThoroughlyexamineand,whereappropriate,testRPEatleastonceamonthandmorefrequentlywhereconditionsaresevere.(Thisdoesnotapplytoone-shiftdisposablerespirators.)Half-maskrespiratorsusedonlyoccasionallyagainstdustorfumesofrelativelylowtoxicitymaybeexaminedatlongerintervals,butnotlessthanonceeverythreemonths.Makesureemployeeshavefacilitiestocleanrespiratorsandknowhowtodothiswithoutdamagingthem.

Ensurethatbreathingairsuppliedtoair-fedequipmentissatisfactory;proprietaryequipmenttodothisiswidelyavailable.

BAD GOOD

BAD GOOD GOOD

BAD GOODBAD



Figure 17 EmployersneedtoprovidesuitablePPEandinformation

Figure 18 Examplesofrespiratoryprotectiveequipment

Eye protectionEyeprotectionwillhavetobeprovidedandused(sometimesthroughoutthewholeworkshop)whereworkthatputseyesatriskiscarriedout,eg:

n theuseofpressure-cleaningapplianceswhichleadstotheprojectionofsprayandparticles;

n theuseofhazardoussubstances,suchassolventswhichmaysplashintotheeye;

n inmaintenancedepartments,grindingandothermachiningprocesses,whichleadtotheuncontrolledejectionofmetallicparticles.

BSEN166:1996Personal eye-protection. Specificationssetsoutthestandardforeyeprotectionforindustrialandnon-industrialuses.Specialarrangementsareappropriateforpeoplewhonormallywearglassessuchastheuseofgogglesorsafetyglasses.

Skin protectionTheselectionofsuitableprotectiveglovescanbeacomplicatedprocedure.Seekexperthelpfrommanufacturersordistributors.Fortheglovetobesuitableitmust:



n beappropriatefortherisk(s)andtheconditionswhereitisused;n takeintoaccounttheergonomicrequirementsandstateofhealthoftheperson

wearingit;n fitthewearercorrectly,ifnecessary,afteradjustments;n eitherpreventorcontroltheriskinvolvedwithoutincreasingtheoverallrisk.

Furtherinformation,includingatablewithasimpleguidetoselection,isgivenintheleafletSelecting protective gloves for work with chemicals(INDG330),thebookletCost and effectiveness of chemical protective gloves for the workplace(HSG206)andtheleafletSkin problems in the printing industry(IACL101rev1).

Forotherprotectiveclothingrequirementssee‘WorkwithUV-curablematerials’earlierinthechapter.

Storage of PPESuitableaccommodationshouldbeprovidedforPPEwhenitisnotinuse.ThestorageshouldbeadequatetoprotectthePPEfromcontamination,loss,ordamageby,forexample,harmfulsubstances,damporsunlight.WherePPEbecomescontaminatedduringuse,theaccommodationshouldbeseparatefromanyprovidedforordinaryclothing,andwherenecessarybesuitablylabelled.SpecialarrangementsmayhavetobemadetocleanPPE.Makesureyouinformyourcleanersaboutanyhazards.



Chapter 5 Process safetySee the ‘References’ section at the back of the book for details of publications which relate to PROCESS SAFETY and also see Appendix 1 ‘Safeguarding terms’


TheHealthandSafetyatWorketcAct1974(HSWAct)requiresemployerstoensure,sofarasisreasonablypracticable,thehealth,safetyandwelfareatworkoftheiremployees.Thisdutyextendstotheprovisionandmaintenanceofplantandmachinerythatissafeandwithoutriskstohealth.

TheProvisionandUseofWorkEquipmentRegulations1998(PUWER98)placegeneraldutiesonemployerstoensurethattheworkequipmenttheyprovideissuitableandsafeforuse.

ManufacturersandsuppliershavedutiesundertheSupplyofMachinery(Safety)Regulations1992(amended1994)toprovidenewequipmentthatmeetscertainessentialhealthandsafetyrequirementsandissafe.Employers,however,shouldstillassessallequipmenttoensureitissafeandfreefrompatentdefectsbeforebringingitintouse.ThefactthatamachineisCEmarkeddoesnotnecessarilymeanthatitissafeforuseinyourprintworks-youmayhaveproceduresandancillaryprocessesthatwerenotconsideredbythemanufacturersoyouwillstillneedtodoyourownriskassessment.

Provision and Use of Work Equipment Regulations 1998 (PUWER 98)

ThemainrequirementsoftheRegulationswhichwillneedtobemetbyemployersintheprintingindustryaretoensurethat:

n equipmentissuitablefortheusethatwillbemadeofitandisnotusedforunsuitableapplications(egunprotectedelectricalequipmentinpotentiallyexplosiveatmospheres);

n equipmentisadequatelymaintained;n guardsandprotectivedevicesarekeptingoodworkingorder,egby

performingdaily/weeklychecksonthesatisfactoryoperationofphotoelectricorinterlockedguards;

n equipmentwhosesafeoperationiscriticallydependentonitsconditioninuseandwheredeteriorationwouldleadtosignificantrisk,suchaspower-operatedguillotinesandhand-fedplatenpresses,areinspectedatsuitableintervalsbyacompetentperson;

n adequateinformation,instructionandtrainingisgiventooperators,eglifttruckoperators;

n newequipment(includingsecond-handequipmentfromoutsidetheEuropeanEconomicArea)conformswithproductsafetylegislation,egtheSupplyofMachinery(Safety)Regulations1992andamendments;

n hazardouspartsofmachineryareguarded,egin-runningnipsatcylindersandrollers;

n thereisprotectionagainstspecifichazards,egdisintegrationandejectionofslittingdiscs;

n controldevicesareclearlyvisible,properlymarked,unambiguous,reliableandperformallthetasksnecessaryforsafeoperation,egprovisionofemergencystopandothercontrolswhereappropriate;



n equipmentcanbeisolatedfromtheelectricalsupplyandothersourcesofenergy,egusingaproperlyearthedelectricalsupplyisolatoradjacenttothemachine,orisolatinggasvalvesatheat-setovens;

n adequatelightingisprovided,egatthetestsheetremovalareaofasheet-fedpress;

n maintenancecanbecarriedoutsafely,egprovisionofladderwaysandworkingplatformsonlargewebpressesformaintenanceoffreerunningrollers;

n equipmentisstable,egboltedtothefloor.

Basic rules of machinery safety

Everyyearseriousaccidentsoccurintheprintingindustryasadirectresultofunguardedorinadequatelymaintainedmachinery.Justbecauseyouhaven’thadanaccidentataparticularmachine,don’tassumethatthemachineissafe.Machinerymayneedupgradingtomeettherightsafetystandards.Doariskassessmenttocheckwhetheryourguardingissuitable,thentakeanynecessaryactiontoreducerisks.(See‘Planningandriskassessment’inChapter1.)

Thefollowingareexamplesofbasicstepsyoucantaketoreducetheriskofmachineryaccidentsatwork:

1 Choosetherightmachineforthejob.

2 Checkthatitisadequatelyguarded,egisthereprotectionfromin-runningnip hazardsatinkingrollersandprintingcylinders,istransmissionmachinery enclosed,areallinterlocksworkingcorrectly,aregapcoversprovidedand usedwherenecessary?

3 Ensureoperatorsandsupervisorsareadequatelyinformed,instructedand trainedsotheyknowhowtoworksafelyandhowtousetheguardsandsafety devicesprovided.Somemachines,includingguillotinesandplatenprinting machines,areextremelyhazardous.Youngpeopleinparticulararelikelyto needadditionaltrainingandahighlevelofsupervision.

4 Checkadequatelightinghasbeenprovidedforworkatallmachines.

5 Provideclearworkingspacearoundmachinery.

6 Testandcheckmachineryregularlytoensuresafeguardsareworking.

7 Carryoutmaintenanceworkonaproactiveratherthanreactivebasis.

Machinery guardingAllmachinerymustbeguardedsothataccessisnotpossibletohazardousparts.Whereverpossible,fixedguardsshouldbeused.However,ifregularaccessisneededtohazardousparts,egprintingcylinders,theninterlockingguards,tripnipbars,fixednipbars,anelectrosensitivesafetysystemoracombinationoftheabovewillbemoreappropriate.

EuropeanNorm(EN)Standardsgivespecificationsfornewmachines.However,someofthesestandardsmayalsoberelevanttoexistingmachines.

Guardsshouldbecarefullydesigned,constructedandfittedtoensurethattheyare:



n inaccordancewiththesafetyreachdistanceslaidoutinBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbssothatopeningsinoraroundguardsdonotallowaccesstothehazardousparts;

n sufficientlyrobust,egnipbarsdonotbecomedeflected;n notheavyorawkwardtouse(egsomegapcoversandlift-offinterlocked

guardsprovidedforflexopresses);n designedtoallowoperatorstoseecertainmachinefunctions(eggluinguniton

anadhesivebinder);n designedtobecompatiblewithmachineryoperation(egfittingofwash-up

trays);n ofadequateelectrical/electronicintegrity(egsuitableforusewithin

flammableatmospheresatgravurepresses),andreliableenoughforasafetyapplication;

n arelocatedcloseenoughtorollersiftheyarenipbars(ienomorethan6mmfromthecylindersurface);

n designedsothattheydonotcauseahazardthemselves.

Figure 19(a) Identifyingbasicmachineryhazards

Thefollowingareexamplesofmachineryhazards-someorallofthesemayberelevanttoyourworkplace.

Partsofthebody,clothingandcleaningclothscanbecomeentangledinrotatingandin-runningpartssuchasinkinganddampingrollers,printingcylinders,nippingrollersortransmissionmachinery.

Transmissionmachinery Conveyors

Gears Inkrollers Nippingrollers Printingcylinders



Figure 19(b) Identifyingbasicmachineryhazards

Interlocking guardsOpeninganinterlockedguardshouldstopmovementofhazardouspartsbeforetheycanbereached.Alternatively,guardlockingcanbeusedtopreventtheopeningofguardsuntilhazardousmovementhasstopped(thisisparticularlyappropriateformachineswithlongrundowntimes).Interlockedguardsshouldbeusedwherethereisaneedforfrequentaccess.

Figure 19(c) Identifyingbasicmachineryhazards

Shearingcanoccurbetweenpartsmovingpastoneanother.

(a) (b)

When a cylinder has a gap in it as shown in (a), a gap cover which completes the periphery of the cylinder as shown in (b) can be fitted. This eliminates the shear trap which arises when the cylinder rotates past the fixtures.

Crushingcanoccurbetweenpartsmovingtowardseachotherorbetweenfixedandmovingparts,egthetrapsbetweengripperbarsandmachinebodyoncertainlithopresses,trapscreatedbyclosingscissorliftsortrapscreatedbetweenmovingpartsofmachinesandfixedstructures,eglithoproofingpresses.

Cuttingandseveringcanoccuratsharpedgesorsurfaces,egweb-severers,slittersandguillotineblades.

Materialscanbeejectedfrommachinery,egreelsfromreelstandsandhotgluesfromadhesivebindingmachines.

Electricitycanalsocauseaccidentsatmachines(seeChapter6).



Figure 20 Integrityofguardinterlocks

Machine controlsControlswitchesshouldbeclearlymarkedtoshowwhattheydo.Emergencystopcontrolsshouldbeprovidedwherenecessary,egredmushroom-headedbuttonsonayellowbackground,withineasyreachofoperatorpositionsthatstopallhazardousmotionandrequirepositiveresetting.

Operationalcontrolsshouldbedesignedandplacedtoavoidaccidentaloperation,egbytheuseofshroudsonstartbuttonsandpedals.Presseswithreversefacilitiesshouldhavethereversecontrolsdistinguishablebytouch.Thisisusuallydonebytheuseofdeepshrouds.Hingedflapscanalsobeused.

Multi-operator equipmentMulti-operatorpressesshouldhavepre-startwarningdeviceswhichautomaticallygiveanaudiblewarningwhenaninch,crawlorrunbuttonisdepressed.Anacousticsignalofonetothreesecondsdurationshouldbegiven.Fromthemomentthesignalisactivated,atleastthreesecondsshouldelapse(waitingtime)beforethemachinecanbestartedbyrepeatedactivationofthesameordifferentcontrolelement.

Afterthewaitingtimeorafteraprecedingoperationintheinchmode(notcontinuousrunmode)themachinecanbestartedwithin0to12seconds(releasetime)withoutanotheraudiblewarning.

Afterthereleasetimeoractivationofastopcontrol,ortheemergencystop,itshouldonlybepossibletooperatethemachineafterrepeatingthewholeoftheabovesequence(seeFigure21).

Zoningofcontrolsshouldbeusedonmulti-operatorpressesorotherequipmentwherethevisionofasecondoperatormaybeobscured.Azonedcontrolwillonlyallowlimitedmovement(slowcrawlorinch)ofaspecificpressareawithaguardopen,suchasonesideofaprintunit,orasinglesectionofagatherer-stitcher-trimmer,whenallotherguardsareintheclosedposition.

Wherehazardouspartshavelongrundowntimes,interlockingmethodsincorporatingbrakingand/orguardlockingshouldbeused.Systemsshouldbedesignedtoincorporateadevicetoeithercausethehazardtobeeliminatedastheguardisopened(byapplyingabrake),orpreventtheguardfrombeingopeneduntiltheriskofinjuryfromthehazardhaspassed(guardlocking).TheStandardprEN1010Safety of machinery. Safety requirements for the design and construction of printing and paper converting machineryrequiresguardlockingtobeprovidedonnewpresseswithrundowntimesinexcessoftenseconds.

Guardinterlockscanfailasaresultofageorroughtreatment.Theyshouldbedesignedtoworkinthepositivemodesothatundernormalcircumstancesafailureoftheinterlockswitchpreventsmachineoperation.

Switch A is installed in the positive mode, ie the contacts have been opened by the positive mechanical action of the cam. Switch B is installed in the negative mode, ie the contacts are opened by spring pressure when the cam is rotated. When switches are used singly, the positive mode should be used. Failure should prevent operation of the machine. Positive switches are also more difficult to defeat. The use of two cam-operated switches positioned next to each other but operating in opposite modes provides an even better standard.

Guardoverlap

SwitchAPositivemode

SwitchBNegativemode

6



Figure 21 Audiblepre-startwarningsignalsequences

Control definitions for press movementTrue inch-asingledepressionofthecontrolbuttoncausingamovementof25mmmeasuredcircumferentially.Itshouldnotbepossibletocauseuninterruptedmovementofthecylindersbyrepeateddepressionoftheinchbutton.

Limited inch-asingledepressionofthecontrolbuttoncausingamovementgreaterthan25mmbutlessthan75mmcircumferentially.Itshouldnotbepossibletocauseuninterruptedmovementofthecylindersbyrepeateddepressionoftheinchbutton.

Hold-to-run slow crawl-uninterruptedmovementofthecylindersat1m/min(5m/minforweb-fedmachines)causedbycontinueddepressionofthecontrolbutton.Crawlspeedmaybeincreasedtoamaximumof5m/min(10m/minforweb-fedmachines)onlyifthereisnosubstantialincreaseinhazard.

Continuous slow crawl-uninterruptedmovementofthecylindersat1m/min(5m/minforweb-fedmachines)whichdoesnotrequirecontinueddepressionofthecontrolbutton.Crawlspeedmaybeincreasedtoamaximumof5m/min(10m/minforweb-fedmachines)onlyifthereisnosubstantialincreaseinhazard.

Note:Certain other types of machines, eg gatherer-stitcher-trimmers, folders, have increased slow crawl speeds necessary for setting purposes. These are referred to where relevant later in this chapter.



To measure crawl speed -countthenumberofrevolutionsperminuteandmultiplybythecylindercircumference.

Trip nip bar performance standard-aftertrippingthestopfunction,thelengthofmovementofthetripbarshouldbegreaterthanthestoppingdistanceofthecylinder,iecylindermovementshouldceasewithinthedeflectiontraveldistanceofthetripbar.(SeeboxinsertbelowTable6fortestingprocedure.)

Safe systems of work

Asafesystemofworkisanagreed,documented,safejobmethodbasedonriskassessmentthatisdesignedtoreducetheriskofaccidentsorillhealth.Examplesarethe‘inch-stop-clean’or‘inch-stop-lock-clean’safesystemsofworkwhichminimisetheriskoffingersbeingdrawnintoin-runningnips.Itisessentialthatthecorrectsystemofworkisusedforthetask-forpresscleaning,seethetablesunderthesectionsdealingwitheachpresstype.

Safe systems of work for press cleaningTherearethreemainsafesystems:

n Inch-stop-lock-clean.Inthissystem,thepressissubjecttolimitedmovementusingtheinchbutton,stoppedandthepowerisolatedusingtheemergencystopbuttonbeforeapplyingthesolvent-soakedcloth.Inmulti-operatoroperation,eachpersonmustretaincontroloverthere-settingoftheirownemergencystopbuttonsothatitisnotpossibleforanotherpersontocausethepresstomoveunexpectedly.

n Inch-stop-clean.Inthissystemthecylindersarerotatedenoughtoexposethenextsectionofcylindersurfacetobecleaned.Thehandwiththecleaningclothisheldclearofthecylinderwhileitisrotating.Thecylindershouldbestationarybeforethesolvent-soakedclothisapplied.Formachineswithatrueorlimitedinchcontrol,severaldepressionsofthebuttonmayberequiredtoexposeenoughofthecylindersurfacetoclean.Multi-operatorcleaningisacceptableusingthissystemonlywherezonedprintunitcontrolsareprovided,iecylindermovementateachprintunitcanoccurandbecontrolledindependentlyoftherest.

Figure 22 Emergencystopcontrolsshouldbeprovidedwithinreachofalloperatingpositions



Avariationofthissystemcanbeusedonsheet-fedpresseswithsemi-automaticplatechange.Bymakinguseoftheplatechangecycle,andpre-cockingthecylinderposition,thereisalmostacompleterevolutionatslowspeedwhichissufficienttoallowcleaningofthewholecylindersurfacewithoutallowingexposuretothecylindergap.

n Slow crawl cleaning.Inthismethod,thecleaningclothisappliedtothecylinderasitrotatesatveryslowspeed.Movementiscontrolledusinghold-to-runslowcrawlcontrolsornon-hold-to-runcontrols(continuousslowcrawl).Note:This method isonlyacceptable where the defined trip nip performance is met and

rigorous guard checking is done. See box insert below Table 6 for the definition of trip nip

performance.

Accident

Anoperatorwascleaningtheblanketcylinderofapressoncontinuousslowcrawl.Theraghewasusingwasdrawnintothenipbetweentheplateandblanketcylinder.Thepresswasfittedwithatrip-nipbarwhichstoppedthemachinebutonlyaftertheprinter’shandhadbeentakeninuptothewrist.Theaccidentcouldhavebeenpreventedbyusingtheappropriatesafesystemofworkandcheckingtheperformanceofthetripbar.

Other essential safeguards

n Operatorsshouldknowhowtostopamachinebeforetheystartit.n Allguardsshouldbeinpositionandallprotectivedevicesworking.n Cylindergapcoversshouldbeusedwhereprovidedbythemanufacturer.n Hickeys(fluff)shouldonlyberemovedfrommovingcylindersusingaproper

hickeypicker(suchasarubberblademountedonawoodenhandle).n Ragsshouldneverbeappliedtomovingrollersorotherpartssuchasduct

rollersoroilytransmissionmachinery.

Machinery maintenance

n Allguardsandothersafetydevicesshouldbekeptingoodworkingorderandcheckedregularly,egdailychecksonguillotinesandhand-fedplatens,andweeklychecksonpresses.

n Machineryshouldbeisolatedfromallpowersourcesbeforemaintenancework,includinglubrication,iscarriedout,especiallyiftheworkinvolvestheremovalofguards.

n Safeguardsshouldbecheckedafteranymodificationstomachinery.n Maintenanceneedsshouldbeconsideredbeforeinstallingnewmachines.n Preventive,ratherthanbreakdown,maintenanceproceduresshouldbe

implemented.

Safety hazards by process

Pre-pressManual design and art workAlthoughthisisgenerallyalow-riskarea,takecarewithscalpelswhichshouldbesheathedwhennotinuse.Provideinclinedlay-upboardswithahighlipatthebasetopreventscalpelsfallingfromthem.Disposeofusedscalpelbladessafely-don’tjustputthemintowastebins.



Electronic/digital image preparationTypesettingandelectronicpre-pressinvolvelargeamountsofworkatvisualdisplayunits(VDUs).TheuseofVDUsbytheemployedandself-employediscoveredbytheHealthandSafety(DisplayScreenEquipment)Regulations1992.Employershaveadutytomakesurethatthedisplayscreenequipmentissafeanddoesnotaffecttheuser’shealth.Experiencehasshownthatrepeateduseofinputdeviceslikeamousecanleadtoupperlimbdisorderssoitisimportanttoconsideralltherisks.

WorkersusingVDUsneedwell-designedworkareaswithsuitablelightingandcomfortable,adjustableseating.Thishelpstopreventunduetiredness,reduceeyestrain,andpreventpainsinthehands,arms,neck,shouldersandback.PlaceVDUsinapositionwherelightingwillnotcausereflectionsorglareonthescreen.Nospecialprecautionsarenecessaryagainstradiation-thelevelsemittedfromVDUequipmentarewellbelowtherecommendedsafelevels.

Employersmust:

n analysetheworkstationsofemployeescoveredbytheRegulationsandassessandreducetherisks;

n ensuretheworkstationsmeetminimumrequirements;n plansotherearebreaksorchangesofactivity;n trainandinformdisplayscreenusersaboutthehealthandsafetyaspectsof

theirwork;n provideeyeexaminationsandtestsforusersonrequestandspecialspectacles

whererequired-foradefinitionofusersandfurtheradviceseeVDUs: An easy guide to the Regulations(HSG90).

Trailingelectricalanddigitaldatacablescancauseaccidents.Runcablesinducts,underthefloor,aroundthewallsorinapendantdroppedfromtheceiling.

Computeranddigitaldatahandlingequipmentoftengenerateslargeamountsofheat.Goodgeneralventilationand/orairconditioningshouldcopewiththis.Automaticgas-floodingfire-protectionsystemsmaybeusedtoprotectmajorsystems.Setupprocedurestoensurethatwhenpersonnelentertheprotectedspacetheautomaticfireprotectionsystemisswitchedtomanualandilluminatedindicatorsareprovidedtoshowthesystem’soperatingmode.

Graphic reproduction and platemakingScreenallUVlightsourcesadequately.Screeningonprintdownframescantaketheformofcurtains(preferablyautomaticorinterlocked),automaticshuttersorautomaticrollerblinds.Blindsshouldbemaintainedingoodcondition.BrushesshouldbeusedtoreduceleakageofUVlightaroundtheperipheryoftheframeonprintdownboxes.

Onlargeformatprintdownframes,asfoundinscreenprinting,theUVsourcesshouldbepositionedsothatlightisdirectedawayfromdoors,windowsandpassageways,andscreenedfromotherworkareas,egbyusingcurtains.Timerswitches(orotheron/offcontrols)shouldbelocatedoutsidethescreenedarea.

ProvidelasercontainingequipmentsuchasscannersandimagesetterswithinterlockedcoversaspartofthelaserbeamscreeningtoensurethatClass1conditionsaremet(ietheoutputofthelaserlightisinherentlysafe)andtopreventaccesstorotatingpartsofmachinery.

Seethe‘Radiation’sectioninChapter4formoreinformation.



Rollersonautomaticfilmandlithoplatedevelopersneedperiodiccleaning.Thebestmethodistoremovetherollersbeforecleaning.In-runningnipsneedtobeguarded(thisisusuallyachievedbyusinginterlockedguards)exceptwheretherollersareheldinpositionbytheirownweightandthemaximumforcethatcouldresultis50newtons.Rollersshouldnotbecleanedwhilethemachinesarerunningasfingersmaybedrawnintoin-runningnips.

Makesuredriptrayshavebeenprovidedbeneathautofilmandplateprocessors.Hotsurfacesonplatedeveloperpre-heatandbakingovensshouldbeshieldedtopreventcontact.

Assesstheergonomicrisksarisingfromhandlingandloadingofplatesandfilmintocomputer-to-plateunits(see‘Manualhandling’inChapter4).

Platebendingmachinesneedtoeitherbeadequatelysafeguardedorprovidedwithasimultaneoustwo-handcontrol.Onplatepunchingdevicesthemovementofthepunchingtoolshouldbesafeguardedeitherbydesignorbyprovidingguards.

Duringflexographicplatemaking,mouldingpressesarefrequentlyusedtoimposeheatand/orpressuretorubberorsyntheticcompounds.Theclosingmovementofthesepressesshouldbesafeguarded.Localexhaustventilationshouldbeprovidedfortheheatandfumegenerated.Alsoconsiderextractionforsolventwash-offfromphotopolymerplatesandpersonalprotectiveequipmentsuchassuitablegloveswherethereisapossibilityofskincontactwithuncuredphotopolymers.(See‘Personalprotectiveequipment’inChapter4.)

Conventional litho proofing pressesThedangerofhandsbeingtrappedinthesheartrapscreatedbythemovingcarriageoflithoproofingpressesshouldbeeliminated.Tripdevicesshouldbeprovidedateachendofthecarriagewhichactuateafail-safestopdevicetoarrestmovementofthecarriage.

Wherehazardousin-runningnipsexistatthestationarydampingandinkingrollerunits,theyshouldbeguarded,egbyfixednipbars.Manylithoproofingpressesavoidthishazardbyhaving‘liftout’rollersorstoppingtheserollerswhenthecarriagemovesaway.

Theinkinganddampingrollersonthemoveablecarriageshouldbesafeguardedeitherbyinterlockingguards,fixednipbarsorothereffectivemeans.Theactionof‘sheetingoff’isahazardousoperationwhichshouldbeprohibited.

Regularlymaintainandchecksafetyfeaturesonallproofingpresses.

Digital printing and copying

Manyofthehealthandsafetyconsiderationsrequiredfortraditionalprintingarealsorelevanttodigitalprintingandcopying.Themainrisksinclude:

n Manualhandling-paperisheavyanditisimportanttokeeptheareaaroundmachinescleartoalloweasyaccesstoclearpaperjamsetc(seeChapter4).

n Electrical-maintainelectricalequipmentandensurecablesandconnectorsdonotbecomedamaged(seeChapter6).

n Fire-maintainaclearairflowtoallowpropercoolingofthemachineandremoverubbishregularly(seeChapter7).

n UVlight-takeprecautionstoensurethatstronglightsourcesinphotocopiersandlargereprographicsinstallationsareadequatelyshrouded(seeChapter4).



n Hazardousmovingparts-feedertrays,staplersandotherattachmentshavethepotentialtotrapfingers.Remembertoisolatethemachinebeforeclearingblockagesandtoreplaceguardsandcoversbeforeoperating.Associatedfinishingmachinery,suchasguillotines,shouldbeproperlyguardedandthoseguardsmaintained.

n Chemicalsandozone-alwayshandleandchangetonerorcleaningagentsinaccordancewiththemanufacturer’sinstructions.Provideadequateventilationtopreventbuild-upofheatandozone(seeChapter4).

n Brokenglass-thetopglassofcopierscanbreakifabused.

PrintingLitho sheet-fedWhereaccesstomovingpartsisneeded,egforcleaningandmake-readyoperationsonprintingmachines,theguardcontrolcircuitsshouldbeinterlockedsothatwithguardsopenthemachinecanbeoperatedbyhold-to-runcontrols(oronslowcrawlonlywhereatripnipdevicemeetingtheperformancestandarddetailedlaterinthischapterisachieved).Thehold-to-runcontroldevicesshouldbedesignedtoallow:

n machinemovementlimitedto25mm(trueinch)oneachdepressionofthecontroloramaximumoperatingspeedof1m/min;or

n wherethemeasuresdefinedabovewouldreducetheabilityofthemachinetoperformitsfunctionandwheretherewouldbenosubstantialincreaseinrisk,machinemovementlimitedtoamaximumof75mm(limitedinch)oramaximumoperatingspeedof5m/min.

Whereinterlockedguardsallowhold-to-runslowcrawlorinching,cylindertripnipbarswithin6mmofthecylindersurfacewhichstopprintingcylindermovementwithinthedeflectiontraveldistanceofthebarshouldbeprovidedtopreventtheriskofentanglementincontra-rotatingrollersorcylinders,especiallywheregapcoversarenotprovided.Fixednipbarsareonlyacceptableinconjunctionwithcylindergapcoverswherethereisaslowcrawlfunction.Theprintunitguardingoptionsforsheet-fedpressesaresummarisedinTable5.

Figure 23 Two-colourpressfittedwithslotted,interlocked,all-enclosingguards



Figure 24 Inmulti-operatorpressesanaudiblepre-startwarningdeviceshouldbefitted

Table 5 Safeguardingsheet-fedoffsetpresses

Safeguarding other parts of litho pressesGuardingisrequiredforthehazardouspartsoffeedtables,including:

n in-runningnipsassociatedwithchainsandsprockets;n rotatingshafts;n swingarmgrippers.

Transfercylindersanddeliverymechanismsneedhighstandardsofguardingduetotheseverityofinjurytheycause.Interlockedand/orfixedguardsareessential.Theinterlockarrangementshouldonlyallowthepresstobe‘inched’(trueorlimited)duetotheseverityofthehazardandusuallackofnipbars.Thedeliverymechanismguardingshouldpermitthesaferemovaloftestsheets.

Hazard Safeguard

Sheet-fed offset

In-runningnipsbetweeninkinganddampingrollerassemblies

All-enclosinginterlockedguardswitheithernopoweredmovementortrueinchonlywhentheguardisraised.

In-runningnipsbetweentheplate,blanketandimpressioncylinders

Anenclosinginterlockedguardwhichallowslimitedpoweredmovementwhenraisedbymeansoftrueorlimitedinch,orhold-to-runorcontinuousslowcrawl;andatripnipbaradjustedtowithin6mmofthecylindersurfacewhicheithermeetstheperformancestandarddetailedintheboxinsertunderTable6,orissupplementedbycylindergapcoversforbothplateandblanketcylinders,orthereisnofacilityforcontinuousslowcrawl;oranenclosinginterlockedguardasabovesupplementedbyfixednipbarsadjustedtowithin6mmofthecylindersurfaceandgapcoversforbothplateandblanketcylinders.Fixednipbarsarenotadequateintheabsenceofcylindergapcoversunlessthereisnofacilityforcontinuousslowcrawl;oroncertainoldmachines,tripnipbarswhichdonotmeettheperformancestandard(seetheboxinsertunderTable6)orfixednipbars,ineithercaseadjustedtowithin6mmofthecylindersurfaceandclose-fittinggapcoversforbothplateandblanketcylinders.Thereshouldbenofacilityforcontinuousslowcrawl.Usersshouldplantoupgradesuchpressesbytheadditionofenclosinginterlockedguards.

In-runningnipsbetweenimpression/transfercylinders

Anenclosinginterlockedguardwhichallowslimitedpoweredmovementwhenraisedbymeansoftrueorlimitedinch.Anemergencystop(or‘stop-lock’)controlshouldbeprovidedateachprintunit.

Unexpectedstart-upduringmulti-operatorcleaning

Pre-startaudiblewarningdevice.



Clearlymarkallpresscontrols.Emergencystopcontrolsshouldnormallybeprovidedatalloperatingconsolesandwithineasyreachofallotheroperatingpositionsandprintstations,andshouldstopallhazardousmovement.Oncertainsmallerexistingpresseswithoutpoweredinching/crawling,additionalemergencystopcontrolswillnotbenecessaryastheywillnotenhancetheoverallsafetyofthemachine.Controlstationsonunitsshouldpreferablybelaidoutsothathold-to-runcontrolsareabove,orimmediatelyadjacentto,theemergencystopcontrols.

Onmulti-operatorpresses,orthoseonwhichitisnotpossibletoclearlyseealloverthepressfromanycontrolstation,anaudiblepre-startwarningdeviceshouldbefitted(seeunder‘Machinecontrols’inthe‘Basicrulesofmachinerysafety’sectionearlierinthischapter).Guardsandotherprotectivedevicesneedtoberegularlymaintainedandchecked(seeChapter8).Aweeklycheckoftheguards,theiroperation,thehold-to-runcontrolsandtheemergencystopcontrolshouldensurethatpressesremainproperlyguarded.

Hickeys(fluff)shouldneverberemovedfromamovingcylinderexceptwithaproperhickeypicker.Ragsshouldneverbeappliedtomovinginkingordampingrollersincludingductrollers,evenifadjacentrollersarewellguarded,becauseoftheriskofentanglement.

Figure 25 Hickeysshouldnotberemovedfrommovingcylindersexceptwithaproperhickeypicking

stick

Safe systems of work for sheet-fed press cleaningAveryhighproportionoftheaccidentstoprintersresultfromcleaningtasks(seeChapter1).UseTable6toselecttheappropriatesafesystemofwork.

Figure 26 Basicguardsforasingle-colourpress

Inking roller guards

Cylinder trip nip bar

Plate and blanket cylinder guard

Cylinder gap covers

Delivery mechanism guards

Inking and damping roller guard

Paper feed mechanism guards



Table 6 Safesystemsofworkforpresscleaning

Trip nip performance standard-ontripping,thelengthofmovementofthetripbarshouldbegreaterthanthestoppingdistanceofthecylinder,iecylindermovementceaseswithinthedeflectiontraveldistanceofthebar.Totest:

n Withthepressstationary,measurethetotaldeflectionofthetripnipbar(t).n Markthecylinderandmachineframe.n Operatethecrawlcontrol.n Pushthetripnipwithacardboardtubewhenthetworeferencepointsare

inline.n Measurethedistancemovedbythecylinder(c)andcomparemeasurements

(t)and(c);(t)shouldbegreater.

Web offset pressesWebbing-upOneofthemainadditionalhazardsassociatedwithweb-fedpressesarisesfromtheneedtoweb-upfollowingawebbreakand/oraformatchange.Itisextremelyimportanttoensurethatasafesystemofworkisdevisedandawrittenprocedurelaiddownandadopted.Onnewpressesthiswillbesuppliedbythemanufacturer.Onolderpressesmanagementmayneedtodevelopasafesystemofworkinconjunctionwithpresscrewsandsafetyrepresentatives.

Thesafesystemofworkshouldtakeaccountofthedifferentwebpathconfigurations(includingpathsthroughcoloursatelliteunitsinnewspaperprinting)andthroughthefolder,involvingcross-associationifappropriate.Itshouldalsodealwiththeuseof

Task Risk factors System of work

Sheet-fed offset

Cleaninginkingrollers,multi-orsingle-operatorcleaning

Itshouldnotbepossibletoaccessrollerswheninmotion

n Useofdemountablewash-up

tray.

Cleaningplateandblanketcylinders,single-operatorcleaning

Frequentlackofgapcoverswithresultantaccessibilitybehindtripnip/nipbars

n Autowash-up.

n Inch-stop-clean,forward

motion.

n Forwardslowcrawlcleaning

onlyifthereissafeguard

checkingandatripniptothe

definedperformancestandard.

Cleaningplateandblanketcylinders,multi-operatorcleaning

Frequentlackofgapcoverswithresultantaccessibilitybehindtripnip/nipbars

Unexpectedstart-up

n Inchstop-lock-clean.

n Ifpresshaszonedcontrols

allowingindependent

movementofprintunit

cylinders,inch-stop-clean,

forwardmotion.

n Forwardslowcrawlcleaning

onlyifthereissafeguard

checkingandtripnipstothe

definedperformancestandard.

Cleaningimpressionandtransfercylinders,multi-orsingle-operatorcleaning

Relativeinaccessibility;absenceofnipbarsandhazardfromgrippers

n Inch-stop-lock-clean.

n Forpresseswithdedicated,

zonedtrueinchcontrols

beneaththefootboardonly,

inch-stop-clean.



part-widthwebswhereweblead-indevicesmaynotbeusable.Thewrittenprocedureswillneedtoincludeacleardiagramofthepressshowingallpossiblewebpaths.

Manualwebbing-upshouldbecarriedoutwiththepressstationaryandoffimpressionsothatthewebcanbepassedbetween/aroundthecylinders.Weblead-indevicescansignificantlyreducethehazardassociatedwithwebbing-upandshouldtakethewebfromthereelstands,throughtheprintunitsanddryerstothetopofthefolder,butnotincludingturnedorbaywindowwebpathswherethetapesmaybeterminated.

Onolderpresses,ormachinesnotfittedwithweblead-indevices,thepracticeoftuckinginorattachingthewebtothecylinderwithadhesivetapeshouldbeusedsothatalloperatorscanwithdrawcompletelyandstandawayfromthepresswhenthecrawlcontrolsaredepressed.

Trapsassociatedwithdrivenweblead-intapesorchainsshouldbeguardedwherethereisariskofinjury,egbyprovidingdiscguards.

Safeguarding of print unitsInkinganddampingrollersmustbeguarded(seeTable7).Oncertainoldinstallationstheinkinganddampingrollersmaybeguardedbynon-interlockedenclosingguards.Theseshouldbeupgradedbyprovidingnipbarsorbyinterlockingtheenclosingguards.Wherealcoholdampingsystemshaveaseparatedrivewhichcontinuesaftertheinterlockedguardisopened,thein-runningnipsshouldbeguardedbynipbars.

Plate,blanketandimpressioncylindersmustbeguarded.Guardingcantaketheformofrobustfixednipbarsiftheprintingandblanketcylinderguttersarelessthan4mmdeepand8mmwide(orexceptionally19mmwideonnewspaperpresses)andthepress’sthrow-off(cylindermovementgoingonimpressionandoffimpression)stillkeepsthenipbarswithin6mmofthecylindersduringmake-readyandwash-up.

Followingwebbreaks,nipbarsshouldbecheckedbyoperatorstoensuretheyhavenotbeendeflectedawayfromthecylindersleavinggapsinexcessof6mm.

Insomesituations,suchastheblanket-to-blanketnip,thewebpathprecludestheuseofasinglefixednipbar.Inthesecircumstances,adualfixednipbaror‘letterbox’guardmaybeused.Thereneedstobealargeenoughgaptoallowforwebflutter,buttheguardsshouldbepositionedfarenoughawayfromtheniptopreventriskofinjury.

Certaintypesofpressesrequiresomenipbarstoberemovedformake-ready.Ahingednipbarsecuredwhenthepressisintherunmodeisacceptableaslongasmeasuresaretakentoensureitmustbeinpositionwhenthepressisrun,egbyinterlocking.

Onunitarchtypepresses,accessmustbepreventedtoroller/cylinderintakeswithinthearch.Thisguardingcantaketheformofinternalguarding,egnipbarsorfixedguardsorinterlockedunitgates.Withinterlockedgatesopen,movementofrollers/cylinderswithinthearchshouldbevialocalhold-to-runcontrolsonlyallowingcrawlspeedsofnomorethan5m/min(10m/minmaybeacceptableinexceptionalcircumstances,egonsomeolderpresses).

Theprintunitguardingoptionsforweb-fedpressesaresummarisedinTable7.



Table 7 Safeguardingweb-offsetpresses

Safeguarding other parts of web pressesDraw rollersDrawrollersmaybeincorporatedintothereelstand,betweenthereelstandandthefirstprintunit,orwithintheframeoftheprintingunits.Wheretheintakebetweendrawrollersisaccessible,itshouldbeguardedusinganipbar,asplitbarwithabell-shapedmouthtoassisthandwebbing-up,oranenclosingguard.

Web severersWebsevererswithinunitarchesandelsewhereonthepressneedtobeguardedorbesafebydesign.Tunnelguardsarefrequentlyused.Precautionsneedtobetakentoensurethatthewebseverersdonotautomaticallyfirewhenoperatorsorothersareinthevicinity.Interlockedaccessgatestounitscanbeused.

Guide rollersDuetothehighspeedsofmanyofthesemachinesandtheinertiaofweb-drivenguiderollers,theserollersshouldbesafeguarded.Guardingsuchasnipbarscanbeprovidedortherollerscanbeseparatedfromothercontra-rotatingrollersandthemachine’sframebyagapofatleast120mm.

Drying unitOvensatheat-setoffsetpressesmayhaveopeninghingedtops.Ensurethatthesewillnotcloseinadvertently,trappingtheoperators.Thecontrolstoclosetheovenshouldbeofthehold-to-runtypeandbelocatedsothattheclosingmovementoftheovencanbeseenalongitsentirelength.SeeChapter7‘Explosionrisksinblanketwashsystems’forguidanceonavoidingfireandexplosionrisk.

Chill rollersAgapofatleast120mmshouldbeallowedbetweenaccessiblein-runningchillrollers,oraguardshouldbefitted.Guardsshouldbefittedoveranyaccessiblebalanceweightsattheendsoftherollers.

Propeller rollersPropellerandslitterrollerintakesshouldbeguarded.Thisguardingisoftenassociatedwithdustcollectionhoodsandshouldalsoeliminatethelacerationhazardposedbyslitters.Theguardingshouldcoveratleast300ºoftheroller.

Hazard Safeguard

Web-fed offset

In-runningnipsbetweenadjacentinking(anddamping)rollers

All-enclosinginterlockedguardswitheithernopoweredmovementortrueinchonlywhentheguardisraised;orfixednipbarsadjustedtowithin6mmoftherollersurface.

In-runningnipsbetweenplate,blanket(orimpression)cylinders

Interlockedguardsallowingtrueorlimitedinchorhold-to-runslowcrawlonlywherenipbarsarenotfitted.Alldangerpointsshouldbewithinviewofasingleoperator,orofseveraloperatorseachofwhomneedstooperateahold-to-runcontrol.Nipsoutofviewshouldbesafeguarded;and/orfixednipbarsadjustedtowithin6mmofthecylindersurface;and/orfixedorinterlocked‘letterbox’distanceguards;and/orsweep-onnipbarsinterlockedwithreversecrawlornofacilityforreversecrawl.Wherenipbarsareprovidedandcontinuousslowcrawlisavailable,thisshouldalwaysbesupplementedbyanemergencystop(or‘stop-lock’control)ateachprintunit.





Figure 27 Propellerandslitterrollersshouldbeguarded

ControlsClutchesusedtodisengagethedrivetopressunitsonolderpressesshouldbeprovidedwithinterlockswhichensurethatthecontrolsonadisengagedunitremainineffectivewiththeexceptionoftheemergencystops.

Misinterpretationofindicationlightsonpresseshasresultedinanumberofaccidents.Itisthereforeextremelyimportantthattheindicatorlightsareclearandunambiguous.

Folding unitsGuardallin-runningnipsandothermechanicalhazardsonfolders.In-runningnipsshouldbeprotectedwithnipbarsand/orenclosingguards,egnippingandcross-associationrollers.Guidanceonfoldersisgivenunder‘In-linefolders,sheetersanddiecutters’laterinthischapter.

Incorporatenoisecontrolmeasuresinenclosingguardsand,wherepossible,extendcontrols,lockingnutsandadjustingdevicesthroughtheguard.

Figure 28 Examplesofareasthatneedsafeguardingatweb-offsetprintingpresses

Webs

Idle rollers, web-driven rollers,and contra-rotating rollers

Slitter andpropeller rollers

Kite former

Printing cylindersUnit arch

Reelstands



Table 8 Safesystemsofworkforweb-fedoffsetpresscleaning

Cleaning and make-readyTofacilitatemake-ready,cleaningoperationsetc,hold-to-runcontrolsshouldbeprovidedwhichmayallowmovementofthepresswiththeinterlockedguardsopen.Onnewandexistinginstallationshold-to-runslowcrawlspeedsshouldbelessthan10m/min.Certainolderinstallationsmaynotbeabletoachievethisspeedandtheslowcrawlspeedattheseshouldbeaslowaspracticable.

Safe systems of work for web-fed offset press cleaningAveryhighproportionoftheaccidentstoprintersresultfromcleaningtasks.UseTable8toselecttheappropriatesafesystemofwork(seeChapter1).

Reel unwinds and rewindsForthepurposesofthisbook,theterm‘reelunwindingandrewindingdevices’appliestosimplesingle-reel,non-automaticequipmentfortheprovisionandcollectionofpaper,polythene,foilorothertypesofweb.Theterm‘reelstands’appliestolargerinstallationscapableofholdingtwoormorepaperreelsandinstallationsassociatedwithautomaticoperationssuchassplicing.

Thefollowingsafeguardsareappropriateforreelunwindingandrewindingdevices:

n Unwindunitsareusuallyoftwotypes,shaftedorshaftless.Onunwindsthein-runningnipsbetweenthereelandpressurerollershouldbeprotectedeitherbyatripdeviceorguards.

n Devicesforbringingthereelsuptospeedshouldbeguardedifdangerpointsareaccessible,egatrunningtensionbelts.

n In-runningnipsassociatedwiththepressure/riderrollersshouldbeguardedovertheentirereeldiameter.Thismaybeachievedbytheprovisionoftripdevices,self-adjustingnipbarsorareainterlockedguards.Atreel-up,thelatterarebestdesignedoncastorswithtongue-operatedinterlockswitchestoallowhold-to-runmovementonlywhenremovedforaccessduringreelchange.

n Ticketstomarkdefectsetcshouldbeself-adhesiveandattachedtothewebatanaccessiblelocationawayfromtheguardednipbetweentheformingreelandlay-onroller.Consideralsoprovidingdeviceswhichwillallowremoteplacingofmarkertickets.

n Anyshearhazardscreatedbymovementofthereelliftingarmsorotherreelliftingdevicesshouldeitherbeguardedorreellifting/loweringshouldonlybepossibleusinghold-to-runcontrolsrestrictedtoaspeedofnomorethan5m/min.


Web-fed offset

Cleaninginkingrollers,multi-orsingle-operator

Itshouldnotbepossibletoaccessrollerswheninmotion

n Autotraywash-up.

Cleaningplate,blanket(andimpression)cylinders,multi-orsingle-operator

‘Smooth’cylindersonly(gutternotexceeding4mmradiallyby8mmcircumferentially(exceptionally,4mmx19mmonnewspaperpresses))

n Inch-stop-lock-clean,

forwardmotion.

n Forwardslowcrawl

cleaningonlyifnip

barsandanemergency

stopareprovidedanda

suitableguardchecklistis

completed.

Cleaningtransfer/pathrollers,multi-orsingle-operator

Relativeinaccessibility;absenceofnipbars n Inch-stop-lock-cleanwhere

rollersarepowered,orby

handturningwherefree

running.



n Whereshaftlessunwindingorrewindingisused,thechuckingconesshouldbedesignedsotheycanonlybeinsertedusingahold-to-runcontrol.Thehold-to-runspeedshouldnotexceed5m/minfornewmachines.Thecontrolsystemofthemachineshouldpreventstart-upuntilthechuckingconeshavebeenfullyinserted.

n Ejectionofareelduetoa‘corechewout’orinadvertentopeningofthechuckingconesmustbeprevented.Thecontrolsshouldnotallowseparationofthechuckingconeswhilethepressisinmotion.

Safeguarding reelstands

n Existingreelstandsshouldhaveaminimum500mmclearancebetweenthesurfaceofthelargestreelthatthestandisdesignedtoacceptandanyobstructionsuchasafullreel,mountedonanadjacentstand,orawall,unlessfixedorinterlockedbarrierspreventwhole-bodyaccess.

n Sinceanyreelbeingloadedwillencroachonthe500mmgapmentionedabove,reelsshouldnotbeleftstandingwithinthereelstandsonthesub-trucks.

n Perimeterfenceguardingshouldalsobeprovidedwherehand/armaccessispossibletoin-runningtraps/nipscreatedbetweenrotatingandstationaryreelsonthesamereelstand,unlessaminimumseparationdistanceof120mmcanbemaintainedbetweenthereels.

n Additionaldangerscreatedbyanadjacentstandindexingduringautomaticsplicingwillneedtobeaddressed,egunexpectedstart-upofthereel,splicingunitmovementandspiderarmmovement.Asafesystemofworkshouldbeimplementedtoaddresssuchhazardsinconjunctionwithsafeguarding.Safeguardingmaybeprovidedbyelectrosensitivedevicesandtripbars.

n Whereturretsorspiderarmsrotateautomatically,pressure-sensitivematsorsimilarshouldbeprovidedtopreventrotationwhenapersonisinthepit.Whererotationismanuallycontrolled,movementshouldbebymeansofahold-to-runcontrol.

n Wherereelsaredrivenbybeltsonthereelcircumference,thedangerpointbetweenthereelandthebeltshouldbesafeguardedbyinterlockedorothereffectiveguards.Guardsshouldalsobeprovidedtoprotectoperatorsfromin-runningnipscreatedatdrive-beltguiderollers.

n Whereflyingsplicingdevicesarefitted,theymusteitherbesafeguardedbyfixedandinterlockedguardsorbe‘safebyposition’(ieoutofreachofanyworkplatform).

n Onpressesfittedwithreelshafts,guardsorloosesleevesneedtobeprovidedforanyexposedendsoftheshafts.Anybrakediscsshouldalsobeguarded.

n Safeguardingfordrawandfestoon/dancerrollersisnecessarytoprotectoperatorsfromin-runningnipsandrollermovement.Thismaybeachievedbyacombinationoffixednipbars,interlockingguards,tunnel-typeguardsorbyensuringaspacingofatleast120mmbetweentherollers.

Figure 29 Reelstandsshouldhaveaminimum500mmclearancebetweenreelsorfixedparts

500mm 500mm 500mm



Reeler/winder slitters used in paper conversion and flexible packagingThesemachinesvaryinsizefromlessthan1mtoseveralmetreswideandareusedwidelyforconvertingpaperandprintedpaperandflexiblepackagingmaterials.Thediameterofthereelsbeingrewoundcanvaryfromlessthan100mmto1mandabove.Themachinespeedsalsovary.Allmachineshaveincommonasignificantaccidenthistory.

Common issues to all types of machine

n Preventreelejectionbyensuringthatthereisgradualstart-upandspeedcontrolandprovideinterlockedrestraintswherethereelshaftrestsonopen-toppedbearings.

n Preventtheriskoftrappingbetweenthereelloadingarmsandthereelshaftbyensuringtheloadingarmsareoperatedunderhold-to-runcontrol.

n Preventtheriskoftrappingbetweenthechuckingconesandreelbyinsertionofconesunderhold-to-runcontrolandwithintheviewoftheoperator.

n Wherethereareweb-drivencontra-rotatingrolls,nipguardsshouldbeprovidedifthesizeandweightoftherollscouldcauseinjury.Webbing-upshouldonlybeundertakenwhenthemachineisstationary.Power-drivenrollsshouldbeprovidedwithpost-boxtypeguards,or,wherethewebanglemakeswebbing-updifficultbecauseofthedistancebetweentheslotandthenip,acombinationoffixedguardsbelowthewebpathandahingedinterlockedguardabove.

n Makesurethereisagapofatleast120mmtopreventnipsbetweendrivenrollsandfixedpartsorprovidefixedguarding.

n Makesureguardingisprovidedwheretherearerunningnipsbetweenthewebandweb-drivenrollsforflexiblepackagingmaterialandpaperwithahighbreakingstrength.

n Guardthewholeofthesurfaceofslittingknives(exceptthatinimmediatecontactwiththesubstrate)byindividualfixedplatesorinterlockedhingedguardsalongthelengthoftheknifeshaft.Adjustmentsshouldnotbemadeontherununlessthiscanbedoneremotely.

Two-drum reelers

n Preventaccesstothein-runningnipbetweenrewindingreelsandthedrivedrumbyoneormoreof:perimeterfencingwithinterlockeddoors;localisedfixed/interlockedguarding;photoelectricdevices;pressure-sensitivemats.

n Wheretherider(lay-on)rollisheldunderhydraulicorpneumaticpressure,orhasaselfweightatapressuregreaterthan300newtons,interlockedguardingoraself-adjustingnipbarwillberequired.

n Whereatrapunderthedescendingriderrolloccursunderpower,atwo-sectionguardwithatripfunctionwhichdescendsinadvanceoftherollshouldbeprovided.Machineswithoutratchet-operatedriderrollsshouldhaveascotchtopreventgravityfall.

n Whenrepairingapaperbreak,asingleoperatorshouldcontrolthemachineusinghold-to-runslowcrawlatnomorethan5m/min.

Centre winders

n Thenippresentbetweenthecentreandthesurfacedriverolluntiltheformingreelhasreachedadiameterof120mmshouldbesafeguardedbylocalisedfixed/interlockedguarding,photoelectricdevicesorpressure-sensitivemats.

n Automaticallyadjustingnipguardsarenecessarytosafeguardthenipbetweenformingreelsandthesurfacedriveroll,asthepositionofthenipwillchangewiththeincreasingdiameteroftheformingreel.

n Theoperationofcross-cutknivesshouldbeoperatedbyahold-to-runcontrolpositionedoutofreachoftheknifewheretheoperatorcanseetheknifemovement.



n Interventionbytheoperatortoinserttickets,‘smooth’theweb,checkforbindingbetweenslitreels,feelthesidesoftheformingreeltoidentifytelescopingandtocorrectproblemswithtrimmustnotbedonewiththemachinerunningatproductionspeed.

Accidents

Anoperatorofasmallslittingmachineconvertingapolyesterwebwasinjuredwhenhisfingersweredrawnintothenipbetweenthepatentrollerandanunpoweredrubbercoatedroller.Hehadattemptedtoremoveapieceofadhesivetapeusedtolabelthepatentrollfromanunpoweredtensionroller.

Theoperatorofawindersufferedafracturedfingerwhenitwastakenintothenipbetweenthepolyesterfoilwebandthetake-uproller.Hehadbeensmoothingcreasesinthefoil.

Frictionburnsweresustainedbytheoperatorofawindingmachinewhenhewasfeedingatailofpapertoweb-up.Theinterlockedguardwasopenandthemachinewasbeingoperatedoncrawlusingafootpedalcontrol.Anairfeedwassubsequentlyfitted.

Flexographic press safeguardingSafeguardingofunwindandrewindingunitsisexplainedunder‘Reelunwindsandrewinds’earlierinthissection.

Safewebbing-upproceduresneedtobeimplemented.Muchoftheadviceunder‘Weboffset’earlierinthischapterisapplicable,thoughmanyolderpresseswillnothaveweblead-indevices.

Flexographicprintingunitsonallsizepresses,eglabelpressestoflexiblepackagingpresses,areafrequentsourceofaccidents.Itisparticularlyimportanttoensurethattheyareproperlyguarded.

Removableenclosinginterlockedguardsorgate/barrierinterlockedguardsaregenerallyconsideredacceptable.Theformerareusuallymoresuitableforsmall-tomedium-sizedpresses,andpresseswithwebwidthsupto1m,andthelatterforlargermachines.

Adjustablenipbarshavenotprovedsatisfactoryastheyarefrequentlyremovedorincorrectlyadjusted(duetotheuseofstereocylindersofvariablediameter).Theyareonlylikelytoprovideasatisfactorystandardofprotectiononpresseswhichcarryoutlong-runworkwithfewornocylinderchangeswherestrictcontrolsareinplacetoensuretheyarealwayscorrectlyadjusted.



Diagramofaflexographicprintingpress

Standards for flexographic presses with removable interlocked guardsThefollowingstandardsshouldbemetonflexographicprintunitsguardedbyremovableenclosinginterlockedguards:

n Aremovableenclosingguardshouldbeprovidedwhichpreventsaccesstointakesbetweenimpression/stereoandstereo/aniloxcylindersasappropriate,fortheentirerangeofstereocylinderdiameters.Thisguardshouldbeelectricallyinterlockedwiththedrivesothat,withtheguardremoved,thepressmayonlyberunatslowcrawlspeed,ienomorethan5m/min.Theoperationoftheslowcrawlshouldbeviaahold-to-runbutton.Onsomesmallpresseswherecylindersmaybeturnedbyhandtheninterlockingshouldbetostop,ienottoslowcrawlorinch.

n Electricalinterlockingshouldbeviaproximityswitchesdesignedforsafetyapplications,andinpressesusinghighlyflammableinksandlacquersshouldbesuitableforpotentiallyexplosiveatmospheres(seeChapter7).

n Inadditiontotheenclosingguard,afixednipbarshouldbeprovidedattheintakebetweenaniloxandductrolleronthedown-runningwebside,astheserollersoftenhaveanauxiliarydrivetopreventtheinkfromdryingwhenthepressisstopped.Thedistancebetweenthisnipbarandthesurfaceofthecylindershouldbenomorethan6mm.Onsomepressesachamberdoctorbladearrangementmaybefitted.Thisdeviceismounteddirectlyontotheaniloxrollerandtheductrollerisremoved.Considerusingplasticdoctorbladestominimisetheriskofcutsduringhandlingandcleaning.

n Gearsdrivingthecylindersshouldbeadequatelyguardedbyeitherfixedsheetmetalenclosingguardsorinterlockedguards(whichoftentaketheformofinterlockedside-openingdoors).

Accident

Anemployeecrushedhisfingersbetweenthecentralimpressioncylinderandstereocylinderwhencleaningthestereoduringmaking-ready.Non-interlockedguardswerefittedandthemachinewasabletorunoncontinuousslowcrawl.Thesafeguardingandthesystemofworkusedforcleaningwereinadequate.

Newandrecentlyinstalledpressesshouldalreadybeguardedbyoneofthemethodsoutlinedinthisbooklet.Manyoldermachineswillnotbeadequatelyguarded,relyingonnon-interlockedlift-offcoversoradjustablenipbars.Youwillneedtoupgradethese.

Standards for flexographic presses with gate/barrier interlocked guardsThefollowingstandardsshouldbemetonflexographicprintunitsguardedby

7

6

5

4

3

2

110

8

9

1Unwindstation 4Drivegears 7Oven 10Rewindstation2Contrarotatingrollers 5Printunits 8Chillroll3Inkpumps 6Accesstoheights 9Web-drivenrollers



gate/barrierinterlockedguards.Theseguardsusuallytaketheformofdistancinghingedmeshbarrierssituatedatthefrontofeachprintunit:

n Side-openingdoorsshouldbeprovidedonthedriveandoperator’ssideofthepresstoguardthedrivegearsandintakesaccessiblefromthesideofthepress.Anyopeningsaroundand/orbetweenthegateguardanddoorsshouldpreventaccesstohazardousparts(seealsoBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs).Onsomeolderpressesthesidelaycanonlybeadjustedwhenthepressisrunningataspeedgreaterthan5m/minsoprovisionshouldbemadeforthis,egbyextendingtheadjustmentmechanismoutsidetheguardedarea.

n Theguardsshouldbeinterlockedsothatwiththeguardopenthepressmayonlyberunatslowcrawlspeed.

n Thefixednipbarfortheintakebetweenaniloxandductrolleronthedownrunningwebsideshouldbefittedasdetailedforflexographicpresseswithremovableinterlockedguards.

Table9summarisesthesafeguardingoptionsforflexographicandrotaryletterpressmachines.

Table 9 Safeguardingflexographicandrotaryletterpressmachines

Safeguarding other parts of flexographic pressesAswellastheguardingoftheprintingunitsonflexopressesthereareoftenotherhazardousintakesorotherpartsthatwillrequireguarding,egbetweenchillandpressurerollers,betweenothercontra-rotatingbutnon-contactrollers,andatunwind/rewindpoints.Gapsoflessthan120mmbetweencontra-rotatingpoweredrollerswillrequireguardingandthiscannormallybeachievedusingnipbarsorfixedguards.

Wherefixednipbarsareused,theyshouldbepositionedtocomplywiththemaximumpermissiblegapofnomorethan6mmfromthecylinderorrollersurface.Ideally,right-anglednipbarsshouldbeused.

Theremayalsobein-runningnipsonnon-poweredridingorguiderollersdrivenbythemovementoftheweb.Assesswhetherthereisaneedforsafeguarding-thiswilldependonanumberoffactors,suchastypeofmaterial,wrappingangleandwebspeed.

Hazard Safeguard

In-runningnipsbetweeninkingrollers(rotaryletterpress),duct,anilox,stereoandimpressioncylinders

Interlockedguardsallowinglimitedinchandhold-to-runslowcrawlonlywhenremovedoropened;andafixednipbaradjustedtowithin6mmoftheanilox/ductrollerswherethesehaveaseparateauxiliarydrivewhichisnotstoppedbyopeningoftheinterlockedguard.

Unexpectedstart-up

In-runningnipsbetweenduct,anilox,stereoandimpressioncylinders


Interlockedguardsallowinglimitedinchandhold-to-runslowcrawlonlywhenremovedoropened;andafixednipbaradjustedtowithin6mmoftheanilox/ductrollerswherethesehaveanauxiliarydrive.

Unexpectedstart-up Pre-startaudiblewarningdevice.

Flexographic and rotary letterpress - small- to medium-size, up to 1 m web

Flexographic - larger format, eg flexible packaging



Enclosingguardsarebestmadeofweldmeshmaterialonarigidframeasthismakesthemreasonablylightweightandallowsgoodvisibilityofthecylindersandprintedweb.Itislikelythatoperatorswillwantsheetmetalsectionsattheductrollertopreventinksplashing,andinsomecasesameansofreplenishinginkbyhandwithoutremovingtheguard.

n Itisveryimportantthatsafesystemsofworkareimplementedforcleaningandmake-readyoperationswhichcannotbecarriedoutwithoutremovingguards.Table10liststheappropriatesafesystemofworkforvarioustasks.Giveparticularattentiontodevelopingandimplementingsafemeansofaccessandmethodsofworkwhenaccessingtheuppersectionofacommonimpressioncylinderonalargepress.

Table 10 Safesystemsofworkforcleaningflexographicandrotaryletterpressmachines

Standardsofsafegardingattherewindunitshouldmeetthosesetoutunder‘Reelunwindsandrewinds’earlierinthischapter.Seealso‘Reeler/winderslittersusedinpaperconversionandflexiblepackaging’.

Wherehold-to-runcontrolsarebeingusedtosafeguardadangerpoint,startingthemachineinthehold-to-runmodeafteropeninganinterlockingguardshouldonlybepossiblewhenotherinterlockingguardsoutsidetheareaviewablebytheoperatorareclosed.Controlsshouldbezoned-thisisparticularlyrelevanttonewmachines.

Careshouldbetakenwhencleaningsharpdoctorblades.Anti-cutglovesshouldbeprovided,orplasticbladescanbeused.

Safeguarding gravure web-fed pressesReelunwindandrewindunitsongravureprintingpressesmustbeadequatelysafeguarded.Therequirementsforthedifferingtypesofreelstandsaresetoutunder‘Reelunwindsandrewinds’earlierinthischapter.Seealso‘Reeler/winderslittersusedinpaperconversionandflexiblepackaging’.

Gravureprintingcylindersneedtobeguarded.Thiscanbedifficulttoachieveastheprintcylindersandgearsvaryindiametertodeterminethepatternrepeat.Guardingshouldtakeaccountofaccessneedsforsafecleaningofdoctorblades.


Flexographic/rotary letterpress

Cleaningduct/aniloxrollers,single-operator

Absenceofnipbarsn Inch-stop-clean.

Cleaningduct/aniloxrollers,multi-operator

Absenceofnipbars n Inch-stop-lock-clean.


allowingindependent

movementofprintunit

cylinders,inch-stop-clean.

Cleaningstereomid-run,single-operator

Accessibilitytoin-runningnipwheninterlockedguardraised n Inch-stop-clean.

Cleaningstereomid-run,multi-operator

Accessibilitytoin-runningnipwheninterlockedguardraised n Inch-stop-lock-clean.


allowingindependent

movementofprintunit

cylinders,inch-stop-clean.

Cleaningstereoatendofrun Stereoremovedfrompressn Off-machinemanualor

auto-washing.



Wherepressesareusedforlong-runwork,adjustablenipbarscanbeusedtoguardthegravure/impressionintakeandimpression/backimpression(boule)rollers.Theseshouldbedesignedsothattheycanbeadjustedtowithinamaximumof6mmfromthesurfaceofthecylindersandareoftenbestmountedoffthedoctorbladecarrier.Safesystemsofworkwillneedtobeimplementedtoensurethenipbarsarealwaysusedcorrectly.

Wherepressesareusedforshorttomediumruns,guardingshouldbeprovidedintheformofinterlockingguards.Thesecaneitherbefittedalongthesideofthepressesoroverindividualprintunits.

Givecarefulconsiderationtotheneedfordoctorbladewiping.Slotscanbecutintheguardswhichallowthedoctorbladetobewipedwithalongpencilbutpreventfingeraccesstothehazardousparts.Alternatively,youmaybeabletoreducetheneedforwipingdoctorbladesbyintroducingreformulatedinks-contactyoursupplier.

Makesureallequipmentissuitableforuseinpotentiallyexplosiveatmospheres(see‘Explosionrisksinflexoandgravure’inChapter7).Table11summarisesthesafeguardingrequirementsfortheprintunitsofgravurepresses.

Table 11 Safeguardinggravurepresses

Asthesepressesareusuallymulti-operator,audiblepre-startwarningdevicesmustbefitted.Usehold-to-runcontrolsformake-ready,cleaningetcanddevelopsafesystemsofworkformake-ready,cleaningandwebbing-upetc.Rememberthatmanyoftheaccidentsthatoccurinprintinghappenwhenitisnecessarytointerveneonamachineintheseways.SafesystemsofworkarelistedinTable12forthevariouscleaningtaskslikelytoberequired.

Gravure - long-run presses

In-runningnipsbetweengravureandimpressioncylinders

Nipbarsadjustedtowithin6mmofthegravure/impressionandimpression/backimpression(boule)cylinderswhicharedesignedtoallowadjustmentforthefullrangeofgravurecylinderdiameters.

Continuousslowcrawlshouldbesupplementedbyanemergencystop(or‘stoplock’)controlateachprintunit.

Ifwipingofthedoctorbladeisrequiredduringtheprintrun,provisionforsafeaccessshouldbemade.Thesafesystemofworkshouldconsiderotheraspectsincludinglightingandprovisionofapurpose-designedtool.

Unexpectedstart-up Pre-startaudiblewarningdevice.

Gravure - short-run presses

In-runningnipsbetweengravureandimpressioncylinders

Interlockingguardsfittedeitherateachprintunitoralongthelengthofthepresswhichallowlimitedinchandhold-to-runslowcrawlonlywhenopen.

Ifwipingofthedoctorbladeisrequiredduringtheprintrun,provisionforsafeaccessshouldbemadeeitherbymeansofaslotintheinterlockedguard,orbymeansofanadjustablenipguard.

Thesafesystemofworkshouldconsiderotheraspectsincludinglightingandprovisionofapurpose-designedtool.





Table 12 Safesystemsofworkforcleaninggravurepresses

Safeguarding screen printing pressesThemainrisksfromscreenprintersarefrom:

n crushrisksfromeitherthescreenriseandfallmechanismorsqueegeemovement;

n in-runningnipsfromfeederanddeliverymechanisms;n shearpointsfromgapsonlowercylindersoncylinder-typepresses;n hazardoussubstances,suchasinksorvarnishes,eitherwheninuse,when

curingorwhencleaningscreens.

Mostscreenprintoperatorsaddinkorvarnishwhilethepressismoving.Althoughthisisnotinherentlydangerous,itpreventsperimeterguardingfrombeingusedtopreventscreencrushinjuries.

Screen crush risksThereareseveralsituationswhichcancreateariskofcrushingtheupperbodyorfingers:

n Whentheframeholdingthescreenisraisedtoallowaccessunderthescreenitmustnotbepossiblefortheframetodescend,crushingtheupperbody.Onsomemachines,lightbeamsareprovided,butthesecansometimesbeineffectiveasitispossibletoreachoverthebeamwithoutinterruptingit.Itisoftennotpracticabletoextendthebeamoverthewholeareaasmachinecomponentsmayinterruptit.Sensitiveedgesmaybeapracticalsolution,orlightcurtainsinfrontofthemachinetodetecttheoperator’slegsratherthantheupperbody.Safesystemsofworkmustbeusedtoisolatethemachinebeforeenteringtheareabelowthescreen.

n Thesqueegeeriseandfallmechanismscanprovidecrushpointsforfingers.Provideafixedguardaroundthem.


Gravure

Wipingdoctorblades Approachclosetoin-runningnipsatproductionspeed n Useofpurpose-madetool

andproperlyadjustednip

barorslotininterlocked

guard.

Cleaninggravure/impressioncylindersmid-run,single-operatorcleaning

Accessibilitytoin-runningnipswheninterlockedguardraised n Inch-stop-clean.

n Forwardslowcrawl

cleaningonlyifnipbars

andemergencystops

areprovidedandaguard

checklistcompleted.

Cleaninggravure/impressioncylindersmid-run,multi-operatorcleaning

Accessibilitytoin-runningnipswheninterlockedguardraised n Inch-stop-lock-clean.

n Forwardslowcrawl

cleaningonlyifnipbars

andemergencystops

areprovidedandaguard

checklistcompleted.

Cleaninggravure/impressioncylindersatendofrun

Gravurecylinderremovedfrompress n Off-machinemanualor

auto-washing.



n Theoscillatingsqueegeecarriagecancreateacrushorshearpointasitmovestotheendofitstravel.Whilethiscouldquiteeasilyhavebeendesignedout,itisgenerallynotpracticabletoshieldthese.

Semi-automatic pressesOnsemi-automaticflat-bedmachines,takeprecautionstominimisethelikelihoodofthereciprocatingtablestrikingtheoperator,byprovidingsensitiveedges,presence-sensingdevicesorchainrailstopreventaccess.Thetrapsbetweentheverticallyreciprocatingframe-holderandthefourmainmachinepillarswillalsoneedtobeguarded.

Cylinder type machinesThesemachinescanposeariskwhenmakingready,thoughthisriskisremovedinnormaloperation.Therisksoccurfrom:

n shearpointsbetweengapsinthecylinder(bythegrippers)andthefixedstructure.Safesystemsofworkmustbeinplacetoaddressthisriskanditshouldneverbenecessaryfortheoperator’sfingerstobeinthisarea;

n in-runningnipsbetweenexposeddrivegearsandthefixedstructure.Thesegearstendtohaveteethlargeenoughtotrapafinger.Itmaybedesirabletoincreasethegapbetweenthegearandthestructuresothatafingerisnotdrawnin.

Hinged presses with power closureHingedorclam-typescreenprocessprintingmachineswithpowerclosureshouldbefittedwithefficienttripguardsaroundthethreeedgesofthescreen(unlesstheclosingforceislessthan300newtonsandtherearenosharpedges).Thesewillstopthescreenormakeitretractifanyonebecomestrapped.Regulartestingofthesafetydevicesshouldbecarriedouttoensuretheycontinuetooperateeffectively.

Safeguardthecrushingpointbetweenthesqueegeeandscreenframebyadjustingthestopgaugetoensureaminimum25mmgap.Ifthedescendingsqueegeecreatesacrushingrisk,makesurethattheliftingpathisasshortaspossible.

Feed and delivery in-running nipsBeltdrivesonmanymachineshaveinadequatenipguardswheretheypassoverrollers.Belttensionstendtobelowwhichreducesthepotentialseverityoftheinjury,butnipguardsshouldbeprovided.

Hazardous substancesWhereUV-curedinksorvarnishesareused,appropriatecontrolsmustbeprovidedtolimitskincontact.Emptyinginkfromscreensattheendoftheruninvolvesmovingasignificantamountofinkandappropriateprecautionsshouldbetakentopreventcontamination.Also,greatcaremustbetakenwhenwashingscreensusingwaterjettingtechniquestoavoidspraysofUV-curedinkshittingtheoperator.Verticalstripcurtains,similartothoseprovidedindoorwaysforfork-lifttrucks,canbeusedtobothpreventthesprayfromhittingtheoperatorandtomakeanylocalexhaustventilationmoreeffective.

Formoreinformationsee‘Screenprintingandcleaning’inthe‘Hazardoussubstances’sectioninChapter4.



Figure 31 Hingedorclam-typescreenprintingpresseswithpowerclosureshouldbefittedwithsafety

tripbars

Label printing machinesPresseswithtwinsideframesshouldmeetthestandardslaidoutundertheheadings‘Weboffset’and/or‘Flexographic’earlierinthischapter.Labelpressesofthecantilevertypeshouldmeetthefollowingstandards.

Thegearwheelsandin-runningnipsoncylindersandrollersoftheprintunitsoncantileverlabelprintingmachinesshouldbesafeguarded,forexamplewith:

n hingedorriseandfallinterlockedguards;orn removableenclosinginterlockedguards.

Hingedorriseandfallinterlockedguardsareoftendesignedtocoverallprintunitswithoneguard.Thisoftenpreventsoperatorsfrombeingabletomakeadjustmentsoraddinkonthe‘run’soprovisionshouldbemadefortheseadjustmentsbyextendingcontrols/inktroughsthroughtheguard.

Removableenclosinginterlockedguardscanbeusedtosafeguardeachprintunitindividuallyand,ifproperlydesigned,allowadjustmentsandtoppingupofinkwhilethepressisrunning.Detailedinformationontheirdesignisgivenunder‘Flexographic’earlierinthischapter.

Someoldermachinesmaybeprovidedsolelywithadjustablenipbarsasguarding.Theyareusuallyfoundtoberemovedorincorrectlyadjustedandarethereforenotadequate.Pacing/drawrollersshouldbeprovidedwithenclosinginterlockedguardsorsuitablenipbarswhereaccessispossibletoin-runningnipscreatedbycontra-rotatingrollers.

Aswellastheenclosingguardonflexographicprintunits,afixednipbarshouldbeprovidedatanyin-runningintakebetweenaniloxandductrollerastheserollersoftenhaveanauxiliarydrivetopreventtheinkfromdryingwhenthepressisstopped.Thedistancebetweenthisnipbarandthesurfaceofthecylindershouldbenomorethan6mm.Lowpowereddrivesmayalsobeacceptableiftheypreventinjury.Onsomepressesachamberdoctorbladearrangementmaybefitted.Adequateproceduresshouldbelaiddownforthesafehandlingofdoctorblades.

Finishing sectionThehazardouspartsofthefinishingsectionoflabelprintingmachinesmustbesafeguarded.Thesesectionswillcomprisesomeorallthefollowingunits:rotarydie-cuttingunits,flat-beddie-cuttingunits,slittingknives,trimremoval/rewind,punchingunits,perforating(crossandinline)etc.Combinationsoffixednipbarsandinterlockingguardsneedtobeusedtoguardthesefinishing/processingstations.Itisimportantto



ensurethattheguardingarrangementsareadequateforallwebpathsincludingthedifferenttrim/labelstrippingpaths.Theseareasoftenproducealotofdustandhighnoiselevelssotheguardingarrangementsshouldtakethesehazardsintoaccount.

Tofacilitatemake-readyandcleaning,labelprintingmachinesmaybefittedwithhold-to-runcontrolstoallowoperationofthepressatslowcrawlspeedswithguardsopened.Table6under‘Flexographic’earlierinthischapterdetailsappropriatesafesystemsofworkforcleaning.

In-line folders, sheeters, die-cutters etcAllin-runningnipsandothermechanicalhazardsonfoldersandotherin-lineprocessingequipmentneedtobeguarded.Guarddesignmayneedtotakeaccountofotherhazardssuchasnoiseanddust.

Onnewandrecentlyinstalledfolderinstallations,thefoldershouldbetotallyenclosedwithfixedandinterlockedguards.Guardlockingdevicesshouldbefittedwherethereisahighriskofsevereinjury(iechopperfolder)andthepresshasarundownperiodofmorethan10secondsevenafteractuationoftheemergencystopcontrol.

Totallyenclosedfoldersshouldbeprovidedwitharrangementsfortheremotecontroloffoldersettingseitherbyelectrical/electronicordirectmechanicalmeans.Thebendingrollersanddeliveryareaarelikelytobeoutsidethe‘enclosedarea’.

Thebendingrollersneedtobeprovidedwitha‘nose’guardatthebaseoftheformer(kite)andadjustableguardsfortheportionofthebendingrollersbehindtheformer.Thedeliveryareamustbeadequatelyguarded.However,ahold-to-runguardoverridecontrolbuttonmaybeprovidedforthedeliverytunnelguard.Depressionofthishold-to-runcontrolwillallowoperatorstoopentheguardatspeedsupto8m/mintoallowremovalofthefirstincompleteproductcopies.

All-enclosingguardsmaynotbepracticableonolderfoldersandlocalisedguardingofthehazardouspartsshouldbeprovided.Inthesecircumstancesthefollowingareasneedtobesafeguarded:thenipping/pinchingrollers,cross-associationrollers,foldingdrum,cuttingcylinders,cross-perforatingcylinders,jawcylinder,quarterfolderetc.Hazardousnipsbetweendeliverybeltsandpulleysshouldalsobeguarded.

Onsheetingunitsthemainareasofdangerarethedrawrollersandtherotaryknife.Thedrawrollersshouldbeguardedbyeitherfixednipbarsorenclosinginterlockedguards.Therotaryknifeisahigh-riskareaandonalargeinstallationshouldbeguardedbyahigh-riskinterlockingarrangement(iedual-circuitinterlocking)andwiththeprovisionofguardlockingiftherundowntimeislongenoughtomakeitnecessary.

Makesurethatprecautionshavebeentakentocontrolemployee’sexposuretonoiseanddust(seeChapter4).

Business forms pressesThehazardouspartsoffinishingsectionsofbusinessformspressesmustbesafeguarded.Thesesectionsandthemeansusedtoguardthemarethesameasthoseforlabelprintingmachines.Ifwanderleadsareprovided,allowingaccesstopartswithguardsopen,theyshouldbeofasimultaneoustwo-handcontroltype.Thesemayallowspeedsinexcessof10m/minwherespecifiedbythemanufacturerandwherethereisappropriateguardzoning.

Where,onbusinessformspresses,thewebisdeliveredbyaspiralfolderasinazig-zagfoldedcontinuousstationerypack,thedeliveryguardmaybefittedwithan



enableguardoverridecontrolbutton.Thisoperatesasahold-to-runcontrolallowingtheguardtobeopenedatslowrunspeedstofacilitateremovalofthefirstincompletecopies.

Aminimumgapof25mmshouldbemaintainedbetweenthespiralsbytheprovisionofadjustmentstops.Wherethespiralsneedtobeclosedtolessthan25mm,alocalguardpreventingaccessintothenipmustbeprovided.Fixedguardsmustbeprovidedforthespiraldrivegears.

Publishing roomsTypesofconveyors,counters,stackers,tyersandstrappersvaryconsiderablysothefollowingguidanceisgeneral.

ConveyorsEffectivemeansforstoppingnewspaperconveyorswhichenterthepublishingroomshouldbeprovidedforuseinemergencies.Wheredumpgatesareprovidedatfolderstodivertcopies,itshouldbepossibletostoptheinsertconveyorleadingtothepublishingroomwithoutstoppingthepress.Wheredumpgatescannotbefitted,itmaybenecessarytoprovidestopbuttonsinthepublishingroomwhichstopthepressaswellastheconveyorswherethesearemechanicallylinked.Normalpressstopsshouldbecarriedoutfromthepressroom,andasignallingsystemprovidedsothatpublishingroomstaffcanrequestthatthepressissloweddownorstopped.

Overheadconveyingmechanismsoutofreach,ie‘safebyposition’willnotnormallyrequireadditionalguarding.However,accessmaybepossibletothesemechanismswhiletheyarerunningsosomelocalisedguardingmayberequired.Operatorshavebeenknowntouseladdersormoveablestepsforcopyorblockageremovaletc.

Hazardouspartsassociatedwithconveyorssuchasbeltandchaindrivesmustbesafeguardedincludingthosesituatedbelowtheconveyors.Lift-upconveyorsontheseunitsshouldbearrangedsothataccesstohazardouspartsisnotpossiblewhentheconveyorsectionisraised,usuallyachievedbyinterlockingtheconveyorsection.

Whereconveyorsenterthepublishingroomfrombelow,adequatebarriersandtoe-boardsshouldbeerectedaroundtheconveyorandflooropening.

Copypick-uppointsshouldbedesignedtopreventaccesstohazardouspartsbyprovidingfixedorinterlockedguards.

Counter stackersCounterstackersshouldbeprovidedwithguardspreventingaccesstohazardousparts,forexamplerotatingcollectionhoppers.Safetyreachdistancestopreventhazardouspartsbeingaccessedwillapply(seeBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs).Whereguardshavetobeopenedbyoperators,theyshouldbeinterlockedtothecounterstackerdrive.Otherwisetheyshouldbefixedinpositionandrequireatoolforremoval.

String-tyers and strappersConveyor-fedautomaticstring-tyersandstrappersmaybedividedintotwogroups:



n thosewithalow-pressureclampnotcapableofinflictinginjury,eglessthan300newtonsandwhereanelasticbottomplatecoverhasbeenprovided;

n thosewithhigh-pressureclamps.

Machineswhichfallintothesecondcategoryshouldbeprovidedwithacombinationoffixedandinterlockedguardspreventingaccessfromthesides,in-feedanddeliveryends.SafetyreachdistancesinBSEN294:1992apply.Lift-offguardsandguardsthatneedtobeopenedfrequentlyforcleaningjams,replacingstringetcwillneedtobeinterlocked,includinganylift-upconveyorsections.

Somestrappingmachinesmayhaveforce-limitingdevices,egslipclutchesontheclampaswellasaresilientrubberfacing,andmayhavenootherassociatedhazardousparts.Gravity-fallcrucifix-turndevicescanbecomehazardouswhenladen,andscreen-guardingshouldbefitted.Thismayrequireinterlockingifaccesstootherhazardouspartsispossible.Whereyourelyonforce-limitingdevices,theseshouldberegularlytestedusingaload-cellpressuregaugeorothersuitableinstrument.

Figure 32 Conveyors,counters,stackers,tyersandstrappersinpublishingroomsneedtobesafeguarded

Insertion equipment

n Therisksposedbyinsertionequipmentareprimarilythoserelatedtoin-runningnipsorpinchpointsfrommovingequipment.Onmodernequipment,theseareeitherhousedbehindfixedorinterlockedguardsorareabove2mfromthefloor.Equipmentmustnotberunwiththeguardsremovedorinterlocksoverridden.Regularchecksmustberuntotestthecontinuedcorrectoperationoftheinterlocks.

n Whereitisnecessarytoruntheequipmentwiththeguardsopenduringmakeready,thenitmustonlybepossibletorunitusingahold-to-runbuttonandatcrawlspeed.Systemsofworkmustrestrictsuchoperationstoappropriatelytrainedpersonnel.



n Systemsofworkmustbeinplaceforelevatedwork,egmaintenance,nearinsertionequipmentortheirassociatedconveyors.Suchworkmustonlybecarriedoutwiththisequipmentisolatedandlockedoff.Equipmentisnormallyautonomousandsoyouneedtoisolateinsertionequipmentandconveyorsseparately.

Automatic insertion disc equipmentControlstationsshouldnotbelocatedinthepathofautomaticallymovingdiscsofinsertionmaterial.Makesuretherearenoaccessiblesheartrapsbetweenthemovingdiscsandcontrol/electricalpanelsandseparatemovingdiscsandpersonnel.Ensuretripwire/pressure-sensitiveedgedevicesprovidedonthedisccarriagesgiveadequateprotectiontooperatorsandthatthesearemaintainedinfullworkingorder.Theintegrityoftheinterfacebetweentheguardingdevicesandtheprogrammablecontrolsystemsforthedisccarriagesshouldbeassessed.Disccarriagesshouldstopsafely,withouttrappingoperatorsorejectingtheirload.

Inserting and stitching drumsFrontandendcoversofinsertingandstitchingdrumsshouldbeinterlockedsothatwhentheyareopenonlymovementbyhold-to-runslowcrawlispossible.

Adequatesafeguardingshouldbeprovidedattherearofthedrumstopreventinjurywhenremovingmisfedcopies.

Interlockedorfixedguardsshouldbeprovidedtopreventaccesstohazardouspartsfromsteps,workingplatformsorotherareas.Accidentshaveoccurredwhenoperatorshaveattemptedtoclearblockagesbyreachingoverinterlockedguardsbystandingonpalletsandshortsteps.Overheadchaindrivesshouldbesafebypositionorguarded.Full-lengthguardingmaybemorepracticalthanmultiplelocalisedguards.Stitchingheadsshouldbefittedwithinterlockedhoodguardswhereotherwiseaccessible,egfromworkplatforms.

Figure 33 Newspaperproduction-printingandpublishingoperations

Envelope-making machinesTherearetwobroadcategoriesofenvelope-makingmachine,blank-fedorweb-fed.Bothtypesofmachineusuallyconsistofprintingunits,gummingstation,window-patchingstation,foldingandgluingstation,acollatordrumandatake-offsection.

Webpaths(Webbing-upandsafeguarding)

Folder(noiseandsafeguarding)

Soundhaven(noise)

Vanway(transportsafety)

Loading(manualhandling)

Conveyors(safeguarding)Reels

(manualhandling)Reelstands(safeguarding)

Printunits(safeguardingandzoningofcontrols)

Tying,strappingandconveyors(safeguarding)



Blank-fedmachineshaveafeedplateorfeedpillar.Web-fedmachineswillhaveareelstand,profilecuttingsystemandrotaryorflyingknifeaswell.

Thehazardouspartsofthesemachinesincludethein-runningrollernips,gummingwheels,knives,reciprocatingfeeddevices,gearwheelsanddrum-relatedsheartraps-thesemustbesafeguarded.Manyofthesehazardouspartscanbeguardedbyfittingsideguardstothemachines.Theseshouldbeinterlockedtothemachine’smovementsothatopeninganyoneoftheseguardsstopsthemachine.Localisedinterlockedorfixedguardingcanalsobeused.In-runningnipsonfoldingrollerswheresafeguardedbytunnel-typeguardsmay,inexceptionalcircumstances,haveopeningsof30mmwherethesafetydistancetothedangerpointis200mm.

Machinesmaybefittedwithtwo-hand,hold-to-runcontrolsforsetup.Thespeedshouldbelimitedto10m/minandguardzoningprovided.Inexceptionalcircumstances,wheretheuseofstroboscopesisneededatproductionspeedsforfault-finding,thefollowingshouldbeprovided:

n hold-to-runcontrol;n guardzoning;n aselectorswitch;n asafesystemofworkwhichincludesusingtheslowestspeedpossible.

Additionallocalfixed,interlockedandadjustableguardsarenecessaryonmanyofthemachine’sindividualunits.Thefeedplateorfeedpillarwillneedlocalprofiledguardsforthedraw,hookrollersandanyscorerollers.Anyhingedgummingunitsshouldbeinterlockedtopreventthembeingleftoutofposition,exposinghazardouspartswhennotinuse.

Standardsforreelstandsonweb-fedmachinesshouldmeetthoseoutlinedunder‘Weboffset’earlierinthischapter.Theprintunitsonbothtypesofmachineshouldbeguardedinaccordancewiththestandardssetoutunder‘Flexographic’earlierinthischapter.

Sealflap,windowandbottomflapgummingunitswillallrequireguardingtopreventaccesstoin-runningnipsorcontactwithhotglues.All-enclosinginterlockedguardingmaynotbefeasibleasaccessmaybeneededtothegluebottles.Acombinationoffixedandinterlockedguardsisoftenmostsuccessful.Thinkaboutthehandlingofthegluebottlesasthismayposeasignificantmanualhandlingrisk.

Theintakesassociatedwiththeglassinetissueknifeandtissueapplicatorin-runningnipsneedtobeguarded.Anysheartrapbetweenthedeliverytableanddryingdrumshouldbesafeguarded.Thismaybeachievedbyprovidingfixedorinterlockedguardingorahingedtableendofatleast25mm.Anybeltorpulleyintakesshouldalsobeguarded.Deliveryguardingcanusuallybeachievedeitherbyfixedtunnelguardingorbyadjustableplates.

Onweb-fedmachines,areasofhighriskincludetheprofilecuttingsystemandseparatingknife.Thesemustbeadequatelyguardedbyprovidingfixedorinterlockedguards.Guardingshouldtakeaccountoftherundowntimesoftheknivesandthefrequencyofaccess.

Noisecancauseseriousproblemsonenvelopemachinessoitisoftenagoodideatocombineguardingandnoise-reductionmeasures.Newmachineswithhighnoiselevelsshouldbesuppliedwithnoisecontrolmeasuresincorporatedasstandard.



Accident

Anemployeewasfatallyinjuredwhenhisheadwastrappedbetweentherotatingspokesofadryingwheelandthefixedframeoftheenvelope-makingmachine.Theaccessdoorstothewheelwerenotsecured.Fixedorinterlockedguardsshouldbeprovidedatbothsidesofthedryingwheeltopreventaccesstotheshearhazardcreatedbetweentherotatingwheelandfixedmachineframe.

Figure 34 Suitablenoise-hoodsshouldbeprovidedforbuckleplates

Sheet-fed folding machines Thedangerpointsonsheet-fedfoldingmachinesmustbeguarded.Thetwomaintypesofmachine,buckleandcombination,giverisetosimilarrisks.Oneoftheseisnoisewhichcanbeaddressedbyprovidingsuitablenoise-hoodsforthebuckleplates.Onnewmachinesnoise-reductionmeasuresshouldbeprovidedaspartoftheirstandardspecification(see‘Noise’inChapter4).

Themainin-feedrollersshouldbeprovidedwithfixedorinterlockedguardswithanarrowslotforsheetentry.Accesstothefoldingrollersshouldbepreventedbyacombinationofguards,themachine’sframeandthebuckleplates.

In-runningnipsassociatedwithdrivetapesshouldbeguarded.Thiscanbeachievedbydesigningthetransport/feedtablesto‘fit’thepulleys,iereachtoapointnomorethan6mmfromthein-runningbelt/pulleynip,ortheprovisionofnipbars.Giveparticularattentiontothenipsassociatedwithtensioningpulleys.

Thehazardouspartsinvolvedwithfoldingknivesshouldbeguarded.Onnewmachinesthismaybeinconjunctionwiththedeliveryareaofthebuckle-foldingunit,ieanall-enclosinginterlockedguard.Onoldermachinesamorelocalisedfixedorinterlockedguardshouldbeprovided.

Perforators,creasingunitsandslittersareoftenfittedtothistypeofmachine.Theintakesassociatedwiththesedevicesshouldbeguarded,includinganyin-runningnipcreatedbetweenthemandfixedpartsofthefoldingmachine.Precautionsalsoneedtobetakentopreventaccesstotheperipheryofrunningslittersandperforators.

Forsettingpurposes,interlockedguardsmayneedtobeopened.Inthesecircumstances,themachineshouldonlystartunderhold-to-runcontrolwithamaximumspeedof70m/minmeasuredatthefoldingrollers.Guardsinareasoutsidetheoperator’sviewshouldbeclosed,aselectorswitchshouldbeprovidedandtherunspeedshouldbeasslowaspossible.



GuillotinesPower-operatedpaper-cuttingguillotinesarepotentiallythemosthazardousmachinesintheprintingindustry.Theymustbeadequatelysafeguarded,regularlycheckedbybothoperatorsandcompetentguillotineengineers,andoperatorsmustbeproperlytrained.

Furtherguidanceontheguarding,maintenanceandtestingofguillotinesisavailableinthePrintingIndustryAdvisoryCommitteebookletThe guide to safe use of power-operated paper-cutting guillotines.Thispublicationalsocontainsinformationontrainingandknifechangeprocedures.

Figure 35 Guillotinefittedwithphotoelectriccurtainandsimultaneoustwo-handcontrols

Common accidents

n Amputationsfollowingdoublestrokingoftheknifeduetofaultybrakesandpoormaintenance(includingtopdeadcentrecams).

n Crushandamputationinjuriesbytheclampparticularlywhenthedynamicgaugingforceexceeds500newtons.

n Amputationinjuriescausedbytrappingfingersinthescrewadjustmentholesoftheclampwhentheclampreturns.

n Trappingaccidentsbetweenthemovingbackgaugeandclamp.n Accidentsduetoincorrectguardpositioningorguardsbeingdefeated.n Accidentsduringknifechanging.

Photoelectric (electrosensitive) safety systemsPhotoelectricsafetysystemsforguillotinesshouldmeetcertainminimumstandardswithfullfunctionmonitoring(FFM)asthelowestacceptablelevelforoldmachines.Newermachineswillneedtomeetmorestringentstandards.

Ingeneral,guillotinessuppliedbefore1974withoriginalphotoelectriccurtainswillrequireupgradingtomeetthestandardsinThe guide to safe use of power-operated paper-cutting guillotines.Guillotinessuppliedbetweenapproximately1974and1987shouldhaveelectrosensitivesafetysystemsdesignedandoperatingtofullfunctionmonitoring(FFM)standards.However,onsomeguillotines,certainmodificationswillneedtobecarriedoutsuchastheremovalofthefullyautomaticfacility.Acompetentguillotineengineershouldbeabletoadviseyou.

Guillotinessuppliedafter1987shouldcomplywithBSEN61496-1:1998,IEC61496-1:1997Safety of machinery. Electro-sensitive protective equipment. General requirements and tests.



Guillotinessuppliedafter1January1995shouldbe‘CE’markedandcomplywiththeSupplyofMachinery(Safety)Regulations1992asamended.

Itisextremelyimportantthatthephotoelectriccurtain(lightcurtain)islocatedcorrectly.Seriousinjurieshaveoccurredwhenthecurtainhasbeenincorrectlymountedandoperatorshaveaccidentallyreachedoverorunderthecurtainwithoutbreakingthebeams.

Asageneralrule,theoutermostbeamshouldbeapproximately635mmfromthecuttingstickandnomorethan185mmabovethetable.

Wherenewmachineshaveausablepileheightofmorethan185mm,theoutermostbeammaybeataposition610mmminimumand700mmmaximumfromthecuttingstickandnomorethan205mmabovethetable.Anelectrosensitiveprotectivedevice(additionalbeam)shouldalsobeprovidedatadistanceofbetween400and550mmfromthecuttingstickandataheightofbetween0and205mmabovethetable.Anadditionalbeamshouldbefittedonallnewmachinesfittedwithfullyautomaticcuttingoperation.Wherethemachinedesignissuchthatthecurtainextendsdowntothemachinetable,theoutermostbeamshouldbeatleast400mmfromthecuttingstickifthebeamislessthan38mmfromthetable.

Theseparationdistanceofthecurtainfromthecuttingstickmustbeconsistentwiththeoverallstoppingperformanceofthemachine.Oldermachineswillgenerallyhaveadistanceofatleast460mmbetweencuttingstickandcurtain.

Sixkeypointstocheckonphotoelectricsafetysystems:

n Thesystemmeetstherequiredstandardsandisupgradedifnecessary.n Thephotoelectriccurtainislocatedcorrectly.n Twofinalswitchingdevicesareprovidedforfullyautomaticmachines.n Simultaneoustwo-handcontrolsarefitted.n Thedynamicgaugingforceoftheclampislessthan500newtons.n Suitablereartableguardingisfitted(see‘Interlockingguards’below).



Figure 36 Positioningoftheelectrosensitiveprotectivedevices(beams)andcurtainhousing

Not more than 185 mm from the centre of the outermost beam to the machine table

610-635 mm from the centre of theoutermost cell of the light barrierto the cutting plane

610 mm or greater from the cutting plane to theoutermost edge of the light barrier housing orits extensions

Housing to be as low as practicable

610-635 mm

Not more than 185 mm from the centre of theoutermost beamto the machinetable

Housing to be equal to or less than165 mm to the machine table

550 mm betweenthe lowest point of thecutting plane and theoutermost edge of thelight barrier housingor its extensions

At least 635 mm

Cutting plane

205 mm

Front table400 mm

500 mm

At least 850 mm fromthe cutting plane tothe outer edge of theside table

Not more than 185 mmfrom the centre of the outermost beam of themachine table Not more than

150 mm

At least 635 mm



Body push guardsBodypushguardsfittedtoguillotinesarenolongerconsideredadequatesafetydevices.Guillotinesfittedwithbodypushguardsshouldhavebeenwithdrawnfromservice.

Figure 37 Guillotineswithbodypushguardsshouldnolongerbeinuse

Interlocking guardsFourkeypointstocheekoninterlockingguards:

n Theguardpreventsaccesstothedangerzone(ieyoushouldn’tbeabletoreachover,aroundorbeneaththeguardwhenitisinthedownpositionandliftingoftheguardstopsthemachinebeforeyoucanreachthebladeorclamp).

n Theinterlockingarrangementisoftherequiredstandard(thiswillnormallyneedtobeadual-channelcontrolsystem-yoursuppliershouldbeabletoconfirmthis).

n Simultaneoustwo-handcontrolsarefitted.n Suitablereartableguardingisprovidedwhichpreventsaccesstodangers

createdbythemovingclamp,bladeorbackgauge.

Automatic sweepaway guardsThesearedesignedtopushoperators’handsawayfromthecuttingareabeforetheycanbeinjuredbytheknifeorclamp.

Fivekeypointstocheckforguillotinesfittedwithsweepawayguards:

n Theguardsweepstowardstheoperatortoapoint500mmfromthefaceoftheclampbeforetheclamporknifehavedescended50mm.Youmayfinditusefultoputamarkatthe500mmpointonthetabletohelpyoucheckthis.

n Additionalguardbars/meshareprovidedtopreventaccessover/throughtheguard.

n Sideaccesstothedangerzoneatthefrontofthemachineispreventedwhentheguardisextended,egbyprovidinglargesidetablesorfixedguards.

n Simultaneoustwo-handcontrolsareprovided.n Suitablereartableguardingisprovided.

Guillotineswithsweepawayguardsshouldnotbesuppliedsecond-handorsoldon.Sweepawayguardsshouldnotbechangedforelectrosensitivesystemsifanon-fail-safebrakeisfitted.



Figure 38 Automaticsweepawayguards

Common requirements for all power-operated paper-cutting guillotinesModificationstoguillotinesafetysystemsshouldonlybecarriedoutbycompetentguillotineengineers,manufacturersorsuppliersbecauseofthecomplexityofthesystemsandthepotentialdangersresultingfrominadequatemodifications.

Simultaneoustwo-handcontrolsshouldbefittedtoallmachinesotherthanthosewithhigh-integrity,all-enclosinginterlockedguards.Thesewouldhavecross-monitoreddual-channelcontrolusingtwoguardpositionswitchesoperatinginoppositemodes.Oldermachinesmayneedtheircontrolsupgrading.Thetwo-handcontrolshouldmeetthefollowingbasicstandards:

n bothbuttonsshouldbeoperatedwithinapproximately0.5secondsofeachotherbeforethemachinewilloperate;

n ifonecontrolisreleased,bothbuttonsshouldhavetobereleasedandre-operatedforre-initiation;

n thecontrolsshouldnotbecapableofbeingspannedbyonehand;n ifoneorbothcontrolsarereleased,themachineshouldstoporreturntotop

deadcentre.

Theaboveguidelinesareverygeneralandthedetailedrequirementsofindividualmachinetypesandmodelsshouldbecheckedwiththemanufacturer/supplierandagainsttheguidelinesinthePrintingIndustryAdvisoryCommitteebookletThe guide to safe use of power-operated paper-cutting guillotines.

Operatorsshouldcarryoutdailytestsandchecksofguillotinesfittedwithelectrosensitive(photoelectric)safetysystemsorinterlockingguards.Thesechecksshouldalsobecarriedoutafterknifechanging.

Sweepawayguardsonguillotinesshouldbecheckedbyoperatorsonamonthlybasis.Alltestsshouldberecorded.Thechecksshouldalsobecarriedoutafterknifechanging.

Six-monthlyexaminationsandtestsshouldbecarriedoutonallguillotinesbycompetentandtrainedengineersandcoversafetycomponents(egbrakeandclutches,interlockswitchesandcams),stoppingperformanceandgaugingpressurestocomplywithregulation6(2)ofPUWER98(seeChapter8).

Sweepawayguardinextendedposition(sideguardsomittedforclarity)

Anunacceptablesweepawayguillotine



FurtherinformationandexampletestformscanbefoundinthePrintingIndustryAdvisoryCommitteebookletThe guide to safe use of power-operated paper-cutting guillotines.

Theintegrityofguardsandbrakingsystemsonguillotinescanonlybemaintainedbyregulartestingandexamination-failuretomaintainaguillotinecouldresultinaseriousandavoidableincident.

Knife changingSpecialprecautionsarenecessarytopreventinjurywhenknivesarechanged.Theguillotinemanufacturer’sinstructionsshouldbefollowed.Theseusuallyentailproceduresinvolvingdevicessuchasknifehandlesorslidesandsupportsforsaferemoval,mountingboardsforsafetransportandstorage,andtheuseofanassistantwhenchangingknivesonlargermachines.Precautionsshouldalsobetakentokeepothersawayduringknifechanging,egbyusingbarriersandatablenearthefrontoftheguillotine.

Other cutting machinesThree-knife trimmersTheseusuallyconsistsofthreeguillotinebladesorknives(theheadandtailknivesandtheforageknife).Theknivesreciprocateautomaticallythroughouttherun.Guardingforthebladesandotherhazardouspartsisessential.Accesstothebladeswiththeguardsopenwillberequiredforknifechangingandadjustment.Three-knifetrimmersmustbeadequatelyguarded.Thisisusuallyachievedbyprovidingfixedorinterlockedguards.

Manually fed machines

n Provideinterlockedtunnel-typeguardstopreventaccesstotheknivesfromtherearofthemachine.

n Feed-sideguardingshouldincorporatetripdevices,forexampleatrippedflaprunningthelengthofthefeedopeningortrippedsideguardsorboth.Thetripdevicesshouldoperateatminimaldeflectionandshouldinstantlycutpowerandmovementofhazardouspartsifanoperator’shandsarecarriedintothefeedopening.

n Provideadjustablefeed-sideguardswherebooksizesvary.Thesewillneedtobemaintainedinthecorrectpositiontoallowfeedingoftheworkbutpreventoperatoraccesstothedangerarea.Fronttabledimensionsmayneedextendingtogiveoperatorsextraprotectionbykeepingthemfurtherawayfromthefeedopening.

n Simultaneoustwo-handhold-to-runcontrolsshouldbeprovidedonnewmanuallyfedmachines.Similarstandardsshouldbeprovidedonolderexistingequipment.

Automatically fed machinesGuardingusuallytakestheformofaslidingtunnelguardoralargehoodsplitintotwosectionshingedatthemiddle.Theseshouldbeinterlocked.

Common provisionsOpeningsintheguardsshouldcomplywiththesafetyreachdistancesinBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs.

Photoelectriccurtainscanalsobeusedtoprovideprotectionatthefeed-side.

Emergencystopdevices,includinglift-upbardevicesatcertainoldermachines,arenotasubstituteforthetripdevicesreferredtointhepreviousparagraphs.

Youwillneedsafesystemsofworkforknifechangingandsetting,incorporatingtheuseofknifecovers.



Forsettingpurposes,two-hand-controlsshouldbeprovidedwhichdonotallowrunningorjoggingofthetrimmersectionwiththeguardsopen.Operatingthetwo-handcontrolwiththetrimmerguardsopenshouldallownomorethanasinglestrokebythetrimmerbladeshoweverlongthecontrolsareactuated,ieifthecontrolsareoperatedandheldinforseveralsecondsthetrimmerbladeshoulddonomorethanonestrokeandthencometoacompleterest.

Whereoperationoftheknivesisnotrestrictedtoasinglecutwiththetrimmerguardsopen,machinesshouldbedesignedtoallownecessaryrunningadjustmentswithguardsclosed.

Loose knife punching machinesManuallyoperatedlooseknifepunching/cuttingmachineshavecausedfingerandhandinjurieswhenoperatorshavenotwithdrawnbeforetheplatendescendsorhaveattemptedtorepositionatopplingknife.Accessshouldbepreventedduringthestrokebyacombinationofaslidingfrontfeedtable,simultaneoustwo-handcontrolsandeitherinterlocked/fallingscreenfrontguardsorself-adjustingtunnel/screenfrontguards,togetherwitheitherlocalisedfixedguardingforthesidesandrear,orperimeter-typefencing.Cutterbalancingspringsshouldbeusedtostopsmallcuttersfallingover.

Automaticmachinesneedahigherstandardofsafeguardingasthetwo-handcontrolsonlyofferprotectionfortheoperatorduringtheinitialstrikeon.Thefeed-sideshouldbesafeguardedbyeitherahingedinterlockguardoranelectrosensitivesafetysystem.Youshouldensurethatthesafeguardingarrangementsatthefeed-sidecomplywithBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs.

Locatethephotoelectriccurtainincorporatedinthissystemcorrectlytopreventpeoplereachingthedangerpointsorbeingabletostandbetweenthephotoelectriccurtainandmachine.Thesidesandrearcanbesafeguardedbyacombinationoffixedandinterlockedguards.

Shearandtrappingpointsonthepaperfeedandtake-offsystemsshouldbeeitherdesignedoutorsafeguardedusingtripdevicesorothermethods.

Figure 39 Exampleofguardingalooseknifepunchingmachineusingafallingscreenguard



Flat-bed cutting and creasing machinesCuttingandcreasingmachinescomeintwoforms:

n purpose-designedmachines;n convertedprintingpresses.TheHeidelbergOriginalCylinderisatypical

exampleofaconvertedmachine.

Themainrisksare:

n movingcomponentswithassociatedcrushorshearpoints.Cuttingandcreasingmachineshaveaninherentoscillatingmotion,andmovementsmaybesudden.Access(includingdirectorindirect,egviathewastechute)tothemovingpartsshouldbepreventedbymeansofguardsorotherdevicesthatstopalldangerousmotionbeforeinjurycanresult;

n weightsofdiesonlargermachines;n noisefromlargermachines,particularlythosefittedwithtrimmingsextraction

systems;n crushpointsattheoutfeedoflargermachines.

Purpose-designed machinesThefeed-endofmachinesissimilartothatofsheet-fedprintingpresses.Footcrushingrisksfromdescendingpallettablesshouldbeavoidedbyhavingamanualsystemforthefinal100mm,oralternatively,hingedflapsthatraisetheoperator’sfootawayfromthetrappingpoint.Transfermechanismsfromtheproductpileneedtobeadequatelyguardedtocoveranyin-runningnipsorshearpointsasin-feeddevicesoscillate.

Thecutting/creasingandstrippingareasmustbeguardedusingeitherfixedorinterlockedguards.Ifyouneedtobeabletoinchthemachinewiththeguardsopen,thenaudiblepre-startwarningsmustsoundbeforethemachineismoved,andthemovementmustbelimited.Itmustnotbepossibletoaccesstheintermittentlymovingtransportchainswiththeguardsopen.

Removetrimmingssothattheydonotaccumulate.Vacuumextractionisoftenused,butthenoisefromtheairflowandtrimmingsmovementcanexceed85dB(A)inmanymachines.Minimisetheleveltowhichtheoperatorsareexposed.

Delivery-endpalletscansometimeshavepooraccess.Itisoftenimpracticaltopreventaccesstothisareabutduringnormaloperationitshouldnotbenecessaryforpersonneltoentertheareawherethepalletdescends.Safesystemsofworkmustbeinplaceforthechangeoverofpalletsortheircarriageplates,statingthatthemachinemustbeisolatedifaccessisrequiredtothepalletdescentarea.Wheremachinepartsorhigherlevelplatformsarepositionedsothattheoperatorsmayhittheirheadsduringunloadingoperations,thenthesepartsmustbeadequatelypadded.Housekeepingandneighbouringequipmentmustnotcauseanobstructionwhenremovingproductonpallettrucks.

Whenchangingdies,appropriateequipmentorsystemsofworkmustbeprovidedtominimisetheriskofinjurythroughmanualhandling.Extendingrailsmaybeprovidedtoenablethedietoberemovedfromthemachineandequipmentorsystemsmustaddressthemovementtoorfromtheserails.

Converted machinesTypicalmachineshavethefeedanddeliveryatthesameend.Guardsmustbeprovidedovertheformeattheotherendandtheseshouldbeinterlockedratherthanfixedtofacilitatechangeoverofdies.Therisksfrominkingrollersareusuallyovercomebyremovingthesewithpressesdedicatedtocuttingandcreasing.Thesheartrapcausedbythegapinthecylinderasitpassesfixedmachinepartsmust



beguardedbyeitherafixedorinterlockedguard.AcommonmethodoffixingsuchaguardistouseU-boltsorsimilardevicesroundthecrosstiebar.Riskscausedbyoscillatingdeliveryfingersmustbecontrolledbyensuringthatthesearetelescopic.Mostpressesweredesignedthisway,butdamageduringusemayhavejammedthetelescopicaction.

AutoplatensAutomaticsheet-fedplatenswerenotoriginallysuppliedwithguardsforthereciprocatingplatenortheinkingrollers.Attheveryleast,usersneedtoensurethatfixedsideandrearguardsareprovidedandthat,wherestillused,inkingrollersareguarded.Safeguardingbymeansofinterlockedgatesorpressure-sensitivematsatthefrontofthemachineshouldalsobeconsidered.Itisparticularlyimportantthatoperatorsareproperlytrainedandsupervised.

Hand-fed platens used for cutting and creasingHand-fedplatenshaveresultedinmanyseriousaccidents,includinganumberoffatalities.Themaindangersarehandinjuryduetolatefeedingortakingoutwhenthemachineisincontinuous(timercontrolleddwell)operation,andbodytrappingduetoaccidentaloperationoftheplatenwhilemakingreadyorclearingwaste.

Allelectro-magneticandelectro-pneumaticmachinesshouldhave:

n aU-shapedtripguardwhichcloselysurroundstheplatentowithin12mmonthreesides;

n atripbarorpressure-sensitiveedgeonthefrontedgeofthemovingplaten;n additionalsideguardingintheformof1mwidepressure-sensitivemats

extending250mmbeyondthebackedgeofthefixedplatenorfixed/interlockedsidetables;

n acontrolsystemandguardingcircuitssuitableforahigh-riskapplication,egdual-circuitcross-monitored.

Ariseandfallguardmaybeprovidedonthefrontedgeofolderplatenmachinestoensuretheminimumgapismaintainedbetweenthemovingplatenandthetripguard.

Wheretimer-controlledoperationora‘dwell’deviceisfitted,the‘dwell’periodmustnotexceed12seconds.Amaximumof6secondsdwellshouldbeusedformostoperations.

Thesafeoperationofhand-fedplatensiscriticallydependentontheirconditioninuse-deteriorationofthesafeguardswillputtheoperatoratsignificantrisk.Youneedtoensurethatregularinspectionsarecarriedoutbyacompetentpersonatleastannuallytocomplywithregulation6(2)ofPUWER98(seeChapter8).

Machines with mechanical (positive) clutchesThesemachinescannotbeprovidedwithallofthesafeguardsdetailedunder‘Hand-fedplatensusedforcuttingandcreasing’unlesstheyarecompletelyrefurbishedandprovidedwithasuitableelectro-magneticclutch/brakeunit.Youshouldplantoupgradeorreplacetheseoldmachines.

SomemachineswerefittedwithatreadleconversionkittodisconnectthefootpedalfromtheclutchonoperationoftheU-shapedtrip,preventingaccidentaloperation.However,thismeasurewasdifficulttomaintainandwasnotenoughonitsown.



Maintenance of hand-fed platen guardsThesafeguardsonallhand-fedplatensneedtobecheckedandtestedonadailyorshiftbasis.BothofthetestsoutlinedbelowshouldbecarriedoutbyproperlytrainedoperatorstoensurethatproperperformanceoftheU-shapedtripismaintained.

Testingshouldalsobedoneperiodicallybyamemberofmanagementoranengineer.Alltestsshouldberecordedandallrecordsheld.

Test 1Theactualtrippingpointshouldbetestedbyturningthemachineoverbyhand.(Thismaynotbefeasibleonlargermachines.)Whenoperated,thetripdeviceshouldensureagapofnolessthan175mmismaintainedbetweentheedgeoftheplatenandtheforme.Onmachineswithatraveloflessthan350mm,trippingmustoccurnotlaterthanhalfwayinthetravel.

Test 2Test2shouldbecarriedoutwhenthemachineiscoldaswellaswhenitiswarmedup.Theoperatorshouldcarryoutthetestsbutonlyfollowingproperandcarefulinstruction.Asuitabletestpiecewouldbea12mmcardboardtube.

Thestoppingeffectofthetripdeviceshouldbetestedwiththemachinerunning.Theplatenshouldcometorestnolessthan90mmfromtheforme,oronmachineswherethetrippingdistancemaybelessthan175mm,nolessthan65mm.

Figure 40 Testingahand-fedplaten

Accidents

TheoperatorofaRabolinimechanicalclutchhand-fedplatenhadhisfingersfrombothhandsamputatedwhenhewasclearingoutstops.Heinadvertentlystoodonthefootpedal,causingthemachinetostrokeandoverridetheU-shapedtrip.

TwobrotherswereseriouslyinjuredwhileremovingtheformefromalargeStrumberplaten.TheU-shapedtriphadbeenpushedintotherearpositionbuttheplatenhadnotbeenisolated.Workingoneithersideofthemachine,theformewassupportedwiththeirhandsbetweentheplatenswhilethesecuringscrewswereundone.Anotheremployeetheninadvertentlyoperatedthepartiallyshroudedfootpedal,causingtheplatentostroke.Heimmediatelyoperatedthesensitiveedgebutnotbeforebothbrothersweretrapped.InvestigationrevealedthattheU-shapedtriphadbeenprovidedwithasinglepositivelyoperatingpositionswitchwhichwasineffectivebecausethegrubscrewsecuringthecamwasloose.Nosideguardshadbeenprovidedandnoguardcheckingwasbeingdone.



Label punching machinesWhereregularaccessisrequiredformanualfeeding,makesurethatthefeedopeningforthematerialtobepunchedissafeguardedbyaninterlockedguardorphotoelectricdevice.

DischargeopeningsshouldbedesignedinaccordancewiththereachdistancesspecifiedinBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs.

Onnewmachines,whenfeedingthematerialrequiresregularandroutineaccesstothedangerpoint,thesafety-relatedpartsofthehydraulic/pneumaticcontrolsystemshouldsatisfyCategory3,andthesafety-relatedpartsoftheelectric/electronicsystemCategory4,ofBSEN954-1Safety of machinery. Safety related parts of control systems.ElectrosensitiveprotectivedevicesshouldsatisfytherequirementsofType4ofBSEN61496-1andBSEN61496-2Safety of machinery. Electro-sensitive protective equipment. General requirements and tests.

Round cornering machinesMakesurethataccesstothetrimmingknifeorsawispreventedbyanadjustabletransparentguardandthatthecuttingoperationcanonlystartoncethematerialhasbeenfedusingapresence-sensingdevice.Operationofthecuttersmustbeunderthecontrolofahold-to-rundevice,whichcanbeeitherhand-orfoot-operated.

Fixedorinterlockedguardsshouldbeprovidedattherearandonbothsidesofthemachine.

Folder gluer machines used in box makingThissectioncoverssmallerfoldergluersusedforcardboardboxmaking;itdoesnotcovercorrugatedcartonmanufacture.Themaindangerpointsonsmallermachinesarerotatingshafts,in-runningnipsandtrapscausedbypartsmovingclosetoeachother.Guardingmaycompriseindividualfixedguardsateachnippoint,enclosinginterlockedguardsorphotoelectricguards.

Power-drivenshaftsshouldbesafeguardedbyself-adjustingtelescopicguards.

Ifautomaticformatsettingispower-driven,hold-to-runcontroloramaximumsettingspeedof0.5m/minshouldbeprovided.

Onmodernmachines,checkwithyoursupplierthatthefollowingstandardshavebeenachieved:

Feeder

n In-runningnipsatthefeed/pullrollsshouldbesafeguardedbyfixedguardssuchas‘cheekplates’.

n Theclearancebetweentheloweredgeofthemoveablesidelayandthefeedingbeltshouldbenomorethan6mm.Furthermovementofthesidelayshouldnotbepossibleunlessresidualpilemonitoringisprovided.

Folding and gluing section

n Safeguardin-runningnipsbetweentheupperandlowerrollertracksorfoldingbeltbyensuringthatthefirstrollerallows25mmdeflectionandtheremainderoftherollershavefixedguardsonbothsides.

n Raisingandloweringofrollertracksunderpowershouldonlybepossibleunderhold-to-runcontrol.

n Guardthetrapscreatedbyfoldinghooksusingfixedorinterlockedguards.



Makesurethatthein-runningnipbetweentheglueapplicatorandblankissafeguarded;thisisoftenachievedbythepositionofthegluingunititself.

Folding belt

n Thenipsbetweenthisbeltandpulleysshouldbeguardedbyfixedguards.Thenipsbetweenthebeltandhold-downrollsshouldbeguardedbyrollswhichhaveaminimum25mmdeflection,fixedorinterlockingguardsorphotoelectricdevicesatleast850mmfromthetrappingpoint.

Pressing section

n Safeguardthenipbetweentheupperandlowerpressingbeltbylimitingthepressingforceto500newtonsandensuringadeflectionofatleast120mmbyoff-settingtheupperandlowerpulleys.Nipsbetweenthepressurerollersandthebeltitselfshouldbesafeguardedbyfixedguardsortherollersallowinga120mmdeflectionundera100newtonscontactforce.

BinderyHandworkGuardsarerequiredonedge-gummingmachineswithnippingrollersandonthein-feedbeltsofedgestrippingmachines.Somemachinesusedinmetalcomb(spiro)bindingworkcanbehazardous-guardsonthepoweredbarorplatenofthemachineswhichclosethecombmustbeproperlyadjustedandkeptinposition.

Adhesive (perfect) bindingThehazardouspartsassociatedwiththeopening/closingandindexingofbookclampsonadhesivebindingmachinesshouldbeguarded.Thiscanoftenbeachievedbyall-enclosinginterlockedguarding,thoughadditionallocalisedfixedandtripdevicesmaybenecessaryathand-feedingstations.

Themillingcutterneedstobewellguarded,typicallybyaninterlockedall-enclosingguardandaself-adjusting/adjustablelocalguard.Youcandealwithcutterrundowntimebyusingbrakedmotorsorguardlocking.Minimiserisksfromhotmeltadhesivesbyprovidingtemperaturecontrolwithlimitmonitoringtogetherwithsuitablescreensorcoversandremotemethodsforrefillingtheadhesive.Provideextractiontocontrolfume.

Machinesusingpolyurethanehotmeltgluesshouldbeprovidedwithlocalexhaustventilationtocontrolisocyanateexposure(seeChapter4).

Wherethecoverhopperishand-fed,theseparatingelementsshouldbedesignedtopreventtrapsandresidualpilemonitoringprovided.Automaticallyfedmachinesshouldbeprovidedwithtunnelguardsatleast550mmlong.

Accesstotrapscausedbythemovementofbookcarriagesatthedeliveryshouldbepreventedbytunnelguardsatleast550mmlong.

Make-readyoperationsmayrequireinterlockedguardstobeopened.Wherethisisnecessary,ahold-to-runcontrolshouldbeprovidedattheslowestspeedpossible.Also,suchoperationshouldonlybepossibleiftheinterlockedguardsfordangerzonesoutsidetheviewoftheoperatorareclosed.Ifmanualfeedingisneededduringsetup,thehold-to-runspeedofthebindermustbelimitedtoamaximumof10m/minwhenevertheinterlockedguardsareopen.

Stand-alone stitching machinesPower-operatedstitchingmachinesshouldhaveaguardforthestitchingheadtopreventaccesswhentheworkisinplace.Guardsdesignedforflatstitchingarenot



effectiveduringsaddlestitching.Eithertwoseparateguardsshouldbeprovidedor,alternatively,reversibleguards(oftensuppliedbythemanufacturer)shouldbeused.Reversibleguardsaredesignedtobeturnedandsecuredinpositiondependingonthetypeofstitchingbeingcarriedout.Operatorsshouldbetrainedtouseguardscorrectly.

Figure 41 Guardsforflatandsaddlestitching

Gatherering, stitching and trimmingSeriousaccidentshaveresultedatgatherer-stitcher-trimmers(GSTs),collator-stitcher-trimmersandgang-stitcher-trimmers,particularlythroughcontactwiththetrimmerknivesandtheincorrectoperationofwanderleadcontrols.

GatheringFixedandinterlockedguardsshouldbeprovidedforhazardouspartsofthegatherer/feedstations.Interlockedguardsnormallytaketheformofhingedperspexlift-upguards,eitherforindividualfeedstations,orasasingleguardcoveringallthefeedstations.Interlockingisnormallyachievedthroughtheuseofpositivelyoperatingcamswitches.Usersneedtocarryoutregularguardcheckstoensuresafetyismaintained.Undernocircumstancesshouldinterlockswitchesberemovedordefeated.

Asingleguardcoveringallfeedstationscaneasilyberenderedineffectiveifonlyasinglecamswitchisprovidedandthismovesoutofalignment.Itisthenpossiblethatthemachinecanbeoperatedwiththeguardraised.Insuchcircumstances,upgradingtoprovideasecondcamswitchoperatingintheoppositemode,mountedbythesideoftheoriginalswitch,wouldachieveahigherstandardofsafety.

Accessshouldnotbepossiblethroughoraroundguardstohazardousparts.BSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbsshouldbeapplied.



Figure 42 FixedandinterlockedguardsshouldbeprovidedforalldangerouspartsofGSTs

StitchingFixedand/orinterlockedguardsshouldbeprovidedforhazardouspartsassociatedwiththestitchersectionincludingthestitchingheadsandcalliperroll.Guardingmaytaketheformofasinglehingedperspexguardfittedwithasinglecam-operatedinterlockswitch.Anyinterlockswitchshouldoperateinthepositivemode.Accessshouldnotbepossiblethroughoraroundguardstohazardousparts.

TrimmingEnclosingguardsshouldbeinterlockedbymeansofpositivelyactinginterlockswitches.Theswitcheswillnormallybecam-operated.Caremustbetakentoensurethatthecamsdonotmoveoutofadjustment-upgradingasoutlinedabovemaybeappropriate.Regularguardcheckingisrecommended.Openingoftheguardswhilethebladesareinmotionmuststophazardousmovementbeforeahandcanreachadangerpoint.

Fixedguardingisusuallynotasuitablealternativetointerlockedguardsbecauseoftheneedforfrequentaccess.

Openingsintheguards,includingfeedanddeliveryopenings,shouldnotallowaccesstohazardousparts.Whereaccessisfoundtobepossiblethroughthedeliveryorotheropenings,guardingshouldbeupgradedtopreventaccess.

Transmissionmachineryshouldbesecurelyfenced.Standardsforfixedorinterlockedguardingshouldtakeaccountofthefrequencyofaccess.Machinesshouldbedesignedsoaccessisnotrequiredtohazardoustransmissionmachineryonafrequentbasis.

Precautionsshouldbetakentopreventrisksfromliftinghingedguardsfallingundergravity.

Setting and adjustment of GSTsLocaltwo-handhold-to-runcontrolsoratwo-handhold-to-runwanderleadcanbeprovidedwhichallowoperationoftheGSTwithoneguardopen.Single-buttoncontrolsarenotacceptable.Two-hand-controlsshouldmeetthefollowingconditions:



n TheyshouldrequiresimultaneousoperationinlinewithBSEN60204-1:1993Safety of machinery. Electrical equipment of machines. Specification for general requirementsandbesuitablypositionedtopreventspanningbyonehand.Controlsthatfailtomeetthisstandardshouldbeupgraded.

n Withthegatherer/feederstationorthestitcherguardopen(butnotthetrimmerguard)themachinemay,inexceptionalcircumstances,runatspeedsofmorethan10m/minalthoughthespeedshouldbesetaslowaspossible.

n Setting,maintenanceandknifechangeoperationswiththetrimmerguardsopenshouldbeaone-personoperationcarriedoutbyatrainedoperatorwhoshouldbeincontrolofanyinchorpendantcontrols.Accidentshaveoccurredwhentwooperatorshavebeenworkingtogetherandonehasoperatedthewanderleadwhiletheotherhashadtheirhandsinthetrimmersection(see‘Threeknifetrimmers’earlierinthischapter).

Book sewingAutomatic/semi-automaticmachinesshouldbeprovidedwithacombinationoffixedandinterlockedguardstopreventaccesstohazardousparts.Fithand-fedmachineswithadequatetripguardstoguardthesewingheads.Theseguardsshouldbeeffectiveduringthreadingupandnormalrunning.

Signature pressesMakesurethatthetrapbetweenthemovingpressplateandmaterialsupplyandtheintermediateplatearesafeguardedusingahold-to-runcontrol.

Book pressesSafeguardanytrapbetweenthemoveableandfixedpressingplatesortheformingbarwithatripdevice.Themovementofthetripshouldbegreaterthanthestoppingdistanceofthepressingplate.

Onpresseswhereseveralpressingplatescanbemovedindependently,aguardshouldbeprovidedbetweentheplatestopreventasheartrap.

Thegapbetweentheguardandthepressingplateshouldnotexceed6mm.

Backlining and headbandingWherebooksignaturesaretransportedbetweenverticallymountedconveyors,guardfeed-sidein-runningnipswithtunnelguardsofatleast550mm.Gluerollersandanyhotmeltpartsshouldbesafeguardedwithinterlockedguardsandwarningsignsaffixed.Thegauzecuttingknifeshouldbesafeguardedbyfixedguardsandthein-runningnipsofthegauzeunwindingsectionbyfixednipbars.Accesstohazardouspartsattheheadbandingsectionandcounterpressuresectionsshouldbepreventedbyfixedorinterlockingguards.

Book nipping (smashing)Safetyonhand-fedbooknippingorsmashingmachinescanonlybeachievedbyprovidingguardingandsafesystemsofwork.Youneedtofitadjustableaccess-limitingguards.

Onhorizontallymovingplatenswherethebookisfedfromthetop,aspring-loadedguardcanbeusedwherethebackofthebookdisplacestheguardsothatitcoversthegapbetweenthebookandtheplaten.Alternatively,letterbox-typeguardswhichhaveaslotopeningofthesamedimensionsasthebookcanbeused,buttheplatensideoftheguardmustoverlapthefrontedgeoftheplaten.

Onverticallymovingplatenmachines,adjustableplatesshouldbefittedwhichareadjustedtothebooksizeforeachproductionrun.Thesewillpreventoperatorsfromleavingtheirfingersontheuppersurfaceofthebook.Theoutsideedgeoftheplateshouldextendbeyondtheplatenedgetopreventasecondarytrap.



Rounding and backingAutomaticmachinesshouldbeprovidedwithacombinationoffixedandinterlockedguardstopreventaccesstohazardouspartssuchasin-runningnipsonthefeedanddeliverybelts,trapsonthetippingsection,trapsandhotpartsonthepreheatersection,andtrapsandshearpointsonthepreforming,roundingandbackingsection.

Onhand-fedmachines,accessisrequiredtofeedthebooktothefeed/roundingrollersbutmustbepreventedduringpoweredmovement.Youcanpreventaccesstothesheartrapbyusingsequentialtwo-handcontrolsandinterlockguarding.

Case making and casing-inOnmosttypesofcase-makingandcasing-inmachines,thehazardouspartscanbeadequatelyguardedbyprovidingall-enclosingguardsinterlockedtothemachine’sdrive.Thefeedanddischargepartsofthemachinesshouldbeoutsidetheguardedarea,withopeningsdesignedtomeetthereachdistancerequirementsofBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs.

Accesstoin-runningnipsandtrapsbetweenfixedandmovingpartsneedtobepreventedoncasemakingmachines,especiallythetrapsbetweentherotatingpickerheadandadjacentfixedpartsonoldermachines.Forthesemachines,acombinationoffixedandinterlockedguardsfittedtotheoutsideedgeofthemachineframearesuitable.Wherecoverclothishand-fedtoacylinder,anyin-runningnipsshouldbeguarded.

Oncasing-inmachines,hazardouspartsincludein-runningnipsatthecoverbendingsection,crushingandnippointsandhotmachinepartsattheheatedformingsection,crushingpointsatthecasing-insection,in-runningnipsatthegluingsectionandin-runningnipsatthecounter-pressuresection.Pictogramswarningofhotpartsshouldbeprovidedinthevicinityofheatedbook-covercrease-formingdeviceswhichareaccessibleoncetheinterlockingguardshavebeenopened.

Atthebooksignaturefeedanddeliverypoints,tunnelguardsatleast550mmlongshouldbeprovidedtopreventcontactwithtrapsbetweenthebooktransportfingersandfixedpartsofthemachine.

Trapsonthebookcoverfeedercausedbyseparatingelementsandtransportdevicesshouldbepreventedbydesignorwhereblanksarefedfromthebottomofthepile,safeguardingcanbeachievedbyresidualpilemonitoring.

Blocking machinesThetrapbetweentheclosingplatens(oneofwhichisoftenheated)onfoilblockingmachinesisveryhazardousandmustbeguarded.Onautomaticmachinesthiscanbeachievedbytheprovisionofall-enclosinginterlockedguards.

Onhand-fedup-strokingordown-strokingmachines,therearandsidesoftheplatenscanbeguardedbyfixed/interlockedguards.Thefrontfeedtableshouldbeprovidedwithanadjustable(oftenrodtype)pivotingguard,whichtripsifthebottomoftheguardispushedin,oratripdeviceandsimultaneoustwo-handhold-to-runcontrols.

Book production linesMakesurethatthein-runningnipsonthefeedanddeliveryconveyorbeltsaresafeguardedusingin-fillblocks.

Trapscreatedbyseparatingelementsonthebookcoverfeedershouldbesafeguarded.



Checkthatfixedorinterlockedguardshavebeenprovidedtopreventaccesstohazardouspartsat:

n thepreheater.Interlockedguardsshouldbesupplementedbysuitablepictogramswarningofhotparts.Onceinterlockedguardsareopened,thepreheatershouldonlyoperateunderhold-to-runcontrol;

n thebackroundingandpressingsections;n thegluesections.Gluereplenishmentshouldbepossibleduringtheproduction

runwithouttheneedtoopenguards.Hotmeltpansshouldhavetemperaturecontrolandlimittemperaturemonitoring;

n theknifeandgauzeclamps.Nipbarsshouldbefittedatanyremainingin-runningnipsatgauzeunwindingrollersoncetheinterlockedguardhasbeenopened;

n theheadbandingandbackliningsection.Nipbarsshouldbefittedatanyremainingin-runningnipsatheadbandingunwindingrollersoncetheinterlockedguardhasbeenopened;

n thecoverbendingandroundingsections;n thecasing-insection.

Afteropeninganyinterlockedguards,itshouldonlybepossibletooperatethelinewithalimitedinchof75mmorahold-to-runmaximumcrawlspeedof5m/min.Ifahighercrawlspeedisrequired,thisshouldonlybepossibleusingacombinationoftwo-handcontrolandensuring:

n allotherinterlockingguardsareclosed;n aselectorswitchforthisoperationhasbeenprovided;andn thehold-to-runspeedistheslowestpossibleanddoesnotexceedamaximum

of20m/min.

Checkthatemergencystopbuttonsareprovidedatleastoneachmaincontrolpanel.Whereoverallvisionoftheproductionlineisrestricted,makesureapre-startwarningdevicehasbeenprovided.

Paper drillsThestrokeofmanuallyfedpaperdrillsshouldbeunderhold-to-runcontrolandaworkpiecesupportprovided.Whenthehold-to-runcontrolisreleased,thedrillorworkpieceshouldreturntoitsstartposition.

Makesuretheshatterandtrappinghazardsondrillsandchuckjawsaresafeguardedbyafixedorinterlockedguard.

Multi-drillmachinesshouldhavefixedorinterlockingguardstopreventcontactwiththerotatingchuckjaws.Makesurethedistancebetweentheworkpiecesupportorguardandchuckjawisatleast25mm.

Accidents

Book sewing

Anexperiencedoperatorcrushedtheirindexfingerbetweenthebottomplatenandthebookasthetopplatencompressedthebook.Noguardinghadbeenprovided.

Anoperatoramputatedthetipsoftwofingerswhilepushingbooksthroughthecontinuouslystrokingpress.



Accidents

Rounding and backing machines

Anemployeecrushedhishandbetweentheroundingrollersandbackingjawwhenheinadvertentlystartedthemachinecycle.

Anoperatorbruisedandlaceratedhisfingerinthepressingplateofaroundingmachine.Aguardwasprovidedbutnotused.

Finishing machinesCoatersCheck:

n withyoursupplier,whereroutineandregularaccessisrequiredtodangerpoints,thatthesafeguardsareoftherightintegrity(thesafety-relatedpartsofthehydraulic/pneumaticcontrolsystemsatisfyatleastCategory3ofBSEN954-1:1997Safety of machinery. Safety related parts of control systems,andthesafety-relatedpartsoftheelectric/electroniccontrolsystemsatisfyatleastCategory4);

n whereoverallvisionofthecoaterisrestricted,apre-startwarningdevicehasbeenprovided;

n web-threadingdevicesareprovidedforwebbingup.

Reelunwindingandrewindingunitsneedtobesafeguarded(see‘Reelunwindsandrewinds’earlierinthischapter).

Ensurethatthefollowingin-runningnipsaresafeguarded:

n betweentheguiderollersandguiderollers/fixedmachinepartsbyensuringaminimumseparationof120mm,orwithfixed/interlockedguardsornipbars;

n atthedosinggapwithfixed/interlockedguardsornipbars;n betweenthecoatingrollerandcoolingroller/coatingrollerwithfixed/interlocked

guards;n attheTeflonbelt(wherehotmeltpolyethyleneisbeingused)withfixed/

interlockedguards.

Preventcontactwithpartsassociatedwithhotmeltmaterialusingfixedguards.

Thetraversingmovementofthecoatingrollersorcoatingrollerandcoolingrollershouldbesafeguardedbymeansofahold-to-runspeedof5m/minorinterlockedguards.

Accessiblein-runningnipsbetweenthecoated,tear-resistantwebandguiderollerswherethereisawrappingangleof45oormoreshouldbeprotectedbyfixedguards.

Forprecautionsrelatingtofireriskoncoaters,seeearlierinthischapter.

Continuous flow dryersCheckwithyoursupplierthatthedryermeetstherequirementsofBSEN1539:2000Dryers and ovens in which flammable substances are released.Safetyrequirementsifthecoatingmaterialyouusegeneratesflammablesubstances.

Itisimportantthatthetrapcreatedwhenclosingtheupperandlowerpartsofthedryerissafeguardedusingahold-to-runcontrol.Automaticclosingshouldonlybepossibleforthelast300mmofmovementandsafeguardedbytripbars.



Ignitionofthewebinthedryershouldbepreventedusinganairwiper/cushionedcurtaintokeepthewebatanadequatedistancefromtheheatsource.

Ifhydraulicorpneumaticcylindersareprovidedforopeningthedryer,makesurethesehavesafety-ratedcheckvalveswhichcanbeoverridden.Inaddition,amechanicalscotchshouldbeinsertedduringinspectionwork.

Ensureemergencystopbuttonsareprovidedateachoperatorposition.

Laminators with adhesive foilReelunwindingandrewindingunitsneedtobesafeguarded(see‘Reelunwindsandrewinds’earlierinthischapter).

Makesurethefollowingin-runningnipsaresafeguarded:

n atfeedanddeliverybeltsbyinfillingbetweenthebeltandroller;n betweenguiderollersandguiderollers/fixedmachinepartsbyensuringa

minimumseparationof120mm,orwithfixed/interlockedguardsornipbars;n accessiblenipsbetweenthelaminated,tear-resistantwebandguiderollers

wherethereisawrappingangleof45°ormorebyfixedorinterlockedguards;n atthelaminatingrollerusingfixedorinterlockedguards.Ifthematerial

thicknessexceeds18mm,theopeningshouldnotbemorethan30mmandthesafetydistanceatleast200mm.

Thetraversingmovementofthelaminatingrollersformake-readyandcleaningshouldbesafeguardedbymeansofahold-to-runspeedof5m/minorinterlockedguards.

Inhotfoilingwork,preventcontactwiththelaminationrollersbyusingfixedguards.

Ensurecuttingdevicesaresafeguardedbyinterlockingguards.

Checkthatemergencystopbuttonsareprovidedatleastoneachmaincontrolpanel.

Laminators with glue applicationWhereisocyanate-containingadhesivesareused,controlofemployees’exposureiscrucial.SeeChapter4‘Useofisocyanates’andthebookletSafeuseofisocyanatesinprintingandlaminating.

Onnewmachines,whereroutineandregularaccessisrequiredtodangerpoints,checkwithyoursupplierthatthesafety-relatedpartsofthehydraulic/pneumaticcontrolsystemsatisfyatleastCategory3ofBSEN954-1:1997Safety of machinery. Safety related parts of control systems,andthesafety-relatedpartsoftheelectric/electroniccontrolsystemsatisfyatleastCategory4.

Whereoverallvisionofthelaminatorisrestricted,makesureapre-startwarningdevicehasbeenprovided.

Web-threadingdevicesshouldbeprovidedforwebbingup.

Reelunwindingandrewindingunitsneedtobesafeguarded(see‘Reelunwindsandrewinds’earlierinthischapter).

Thefeederanddeliveryunitsneedtobeproperlydesignedandsafeguarded(see‘Pileliftingandloweringdevices’earlierinthischapter).

Checkthatthefollowingin-runningnipshavebeensafeguarded:



n onbeltsusingfixedorinterlockedguards;n betweenguiderollersandguiderollers/fixedmachinepartsbyensuringa

minimumseparationof120mm,orwithfixed/interlockedguardsornipbars;n accessiblenipsbetweenthelaminated,tear-resistantwebandguiderollers

wherethereisawrappingangleof45°ormorebyfixedorinterlockedguards;n onthesheetfeedrollsbyensuringthattherollshaveadisplacementofatleast

25mmorrollercontactisbytheirownweight;n atthegluerollersandonthedosinggapusinginterlockedguards;n betweenthelaminatingrollersusingfixedorinterlockedguards.Ifthematerial

thicknessexceeds18mm,theopeningshouldnotbemorethan30mmandthesafetydistanceatleast200mm;

n betweenpressingrollersandguiderollersandpressingbeltbyfixedguards,orbyensuringrollersareheldinpositionbytheirownweightandhaveadisplacementofatleast120mm;

n betweentheupperandlowerpressingbeltsattheinfeedpoint.Useeitherfixedorinterlockedguardswithasafetydistanceofatleast850mmfromanopeningapertureofatleast120mmtothepointwherethereisatleast10mmbetweenthebelts,orpressingrollerscapableofdisplacementtoacreateagapof120mmandwithamaximumpressingforceof200newtonsatthe850mmpoint.

Makesurerotaryknivesarefullyenclosedusingfixedguardswhichpreferablydonothavetoberemovedfortoolchange.

Checkthattheopeningandclosingmovementofthelaminatingrollersissafeguardedifthetravelpathismorethan6mmbymeansofhold-to-runcontrolnotexceeding5m/minorinterlockingguards.

Checkthatdangerpointsonthesheeterarenotaccessiblebymeansofinterlockedorfixedguards.

Makesurethatthecrushingpointbetweenthepackagestopandtransportbeltissafeguardedwithinterlockedorfixedguardsifthemaximumclosingforceexceeds200newtons.

Ensurethatshearingpointsbetweentheturningbeltandtransportbeltsaresafeguardedwithfixedguards.

SeeChapter7forfireprecautionsrelatingtolaminators.

Baling machinesMachinesusedforbalingwastepaperandboardhavecausedfatalaccidentsandamputationinjuries.Largemachinestypicallyconsistofahorizontalorverticalbalingchamberwhichisconveyorfed.Thesemachineswillhaveanautomaticorsemi-automaticbalewiringmechanism,incorporatingwiringneedlesthatpassthroughslotsinthefaceofthebalingram.

Fatalaccidentshaveoccurredwhenpeoplehavefallenfromtheconveyorintothechamberwhilethebalerisinoperation,forexamplewhenfollowinganunsafesystemofworkforclearingblockages,andwhentheyhavegainedaccesstotheareabehindtheraminitsforwardpositionforrunningrepairs,andtheramhasretracted.

Amputationinjurieshavebeencausedbypeoplegainingaccesstotrapscreatedbymovingpartssuchastheram,wiretyingmechanismorwiringneedles.Onlargemachines,distributorsmayalsoconstituteadanger.



Atsmallcompactorstheremaynotbeahighriskoffatality,butprecautionswillbeneededtopreventamputations,crushingandsimilarmajorinjuries.

Ahighstandardofinitialsafeguardingisneededatallmachines,combinedwithregularchecksontheoperationofthesafetydevicesandmaintenance.Followsafesystemsofworktodealwithoccurrencessuchasblockages,andmaintenanceactivities.Suchsystemsshouldincludelock-offisolationproceduresforbothconveyorandbaler.

Initialsafeguardswillincludeahighstandardoffixedandinterlockedguarding,emergencystopsandtripwires,fixedladders(withhoopsasappropriate)andworkingplatformsforaccesstohighlevelsofthemachine.

Wasteisusuallyloadedontotheconveyorusingvehicles.Guardtheedgeoftheconveyororpitasfaraspossibleandmaketheexposedareaforloadingclearlyidentifiable,forexamplebyusingrobustoverheadindicators.

Accessontoconveyorsshouldbestrictlycontrolledbyasafesystemofworkincorporatinganeffectiveisolationprocedure.Themeansofelectricalisolationshouldbereadilyaccessibleandlockable.Itmustisolateboththeconveyorandthebalingmachine.

Fitconveyorswithemergencystopdeviceswhichstopboththeconveyorandthebalingmechanism.Emergencystopbuttonsshouldbereadilyaccessiblefromalloperatingstations.Emergencystopbuttonsortripwiresshouldalsobeprovidedontheinclinedsectionoftheconveyor.Theycaneitherbefittedtorunuptheside(preferablyonbothsides)ortheycanbepositionedlikegoal-postshorizontallyacrosstheconveyorandhungwithverticalcordsforeaseofoperation.Personaldetectionsystemscanbeusedaswellasbutnotasanalternativetosafeguards.

Iffrequentblockagesoccurinthehopperabovethebalerthenapermanentplatform(atleast1.1mbelowthetopofthehopper)withafixedaccessladdershouldbeprovided.Ifitisnotpossibletoprovideafixedaccessplatform,harnesseswithanchoragepointsmaybenecessaryinadditiontothesafesystemofworkandisolationproceduredescribedabove.

Figure 43 Anunacceptablebalingpress



Accidents

Anoperatorwasattemptingtoclearablockageinabaler.Paperwasfedautomaticallyfromtheshreddertothebaler.Whenthepaperlevelreachedamagiceyetheramoperated.Theoperatorhadclimbedintothechuteboltedtothebaler.Whenthebaleroperated,hisfootwasbadlycrushedbytheram.

Anemployeewascrushedtodeathwhenhebecametrappedbythereturningramofalargehorizontalpaperbalingmachine.Hehadgainedaccesstothebalingchamberviatherearoftheejectorramwhentheramwasintheforwardposition.Themachinehadnotbeenisolatedandtheramretracted.

Anemployeewaskilledwhenhefellintothebalingchamberandcoveredthemagiceyewhichactivatedtheram.Theemployeehadbeenclearingablockageatthetopendoftheconveyor.Themachinehadnotbeenisolated.

Effectivelyguardallopenings(evensmallonesallowinghandaccess)inthevicinityofthebalingchamberandthecompactor/ejectorram.Accesspanelsmaybefixedinpositionifinfrequentaccessisrequiredandthisshouldbemadethroughapermit-to-worksystemincorporatinganisolationprocedure.

Whereaccessisrequiredmorefrequently,aninterlockedguardshouldbeprovided.Thestandardoftheinterlockingrequireddependsonthenatureoftherisk.Ifheadorbodyaccessispossibletheninterlockingtoahighstandardwillberequired,forexample,guard-inhibitedpowerinterlockingorakeyexchangesystem.Alternatively,useadual-channelsystemwithinterlocksandcross-monitoring.

Onhydraulicmachines,dual-channelinterlockingcanuseadifferentcontrolmediumforeachchannel,ieonehydraulicandoneelectric.Wherewhole-bodyaccessispossible,provideprotectiontopreventinadvertentclosingoftheguardpanel/doorwhileapersonisinsidethemachine.Keyexchangesystemsprovidethisprotection.Anequivalentstandardofprotectionwillbeneededifothertypesofinterlockingareused.Whereheadorbodyaccessisnotpossible,interlockingbymeansofasinglepositivelyinterlockedswitchmaybeacceptableaslongasitisproperlymaintained.

Accesstothemovingpartsoftheneedlesandwire-tyingmechanismshouldbepreventedbyusingfixedorinterlockedguardingaccordingtotheprinciplesdescribedinthepreviousparagraphs.Needleswilloftenpassverticallythroughthebale,withanaccesspitunderthemachine,buttheymayalsobehorizontal.Ifpeoplehavetoworkundertheneedlesduringmaintenance,mechanicalscotchesshouldbeprovidedtoholdtheneedlesinasafeposition.

Maintenanceisveryimportantbecauseoftheheavydutyenvironment.Notonlyisitessentialtoensurethatsafetyswitches/devicesareregularlychecked,butpreventivemaintenanceontheequipmentisimportanttoreducetheneedforoperatorintervention.



Figure 44 Simplifieddiagramofabalingmachine

ShreddersMachinescanbehand-fedeitheronverticalorhorizontalplanes.Horizontallyfedmachinesmayhaveshortfeed-sideconveyorstoaidthetransferofmaterialtothecutters.Somemachinesmayhaveasecondconveyortodelivertheshreddingsattheoutrun.

Feed-side access to rotary cuttersAccesstothecuttingrollersshouldbepreventedbysuitabledistanceguardinginlinewithBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs.

Forthesmallestoffice-basedmachines,thiscanbedonebyusingnarrowfeedslots(typicallynarrowingtonomorethan4to6mm).Theslotsshouldnotbeinadirectverticallinewiththein-runningnipcreatedbythecontra-rotatingcuttersbecauseofentanglementhazardstooperators’hair,jewelleryorclothing.Whereresidualrisksremain,suitablewarninglabelsshouldbeplacedinprominentpositionstoalertoperatorsofthepotentialhazard.

Wherewastepaperetcisfedintoashredderviaatop-feedchute,thechuteshouldextendfarenoughtopreventtheoperator’shandorarmaccessingtherotatingcuttersthroughthechute.Youcanalsousehingedinterlockedflapsfittedwithsinglepositivelyoperatingcamswitches.Openingoftheflapswhilethecuttersareinmotionshouldstophazardousmovementbeforeahandcanreachthehazardousparts.

Feedchutesshouldbefixedinpositionorinterlockedusingpositivelyoperatingswitcheswhichstopmovementofthecuttersbeforeaccesscanbegained.Thetypeandmethodofinterlockingshouldtakeaccountofcutterrundowntimeswhereapplicable.Considerguardlockingformachineswithlongcutterrundowntimes.

Wheremachinesarefedhorizontallyusingfeedtables(oftenfittedwithsmallintegralfeedconveyors),thefeedtableshouldactasadistanceguard.Suitablesidepanellingand/orfixedorinterlockedtunnelguardingshouldbeprovidedtopreventaccesstohazardouspartsfromthesidesofthefeedtable.SafetyreachdistancesshouldcomplywithBSEN294:1992.Wherehingedsectionsareprovidedintheguardingarrangements,theseshouldbeinterlockedusingpositivelyoperatinginterlockswitches.

Outrun access to rotary cuttersShreddingmachinesareusuallyprovidedwithareversingdrivefortherotarycutters



toaidblockageremoval.Thereversefacilityresultsintheotherwiseout-runningnipsatthedeliverysideofthecuttersbecominghazardousin-runningnips.Accesstothesehazardouspartswhiletheyareinmotionshouldbepreventedbymeansoflocalisedfixedguarding(foundonsomesmallermachines,particularlyverticallyfedmachines);suitabletunnelguards(fixedorinterlocked);orinterlockedguards.LocalisedfixedguardsortunnelguardsshouldcomplywithBSEN294:1992safetyreachdistances.

Inexceptionalcircumstancesreversalbymeansofatwo-handhold-to-runcontrolplacedoutofreachofhazardouspartsmaybeacceptableforstrictlysolooperatingpractices.Suchcontrolsshouldbedesignedtoprovidelimitedinchmovementonly.ThecontrolsshouldrequiresimultaneousoperationandcomplywithBSEN60204:1993Safety of machinery. Electrical equipment of machines. Specification for general requirements.

Two-hand-controlsarenotconsideredacceptableifthecuttersarecapableofautomaticreverserunning.Somemachinesmaybefittedwithovercurrentsensorswhichautomaticallyreversethedirectionofthecutters(andofthefeedtableconveyor)ifthemachineiselectricallyoverloaded.Afteraboutfivesecondsofreversemotion,themachineswitchesitselfoff.Providefixedorinterlockedguardingwherethereisapossibilityofautomaticreversal.

Wheretherearehazardsafterinterruptionofthepowersupply,considerinterlockingmethodsincorporatingbrakingand/orguardlocking,forexamplewherecuttersorotherhazardouspartshavelongrundowntimes.Systemsshouldbedesignedtoincorporateadevicetoeithercausethehazardtobeeliminatedastheguardisopened(byapplyingabrake),orpreventtheguardfrombeingopeneduntiltheriskofinjuryfromthehazardhaspassed(guardlocking).

Whereshreddersarecombinedwithintegralbalingmechanisms,anyaccessdoorprovidedattherearoftheshredder/topofthebalershouldbeinterlockedusingatleastonepositivelyoperatinginterlockswitchwhichpreventsmovementofboththeshreddingcuttersandthebalingramassoonastheaccessdoorisopened.Hydraulicorpneumaticoperatedbalingramsshouldblockanddumptheirsupplyonoperationoftheinterlock.

Provideatripmechanismintheformoftrippedaccessflapsorafull-lengthtripbaraswellasdistanceguardingwherethereisanypossibilityofanoperatorbecomingentangledanddraggedtowardsthecutterblade.

Accident

Anoperatorwasfeedingapapershredderwitholdnewspaperswhenherfingertouchedbladesthroughanopeninginthemachine.Thefeedopeninghadnotbeenrestricted.

Anoperatorseveredthetipofanindexfingerinthecuttersofapapershredderwhilecheckingforafault.Afixedguardhadbeenremovedfromoverthecuttinghead.Closingtheelectricallyinterlockeddoorofthewastesackbinhadactivatedthecutters.

Anoperatorlostpartsofthreefingerswhentheywereshearedoffbyoneofthecompactingramsonashredderbalermachinewhichmakesshreddednewspaperintobalesforanimalbedding.Blockagesonthemachinewerearegularoccurrenceandwerefrequentlyclearedbyinsertinganarmthroughaslotinthemachineryhousingwhiletheramswereinmotion.Nofixedorinterlockedguardwasinplacebeforetheaccident.



Acquiring machinery and other work equipment

The lawSupply of Machinery (Safety) Regulations 1992 (amended 1994)TheseRegulationsimposedutiesonthemanufacturers,suppliersandimportersofnewmachineryandareintendedtoprovideprotectionfortheusersoftheequipmentasmachinerywhichcomplieswiththeseRegulationsshouldbesafe.

TherequirementsoftheRegulationswerevoluntaryfornewandsecond-handmachinesfrom1January1993until1January1995(iftheywerenotfollowedthemachinerystillneededtocomplywiththehealthandsafetyprovisionsinforceintheUnitedKingdom).TherequirementsoftheRegulationsbecamecompulsoryfrom1January1995.

Duties on manufacturers or their responsible persons

n Ensuringthatthemachineryorsafetycomponentsatisfiestherelevantessentialhealthandsafetyrequirements(EHSRs).

n EnsuringthatanappropriateconformityassessmentprocedurehasbeencarriedoutinaccordancewiththeRegulations.

n EnsuringthatthemachineryorsafetycomponenthasbeenissuedwitheitheraDeclarationofConformityoraDeclarationofIncorporation.

n Ensuringthatthemachineryorsafetycomponenthasbeen‘CE’markedtoshowthatitsatisfiestheEHSRs(unlessitishasaDeclarationofIncorporationandisgoingtobeincorporatedintoamachineorassemblyofmachinesthatwillbe‘CE’markedasawhole).

n Ensuringthatthemachineryorsafetycomponentissafe.n Carryingoutresearchandtestingtodeterminethatthemachineryiscapableof

beingerectedandputintoservicesafely.

Duties on suppliers (where the supplier is not the manufacturer or the manufacturer’s appointed responsible person)

n Ensuringthattherelevantmachineryorsafetycomponentissafe.

Duties on users

n Ifyoudirectlyimportanymachinery(second-handornew)fromoutsidetheEuropeanEconomicArea,thentheRegulationsregardyouassupplyingthemachinerytoyourselfandimposethedutiesofasupplierundertheRegulations.

Examplesofmatterscoveredbytheessentialhealthandsafetyrequirementsinclude:principlesofsafetyintegrity;lighting;designofmachinerytofacilitatehandling;safetyandreliabilityofcontrolsystems;preventionofrisksrelatedtomovingparts;requirementsforguardsandprotectivedevices;protectionfromhazards(includingtemperature,electricitysupply,staticelectricity,fire,explosion,noise,vibration,radiationanddusts);markings;andinstructions.

Provision and Use of Work Equipment Regulations 1998 (PUWER 98)Duties on users/employersTheseRegulationsapplytobuyingorhiringmachinery.Asanemployeryoumustensurethattheworkequipmentyouprovideissuitableandsafeforuse.

TheseRegulationsalsorequireyoutocheckthatanyequipmentyouacquireconformstotherelevantCommunityDirectives,egtheSupplyofMachineryRegulations.

Forpracticalpurposes,youcanstartbyensuringthat:



n machinerysuppliedfrom1January1995comeswithacopyofthemanufacturer’sDeclarationofConformitywhichstatesthemanufacturer’snameandaddress,themachinemodelandtypeetc;

n themachinecomplieswiththeessentialhealthandsafetyrequirements(EHSRs);

n themachineisaccompaniedbyinstructionsforuseandis‘CE’marked.Sometimes,ifthemachineryisgoingtobeincorporatedintootherrelevantmachinery,egatnewspaperpresses,itwillcomewithoutCEmarkingandaDeclarationofConformity,inwhichcaseyoushouldasktoseethemanufacturer’sDeclarationofIncorporation.Oncetheequipmentisassembled,theassemblyasawholewillneedtomeettheEHSRstobeCEmarkedandyouorthepersonassemblingtheplantwillneedtodrawupaDeclarationofConformity.

Health and Safety at Work etc Act 1974, section 6ThissectionoftheActplacesdutiesondesigners,manufacturers,importersandsupplierstoensure,sofarasisreasonablypracticable,thatanyarticlesforuseatworkaresafeandwithoutriskstohealthandareaccompaniedbyadequateinformationforuse.

Word of cautionWhenpurchasingorhiringneworsecond-handmachineryandworkequipment,takespecialcaretoensurethatanyassociatedriskshavebeenassessedandthatyouarecomplyingwiththelaw.Youshouldcheckthatanycontractdealswithhealthandsafetyandthatthereisnomisunderstandingabouttheconditionofthemachineanditsguards.Thelawappliesnotonlytoguarding,buttootheraspectswhichmayaffecthealthandsafety,suchasnoisegeneratedbymachinery,solventvapouremission,andprotectionagainstfireandexplosion.

Situationsmayarisewhere‘CE’markedequipmentisnotentirelysafeasthemarkinganddeclarationprocessisaself-certifyingoneandmanufacturersorsuppliersmayhavefailedtofulfiltheirobligationsundertheRegulations.

Itisyourdutyasanemployertomakesurethatmachineryissafebeforeitisbroughtintouse.Employersareobligedbylawtocarryoutandactupontheirownassessmentsofhealthandsafetyrisks(see‘Planningandriskassessment’inChapter1).Assessbothnewandexistingmachineryandbringthemuptorequiredstandards.



Chapter 6 ElectricitySee the ‘References’ section at the back of the book for details of publications which relate to Electricity


TheElectricityatWorkRegulations1989requireprecautionstobetakenagainsttheriskofdeathorinjuryfromelectricityatwork.The memorandum of guidance on the Electricity at Work Regulations 1989(HSR25)hasfurtherinformation.

Electricitycankill,atnormalmainsvoltageof230Vacandevenatvoltagesconsiderablylessthanthis.Eachyearabout1000accidentsatworkinvolvingelectricshockorburnsarereportedtoHSE,around30ofwhicharefatal.Firesstartedbypoorelectricalinstallationscancausedeathsandinjuries.Explosionscanbecausedbyelectricalapparatusorstaticelectricityignitingflammablevapoursordust.

General hazards and precautions

Checkthat:

n allelectricalwiringisinstalledtoasuitablestandardbyacompetentpersonsuchasaqualifiedelectrician.Poorworkmanshipcanbedangerousanddangerousinstallationsareillegal.(Allnewelectricalworkshouldbeinspectedandtestedbeforebeingputintouse.)BS7671:1992Requirements for electrical installationsgivesguidanceonsuitablestandards;

n powercablestomachinesareinsulatedandprotected,egsheathedandarmouredorinstalledinconduit.Allconnectionsshouldbeingoodcondition.Switches,fusesandcircuit-breakersshouldbelabelledtoidentifythecircuitstheyserve;

n thereisaswitchorisolatorneareach(fixed)machinetocutoffpowerinanemergency;

n plugs,socketsandfittingsareadequatelyprotectedandsuitablefortheworkingenvironment;

n wheneverpracticable,flexiblecablesandwiresdonottrailonthefloor.Theyaremoreliabletodamage,andmaycauseatrippinghazard;

n flexiblecableshaveasuitableplugwiththeflexfirmlyclampedtostopthewires(particularlytheearth)pullingoutoftheterminals;

n whereverreasonablypracticable,enoughsocketoutletsshouldbeprovidedforthenumberofappliancestobeusedatanyonetime.Whenthisisnotpossibleafusedextensionleadwithamultiwaysocketblockcanbeusedinappropriatelocations;

n frayedanddamagedcablesarereplacedcompletely.Joinlengthsingoodconditiononlybyusingproperconnectorsorcablecouplers-‘chocolate-block’connectorsdonotprovidethestrengthorprotectionrequiredforajointinacableandarenotsuitableforthispurpose;

n accessispreventedtoelectricaldanger,egbykeepingisolatorandfuseboxcoversclosed,securedand,itisstronglyrecommended,locked,withthekeyheldbyaresponsibleperson;

n fuses,circuit-breakersandotherdevicesarecorrectlyratedforthecircuittheyprotect;

n homeappliancessuchasfires,radiosandkettlesarenotbroughtinforuseatwork;

n therearenooverheadcablesthatcouldbeaccidentallystruckinareaswherelifttrucksoperate.



Particular hazards and precautions for printing

Someprecautionsrelatetothespecialconditionstobefoundinprinting.Theseinclude:

n notusingportablefanheatersorhairdryersindarkroomsorinwetconditions-theyarenotdesignedforuseinsuchenvironmentsandcancauseelectricshocks;

n makingsurethatthepowertohigh-pressurewater-jetmachinesissuppliedthrougha30mAresidualcurrentcircuit-breakerwhichisregularlytestedbyoperationofitstestbutton.Thisprecautionwillprovideaddedprotectionagainstelectricalshock;

n ensuringelectricalequipmentisofsuitableexplosion-protectedconstructionifitistobeusedinapotentiallyexplosiveatmosphere.Potentiallyexplosiveatmospheresmay,forexample,ariseinsolventstorageareasandinsomeprocessareassuchasinthevicinityofflexographicandgravurepresses,andinkmixingareas.Youmayneedspecialistadvicetochoosethecorrectequipment.Lowvoltageequipment,eg12V,givesnoprotectionagainsttheriskofignitioninsuchenvironments.

Staticelectricitycanalsobeasourceofignitioninsuchenvironments.Thisisaparticularprobleminflexographicandgravureprinting.Importantprecautionsinclude:

n theusebyoperatorsofanti-staticfootweartopreventthebuild-upofelectrostaticchargeswhichmightcauseaspark.Wherethisisahazard,operatorsalsoneedtoavoidwearingclothingmadeofman-madefibre(thiscanhavetheadditionaladvantageofreducingtheseverityofburnsintheeventofafire);

n theuseofclosedmetalcontainerswhencarryingflammableliquidssuchassolvents;

n thebondingandearthingofmetalworkasnecessarytopreventaccumulationofstaticwhereflammableliquidssuchassolventsaretransferredbypipeorpoured.

SeeChapter7forfurtheradviceonfireandexplosion.

Inspection and maintenance

Allelectricalequipment,wiringinstallations(includingbatterysets),theirconnections(includingfixeditemsofmachinery)andportableelectrictoolsmustbemaintainedsofarasisreasonablypracticabletopreventdanger.Youwillneedtocarryoutinspectionandtestingtochecktheconditionoftheequipment,andfollowthisupwithrepairorreplacementwherenecessary.Thefrequencyoftheinspectionandtestingwilldependontheequipmentyouuseandwhereyouuseit.Youmayfindithelpfultokeeprecordsofinspectionandtesting.

Takesuspectorfaultyequipmentoutofuse,labelit‘DONOTUSE’and,whereappropriate,removetheplugandkeeptheequipmentsecureuntilacompetentpersonconfirmsthatitis,orhasbeenmadesafetouse.Makesureyouremployeesknowhowtoreportanydamageordefectstheydiscoverandwhotheyshouldtell.Don’toverlookhiredorborrowedelectricalequipmentorequpmentsuchasfloorpolisherswhichmaybeusedafterthepremiseshaveclosed.Checktoensurethatanyelectricalequipmentthatcontractorsbringontositeissafetouse.

Checkthatresidualcurrentcircuit-breakersworkbyoperatingthetestbuttonregularly,inaccordancewiththemanufacturer’sadvice.



Anyonecarryingoutelectricalworkmustbecompetenttodoitsafely.Thismaymeanbringinginoutsidecontractors.IfyoudoneedtouseelectricalcontractorsyoushouldusethosewhobelongtoarecognisedtradeorganisationwhichcheckstheirworksuchastheNationalInspectionCouncilforElectricalInstallationContracting(NICEIC).Yourownstaffmustalsobecompetentifyoudotheworkin-house.

Ifyoudouseelectricalequipmentinflammableatmospheres,makesurethatspecialmaintenancerequirementsforexplosion-protectedequipmenthavebeenwrittendownandthatsomeonewithenoughtrainingisresponsibleforcarryingoutthework,andrecordsthattheyhavedoneso.Themanufactureroftheequipmentshouldbeabletogiveyouadviceonthis.

Nooneshouldbeallowedtoworkonornearexposedliveequipment.Inexceptionalcircumstancesliveworkingmaybepermissible,butonlyifthiscanbedoneinfullcompliancewithregulation14oftheElectricityatWorkRegulations1989andthepersondoingtheworkiscompetenttoundertakethespecifictask(s)involved.Ifindoubt,askyourhealthandsafetyinspectororenforcingauthorityforadvice.

Electric shock

Wouldyouknowwhattodoifsomeonereceivedanelectricshock?Knowingwhattodoshouldbepartofyouremergencyproceduresandfirst-aidarrangements.Thinkaboutdisplayingacopyofthe‘Electricshockplacard’whichshowsyouwhattodo.

Accident

Aminderreceivedanelectricshockwhenhetouchedametaltablebesidehismachine.Adamagedcablerunningalongthefloorwasincontactwiththetable,makingitelectricallylive.Themanwasoffworkforoneweek,buttheaccidentcouldhavehadfarmoreseriousconsequences.

Amanagerwaskilledwhileusingapressurewasher.Anelectricalfaultonthewashermadeitsframeandlanceliveat240V.Earthingwasinadequateandnoresidualcurrentdevicewasfittedinthesupply.

A16-year-oldtraineeprinterreceiveda240Velectricshockandburnstohisfingerswhenhetouchedaswitch,thecovertowhichhadbeenremovedandnotreplaced.



Figure 45 Electricshockplacard



Chapter 7 Fire and explosionSee the ‘References’ section at the back of the book for details of publications which relate to Fire and explosion


Requirementstoassessandcontrolfireandexplosionriskscanbefoundinthefollowingpiecesoflegislation:

n HealthandSafetyatWorketcAct1974(HSWAct)n ManagementofHealthandSafetyatWorkRegulations1999n Workplace(Health,SafetyandWelfare)Regulations1992n ProvisionandUseofWorkEquipmentRegulations1998(PUWER98)n SupplyofMachinery(Safety)Regulations1992(asamended)n Chemicals(HazardInformationandPackagingforSupply)Regulations1994

(CHIP)n HighlyFlammableLiquidsandLiquefiedPetroleumGasesRegulations

1972(HFL&LPG)(tobereplacedbyDangerousSubstancesandExplosiveAtmospheresRegulations(DSEAR))

n EquipmentandProtectiveSystemsforUseinPotentiallyExplosiveAtmospheresRegulations1996

n ElectricityatWorkRegulations1989n Petroleum(Consolidation)Act1928

(tobeamendedbyDSEAR)n FirePrecautions(Workplace)Regulations1997(asamended)(FPWR)n FirePrecautionsAct1971

Severalhundredfiresoccureveryyearintheprintingindustry.Therehavealsobeenanumberofexplosions.Insomeincidentspeoplehavebeenkilledorinjured;inmanyotherstherehasbeenextensivedamagetobuildings,equipmentandmaterials.

Explosionscanoccuratdryersusedinassociationwithflexographicpressesandwhenblanketwashingonheat-setweboffsetpresses(seeBSEN1539:2000Dryers and ovens in which flammable substances are released - Safety requirementsandprEN12753Thermal cleaning systems for exhaust gas from surface treatment equipment - Safety requirements).Theyoccurwhenflammablesubstances,suchassolvents,blanketwashetcareusedorstoredincorrectly,andthevapourformsanexplosivemixturewithair.

Risk assessmentTheManagementofHealthandSafetyatWorkRegulations1999andTheFirePrecautions(Workplace)Regulations1997containexplicitriskassessmentrequirementsinrelationtofiresafetycoveringbothgeneralfireprecautionsandprocessfireprecautions.

Fire risk management

Managementarrangementsareneededtoensurethatfirerisksareadequatelycontrolled.Theseshouldincludearrangementstoensurethat:

n theriskoffireoccurringisreducedtotheabsoluteminimum;n theriskoffirespreadingisminimised;n adequatefire-detectionandwarningsystemsareinplace;n everyoneisabletoescapefromthebuildingquicklyandsafely.



Itmightbeappropriatetodesignateaseniormemberofthemanagementteamtohavespecificresponsibilityforfire-riskmanagementandstafftraining.

Athoroughfiresurveyislikelytobenecessarytoproperlyassessthefirerisksfrommaterialsandprocesses,theactionsnecessarytoreducetheriskoffireoccurringandarrangementsthatareneededintheeventoffirebreakingout.TheactionplaninFigure47dealswithbothidentificationandfollow-upaction.AnexampleisgiveninFigure46.

Figure 46 Exampleofaplanpreparedduringafireassessment



Figure 47 Actionplanforfireriskmanagement



General fire precautions

Theseareintendedtofacilitatetheunaidedevacuationofpremisesintheeventofanescalatingfire,egfire-alarmsystems,signage,meansofescapeandfire-fightingequipment.

TheFirePrecautions(Workplace)Regulations1997(FPWR)requireemployerstotakeaccountofgeneralfireprecautionsincludingfire-fighting,firedetection,emergencyroutesandexitsandtheirmaintenance.TheFPWRalsointroducerequirementsforcompetentassistancetodealwithgeneralfiresafetyrisks,provisionofinformationtoemployees,co-operationandco-ordinationwithothersandprovisionofcomprehensiveinformationonfireprovisionstooutsideemployers(egtheemergencyservices).SeeFire safety: An employer’s guideinthe‘References’section.

Yourlocalfireauthority,ratherthanHSE,willgiveyouadviceonthis.Youmayneedafirecertificateforyourbuilding-thiswilldependonthekindofbusinessyourunandthenumberofpeopleemployedinyourbuilding.ThemainpiecesoflegislationaretheFirePrecautionsAct1971andtheFirePrecautions(Workplace)Regulations1997(asamended).

Afirecertificateissuedbytheappropriateenforcingauthorityisgenerallyrequiredifmorethan20peopleareatworkinthepremisesatanyonetimeorifmorethantenpeopleareatworkatanyonetimeelsewherethanonthegroundfloor.Itdetailsthegeneralfireprecautionsrequiredatthepremises.Afirecertificatemayalsoberequiredifexplosiveorhighlyflammablematerialsarestoredorusedeitherin,onorunderthepremises.

Firecertificatesaretailoredspecificallytoindividualpremises.Theymaydemandrequirementsformaintainingthemeansofescapeandassociatedfireprecautions,trainingtheworkforce,limitingthenumberofpeoplewhomightbeinthepremisesatanyonetimeandotherprecautionsthathavetobeobserved.Normallytheoccupierofthepremisesisresponsibleforensuringallrequirementsofafirecertificatearemet.Thelawstatesthatfirecertificatesarekeptonthepremisestowhichtheyrelateandareavailableforreferenceorinspectionatalltimes.Ifanyofthefollowingareproposed,thefireauthorityshouldbeinformedinadvance:

n youintendtoundertakestructuralalterationstothebuilding;n youintendtoreorganisetheinternalarrangementsofthepremises,egmove

internalwallsand/ordoors;n youintendtostore,useorincreaseexplosiveorhighlyflammablematerialson

site.

Youneedtocheckthat:

n everyoneknowswhattodoincaseoffire.Displayclearinstructionsandhaveafiredrillperiodically;

n peopleknowhowtoraisethealarmandusetheextinguisherswhereappropriate;

n arrangementsareinplaceforcallingandmeetingthefirebrigadefollowinganysuspectedoutbreakoffire;

n enoughexitsareprovidedforeveryonetogetouteasily;n firedoorsandescaperoutesareprovidedwhichareclearlymarkedand

unobstructed;n fireescapedoorscanbeopenedeasilyfromtheinsidewheneveranyoneison

thepremises-don’tforget‘outofhours’working;n firedoorsareneverwedgedopen-theyaretheretostopsmokeandflames

spreading;



FUEL

OXYGEN IGNITION

n ifawallismeanttobefire-resisting,ithasnoholesorgaps(egaroundpipework)andthewallcontinuesaboveanyfalseceiling;

n firealarmsarecheckedregularlyandwork.Cantheybeheardeverywhereovernormalbackgroundnoise?

n enoughfireextinguishersareprovidedandtheyareoftherighttype(andproperlyserviced)todealpromptlywithsmalloutbreaks.

Process fire precautionsTheseareintendedtopreventafirestarting.Theyrelatetospecialprecautionsinconnectionwithanyworkprocess,includingtheuseandstorageofmaterialconnectedwiththatprocess,topreventorreducethelikelihoodoffirebreakingoutandcontrolitsintensity.

Main fire hazardsThemainfirehazardsare:

n poorhousekeeping/accumulationofwastematerial;n handling/storageofflammableliquids,solidsandgases,egsolventsinlithoand

letterpressprinting;n heatinganddryingequipment,egultravioletcuringunits,gravuredryers;n poorlymaintainedorunsuitableelectricalequipment;n frictionalheat,egfromhotbearings;n frictionalsparks,egfromusingtools;n electrostaticsparks;n weldingandcutting;n smokingmaterials;n arsonandhorseplay

The Fire Triangle

Eachpointofthetrianglerepresentsoneofthethreeelementsessentialforfire:fuel,oxygenandasourceofignition.Firecanbepreventedbyavoidingallthreeoftheseelementsexistingsimultaneously.

Forexample,itisimportanttoensurethatcombustiblematerialssuchaspaper,boardandinksdonotcomeintocontactwithpotentialsourcesofignition,eghotsurfaces,staticelectricity,cigarettes,batterychargers.

Figure 48 Firetriangle

Storage and use of flammable liquidsFlammableliquidsinthiscontextincludethosematerialsdefinedbytheCHIPRegulationsas‘ExtremelyFlammable’,‘HighlyFlammable’and‘Flammable’(seeHSG51The storage of flammable liquids in containersandHSG140Safe use and handling of flammable liquids fordefinitions).



Themainhazardinthestorageofflammableliquidsisfireinvolvingeitherthebulkliquidorescapingliquidorvapour.Mostvapoursareheavierthanairandcantraveloveralargedistance.Ignitioncanoccurforaslongasthevapourconcentrationexceedsthelowerexplosionlimit(LEL).Thisistheconcentration(percentage,byvolume,ofthematerialinair)belowwhichthemixtureistooleantoundergocombustion.

Figure 49 Flammableliquidstoresshouldbesecureandhavesuitablemarkings,ventilationand

spillageretention

Someflammableliquidscanbeeliminatedorsubstitutedbysubstancesthatarelessflammableornon-flammableanddonotrequirethesamespecialiststoragearrangements.Wherethiscannotbeachieved,flammableliquidsshouldbekeptinsuitablecontainersin:

n asafepositionintheopenair(wherenecessary,protectedfromdirectsunlight);orn astoreroomthatisinasafeposition;orn afire-resistingstore;orn ifthetotalquantityislessthan50litres,intheworkroominasuitablefire-

resistingcupboardorbin.

Allstorerooms,cupboardsorbinsshouldbemarkedtoindicatethenatureoftheircontents,eg‘highlyflammable’.Storeroomsshouldalsohaveadequateventilation.Allstoragefacilitiesshouldhavespillageretention,egbunding.

FurtherguidanceonthestorageofflammableliquidscanbefoundinHSG51Storage of flammable liquids in containersandHSG176Storage of flammable liquid in tanks.

Someofthekeystepsforthesafeuseandcontrolofflammableliquidsareto:

n minimisetheamountkeptattheworkplace;n dispenseandusetheminasafeplacewithadequatenaturalormechanical

ventilation;n keepcontainersclosed,egalwaysreplacethecapafteruseorusesafety

containerswithself-closinglids;n containspillages,egbydispensingoveratrayandhavingabsorbentmaterial

handy;n provideasafeprocedurefordealingwithspillagesshouldtheyoccur;n ensurethatallelectricalequipmentinstalledorbroughtintoareaswhere

flammableliquidsarestoredorusedissuitable,egintrinsicallysafeorflameproofwhereappropriate;

n controlignitionsources,egnakedflamesandsparks,andmakesurethat‘nosmoking’rulesareobeyed;



n minimisethepotentialforignitionbystaticelectricitybyearthbondingwhereappropriateandintroduceregularbondingefficiencychecks;

n keepcontaminatedmaterial,egragscontainingisopropylalcohol(IPA)inasuitablylabelled,lidded,metalbin.Thisshouldbeemptiedregularlyandthecontentsdisposedofinasafemanner;

n preventtheaccumulationofcombustiblematerialssuchaswastepaperinareasinwhichhighlyflammableandflammableliquidsarekeptorused;

n disposeofwastesafely,usingpreviouslyagreedsafeworkingprocedures,egburnrubbishinasuitablecontainerwellawayfrombuildingsandflammablematerials.Havefireextinguishersonhand.Neverburnaerosolcansor‘brighten’fireswithflammableliquids.

FurtherguidancecanbefoundinHSG140Safe use and handling of flammable liquids.

Storage of paper reelsAsmallfireinapaperreelstorecanrapidlyescalateintoaseriousfireastheverticalreelsareabletounwrapquicklytofuelthegrowingfire.Thechimneyeffectoftheverticalreelscreatesadraughtwhichalsoexacerbatesthefire.

n Ensurethatloosepapersuchaswrappersandendsaredisposedofandthatdamagedreelsarewrappedortapedondelivery.

n Minimisethechimneyeffectbetweenadjacentreelsstackedonendbyreducingstackheightandthespacebetweenstackstolessthan25mm,andstaggeringthereels.

n Wherethiscannotbeachievedwithoutriskofdislodgingreelsinadjacentstacks,increasethespaceto1.1m.

n Ensuresprinklersystemsaredesignedtodealwithfireswithinstackedreels.n Provideameansofautomaticsmokeventing.n Rigorouslycontrolsourcesofignition.n Ensurethatthereisameansofescapefrominnerrooms.Ifpeopleworkinan

innerroom,provideavisionpanelandanalternativemeansofescape(ienotthroughthereelstore)ifnecessary(seeFire safety: An employer’s guide).

n Avoidstoringverticallystackedpaperreelsbeneathanoccupiedfloororbasement.

n Checkthatstackedreelsdonotadverselyaffecttheaudibilityofthefire-alarmsystem.

n Ensureadequatefireseparation(atleast1/2hourfireresistance)betweenstorageandproductionareas.

Charging electrically operated lift trucks

n Topreventaccidentalshortcircuitofthecellterminalsandignitionofhydrogenvapour,alwaysuseinsulatedtoolsandremovemetallicjewelleryfromtheneck,handsandwrist.

n Alwayscarryoutcharginginanareaintendedforthepurposewhichhasahighlevelofventilation(seeBS6133:1995Code of practice for safe operation of lead-acid stationary batterieswhichincludesaformulaforcalculatingventilationratesforbatterychargingrooms).

n Ensurethatlightandotherelectricalfittingsarepositionedawayfromtheimmediatechargingarea.

n Prohibitsmokingandnakedlightsfromthearea.n Alwaysensurethatthechargerisswitchedoffbeforemakingorbreakingthe

plugandsocketconnection.n Maintainallventplugsinpositionduringcharging.



n Beforedisconnectingbatteryterminalconnections,switchoffallelectricalcircuitsincludingthechargerandensurethattheterminalconnectedtothevehiclebodyisdisconnectedfirstandreconnectedlast.

n Keepsuitablefire-fightingequipmentavailableinthearea.

Lithographic printing

n Observethegeneralprocessfireprecautionsdescribedearlierinthischapter.n Avoidtheuseofblanketwashes,inkstrippers,blanketreviversetcwithlow

flashpoints,egmethylethylketone(MEK).n Substitutelowflashpointproductswithhighflashpointpreparationssuchas

blendscontainingvegetablecleaningagents(VCA).n Whereinfrareddryersandultravioletcuringunitsareused,provideautomatic

systemstoshutofftheheat/lightsourceifpaperremainsunderthedrying/curingunitforanextendedperiod.

Explosion risks in blanket wash systemsSeriousexplosionshaveoccurredatblanketwashsystemsatheat-setweboffsetprinting.Explosionshaveoccurredindryersonweboffsetprintinglineswhenthewebhastransferredblanketwashsolventintothedryerandtheconcentrationofsolventvapourinthedryerhasexceededthelowerexplosionlimit(LEL)(See‘Precautionsfordryers’laterinthischapter).

Thedesignandoperationofheat-setdryersaresuchthatignitionofsolventvapourisalmostinevitableifaconcentrationabovethelowerexplosionlimitisformedwithinthedryers.Standardshavebeendevisedtoensurethesafeoperationofthistypeofplant.Youwillneedtocheckthatyourequipmenthasbeendesignedwithsafetyinmind.

Newdryersandwherefitted,thermaloxidisersshouldbedesignedaccordingtoBSEN1539:2000andprEN12753,whichdetailthemeasurestopreventandmitigatefireandexplosionhazardsindryersandovensinwhichflammablesubstancesarereleased.Youwillneedtoensurethatthesafetyfeaturesareunderstoodandthattheovenandassociatedcoatingequipmentareoperatedandmaintainedinaccordancewiththemanufacturer’sinstructions.

Thelowerexplosionlimitofflammableliquidsistemperaturedependent-animportantfactorwhichneedstobeconsideredwhendeterminingprocessoperatingconditions.Thestandardsalsogiveinformationonhowthelowerexplosionlimitisaffectedbyoperatingtemperature.

FordryersinstalledbeforethepublicationofBSEN1539youwillneedtocheckthattheyhave:

n suitablegassafetyfeaturesongas-fireddryers,includingsafetyshut-offvalves,ignitionsystems,flamefailuredevicesandpurgingarrangements.Equivalentsafetyfeaturesshouldbeincludedonoil-firedsystemswhereappropriate;

n adequateexplosion-reliefdoorsorpanelsonthedryer.Thisprotectioniscriticalifthedamagecausedbyanexplosionistobeminimised.Theareaandweightofexplosionreliefpanelsneedtobecarefullycalculated,sothattheyareeffectiveifthereisanexplosion;

n enoughexhaustventilationfromthedryer,sothatunderalloperatingconditionstheconcentrationofsolventinthedryerdoesnotexceedthelowerexplosionlimit.Toensurethis,dryersshouldbedesignedsothatundernormaloperatingconditionsthesolventlevelsaremaintainedatlessthan25%ofthelowerexplosionlimit.Asfailureoftheexhaustsystemmayhavecriticaleffects,itshouldbemonitoredsothatanyreductionintheairflowbelow



pre-determinedlevelswillautomaticallyandsafelyshutdownthefuelsupplytothedryer,theblanketwashsystemandtheprintedweb.Itshouldalsoactivateavisibleandaudiblealarm;

n anannualchecktoconfirmthatsolventvapourlevelsinthedryerremainwithindesignparametersforalloperatingconditions.

Checktheautomaticblanketwashsystemsforthefollowing:

n themonitoringandcontroldevicesautomaticallyensurethatinallcircumstancestheoverallsolventconcentrationinthedryerdoesnotexceed25%ofthelowerexplosionlimit;

n thesystemisnotusedforthefirsttimeuntilithasbeencommissionedandsafeoperatinglimitsestablished.Thisshouldincludemeasurementofthemaximumconcentrationofsolventwithinthedryer,bothaboveandbelowtheweb,assolventapplicationisprogressivelyintroducedatadditionalprintunits;

n commissioningtestsusethemaximumwebwidthandallpapertypes.Wherenecessary,tomaintainsolventconcentrationswithinthedryertobelow25%ofthelowerexplosionlimit,anautomatictimedelayoperatesaftercompletionofoneblanketwashcyclebeforeanotherstarts;

n therearemeasurementchecksofsolventlevelsinthedryerannually,andafteranychangetooperatingconditions,plantorblanketwashtoensurethatvapourlevelsinthedryerremainwithindesignparametersforalloperatingconditions;

n thesolventorinkusedinthesystemisthesameasthatwhichwasusedwhenthesystemwascommissioned.Differentsolventsmayhavedifferentexplosionlimits,andachangeofsolventmayresultindangerousconditions.Checkwiththesupplierofthesystembeforemakinganychanges;

n theblanketwashsupplierhasprovidedinformationaboutthelowerexplosionlimitforthesolventused,inrelationtothetypicaldryeroperatingtemperatures(160-260ºC);

n thequantityofsolventappliedtotheblanketcylindersismetered,andistheminimumnecessary.Thisvolumewillhavebeensetduringcommissioning.Checkthatunauthorisedaccesstothecontrollingmechanismisprevented;

n themanualapplicationofadditionalsolventisstrictlyprohibited.Safetywillbecompromisediftheamountofsolventreachingthedryerisgreaterthanthatexpectedbythedesignerofthesystem;

n ifblanketwashdrip-traysareused,careistakensothattheydonotoverflowandallowthewebtotakeexcesssolventintothedryer;

n adequatewritteninformationhasbeenprovidedbythesupplierabouttheconditionsunderwhichthesystemhasbeencommissioned,operationallimitations,thesafetydevices,theresultsofcommissioningandnecessarymaintenancerequirements.Whereapplicable,thesuppliershouldhaveprovidedanECDeclarationofConformity;

n managers,operatorsandassistantsareadequatelytrainedintheexplosionhazardassociatedwithblanketwashingandinthenecessaryprecautionarymeasures.

Inaddition,whenblanketwashingbyhand,rememberthatitisimportantto:removeorbreakthewebbeforethedryer,anddon’tuseitasawiper;keepthequantityofsolventappliedtoaminimum.



Fires in the printing industry

Fire in reel storeThreeemployeesdiedinafireinthereelstoreofaprintingfactory.Thefirestartedinsomereelsofpaperatoneendofthereelstoreinthesingle-storeyfactory.Therewasnofireseparationbetweenthereelstorageareaandtheproductionarea.Shortlyafterthefirewasfirstdiscoveredtherewasasuddenrapidspreadoffire(flashover)acrossthetopofreelsofpaperandthewholebuildingrapidlyfilledwithsmoke.Theroofcollapsedwithinminutes.

Horseplay with flammable thinnersA17-year-oldapprenticediedofextensiveburnsafteraninitiationceremonyinwhich2litresofflammablethinnerswerepouredonhisclothing.Thevictimwaschanginghissoakedclothinginatoiletcubiclewhensomematcheswerelit.Theapprenticewasengulfedinflamesanddiedthreeweekslaterofburnswhichcovered80%ofhisbody.

ArsonOnarrivingatawarehousejustaftermidnight,thefirebrigadefoundatimberteachestorpalletonfireoutsidedoubletimberdoorsinanalleywayadjacenttotheseven-storeybuilding.Thedoorswereburningandfirewasspreadingunderthedoorsintoastairwell.Thefirstandsecondfloorswerealsoalight.Firespreadwasrapidduetothetypeofstorageandunprotectedstairwaysinthewarehouseareas.Theentireseven-storeywarehousewasseverelydamaged.

Ignition of toluene vapourAprinterwasoffworkforsixweeksafterreceivingsevereburnstohisrighthandwhenastaticdischargeoccurredashewasusingatoluene-soakedragtocleanthedoctorbladeofagravureprintingpress.Itisthoughtthatanearliermodificationtoacoveratthedoctorbladehadreducedtheextractionsystem’sabilitytoremovevapoursgivenoffbytheprintingink.Anti-staticfootwearwasnotinuse.

Smoking near flammable solventAnemployeesustainedburnstohisfaceandhairashecleanedarollerwashingmachinewithflammablesolventwhilesmoking.Aftertheincidentallstaffwereinstructednottosmokeintheroomwherethemachinewaslocatedand‘nosmoking’signswerepostedup.

Explosion risks in flexographic and gravure

Theseprocessesoftenuseflammableinkswhichcreatesignificantfireandexplosionrisks.Considersubstitutionwithwater-basedinks.Wherethiscannotbeachieved:

n segregateprintingareasfromstorageareasandotherpartsofthebuildingwithhalf-hourfire-resistantpartitioning;

n mixinkswithinadedicatedfire-resistingroomprovidedwithspillageretentionandmechanicalventilation,whichisseparatefromthestoragearea;

n drumsandhandlingequipmentshouldbeearthbonded;n providelocalexhaustventilationatprintunitstopreventflammablevapour

enteringtheworkroomandreduceemployees’exposure.SeeHSG37An introduction to local exhaust ventilationandHSG54Maintenance, examination and testing of local exhaust ventilation(Chapter4references);

n ensuretheworkroomitselfisadequatelyventilated;n minimisetheamountofsolventvapourreleasedintotheairbycoveringinkducts

andkeepingsupplycontainersclosedwhennotinuse.Pumpinktopressesandreturntostorageusinganenclosedsystem;



n whereconnectionsarefrequentlybrokenandre-made,useasealedendcoupling;

n makesurepipeworkandfittingsaretoasuitablestandard(suchasANSIB31.3)andmakearrangementsforplannedpreventivemaintenance;

n useinksandcoatingsataslowatemperatureaspossibletoreducetheamountofvapourproduced;

n ensurethatanyelectricalequipmentonthepressorintheimmediatearea,includingportableequipment,issuitableforuseinpotentiallyexplosiveatmospheres;

n thefanmotorofextractionequipmentshouldnotbelocatedinthepathofthevapour,egwithinthetrunking.Thetrunkingshouldbeoffire-resistingconstructionandfumesshouldbeexpelledtoasafelocation,preferablyathighlevel,andnotlocaltoairintakesforequipmentorventilationsystemsetc;

n providefixedfire-detectionandextinguishingsystemssuchasCO2,designedforbothmanualandautomaticoperation.Furthersolventshouldbepreventedfromenteringdryers/extractductingonoperationofthesystemanddampersshouldshuttostopthelossoftheextinguishingmedium;

n wherethereisasolventrecoveryunit,providetomonitoradampertoisolateitfromanyfireonthepressorintheducting;

n wherevapourdetectionequipmentisnotprovidedtomonitorinsideprintunits,takeregularmeasurementstoensurethattheatmosphereismaintainedbelow25%ofthelowerexplosionlimit;

n cleanrollers,cylindersandancillaryequipmentusinghighlyflammableliquidsonlyinacontainedsolvent-cleaningmachinewithexhaustventilationorinaventilatedpurpose-designedbooth;

n avoidthegenerationofstaticelectricitywhichcanigniteflammablevapourbytakingthefollowingprecautions:

– limittheflowspeedofpipedflammableliquidsto1m/secondwherewatercouldbepresentorto7m/secondwherethereisnopossibilityofthis;

– useanti-staticadditivestoincreasetheconductivityoftheliquid;– useconductive,bondedandearthedcontainers,pipeworkandhoses;– regularlychecktheresistancetoearthofallmetalpartsoffixedplant;

equippersonnelwithanti-staticfootwearandprotectiveclothingmadefromnaturalfibresandinstructthemnottoremoveitemsofouterclothinginareaswhereflammablevapourmaybepresent;

– avoidflooringmaterialsthatarehighlyinsulating;– provideelectrostaticeliminatorsconstructedtoanexplosion-protected

standardwhereinsulatingwebmaterialisbeingprintedon.

Precautions for dryers

NewdryersshouldbedesignedaccordingtoBSEN1539:2000whichdetailsmeasurestopreventormitigatefireandexplosionhazards.Fordryersinstalledbeforethepublicationofthisstandarditisnecessarytocheckthatcertainsafetyfeaturesareincorporated.(See‘Lithographicprinting’and‘Explosionrisksinblanketwashsystems’earlierinthischapter).

Dryersshouldbedesignedwithenoughairflowtokeepthesolventconcentrationbelow25%ofthelowerexplosionlimit-checkatcommissioning.Airflowshouldbemonitoredsothattheprintingprocessandmeansofheatingisstoppediftheairflowisinadequate.

Provideanemergencystopbuttononthedryerwhichshutsdownthemeansofheatingbutnottheexhaustventilation.



Continuousmonitoringofthesolventconcentrationshouldbeprovidedwhereinexceptionalcircumstancesdryershavebeendesignedtooperatebetween25%and50%ofthelowerexplosionlimitandvapourconcentrationschangeslowlyrelativetodetectionandactivationofshut-downsystems.Suchdetectionequipmentshould:

n besuitableforthesolventtype;n besuitablycalibratedfortheconditionsofuse(egoperatingtemperature),

testedandmaintained;n sampleatthehighestvapourconcentrationpoints;n operateanaudibleandvisualalarm;n havetwoindependentmeansofmeasuringconcentration,eachcapableof

shuttingdowntheprintingprocessandheatsourcebeforethe50%lowerexplosionlimitisreached;

n bearrangedtofullyopendampersifthereisamalfunctioninthemonitoringsystem;

n monitortheprogressionofthesolventvapourconcentration.

Note A detailed risk assessment should be carried out to identify additional control measures which may be necessary to prevent and mitigate hazardous conditions arising, eg explosion relief. Further

information is given in BS EN 1539.

Precautions for coating machines

Makesurethatfansexhaustingpotentiallyexplosiveatmospheresorcombustibledustsareexplosionprotected.Ductingusedforexhaustingthesematerialsshouldbeoffire-resistingconstruction,conductiveandelectrostaticallygrounded.Thefanmotorshouldnotbelocatedwithintheduct,ieinthepathofthevapour.Fumesshouldbeexhaustedtoasafelocation,preferablyathighlevel,awayfromairintakesforotherequipmentorventilationsystems.

Explosion-protectedelectricalequipmentwillonlyberequiredonthecoaterwherethereisariskofgeneratinganexplosiveatmosphere,forexamplewhenusingahighlyflammableliquidorheatingaflammableliquid,suchastheelectricdrivemotorontherecirculationpumpsandswitches(wherethesearemountedonthepump).Makesurethatthedistancebetweenthedrivemotorandtheouterflangeofthelanternagitatorforviscositycontrolisatleast50mmandadiscismountedontheshafttoincreasethepreventiveeffect.

Precautions for laminators with glue application

Asforcoatingmachines,anyfansexhaustingpotentiallyexplosiveatmospheresorcombustibledustsshouldbeexplosion-protected,andtheductingusedforexhaustingthesematerialsshouldbemadeoffire-resistingmaterial,conductiveandelectrostaticallygrounded.Thefanmotorshouldnotbelocatedwithintheduct,ieinthepathofthevapour.Fumesshouldbeexhaustedtoasafelocation,preferablyathighlevel,awayfromairintakesforotherequipmentorventilationsystems.

Explosion-protectedelectricalequipmentwillonlyberequiredonthelaminatorwherethereisariskofgeneratinganexplosiveatmosphere,forexamplewhenusingahighlyflammableliquidorheatingaflammableliquid.

Theelectricdrivemotoronlaminatingmaterialrecirculatingpumpsshouldhaveexplosionprotectioninaccordancewiththerelevantstandard,currentlyBSEN



50018:2000Electrical apparatus for potentially explosive atmospheres. Flameproof enclosure ‘d’,orBSEN50019:2000Electrical apparatus for potentially explosive atmospheres. Increased safety ‘e’.



Chapter 8 MaintenanceSee the ‘References’ section at the back of the book for details of publications which relate to Maintenance


n ProvisionandUseofWorkEquipmentRegulations1998(PUWER98)n Workplace(Health,SafetyandWelfare)Regulations1992n HealthandSafetyatWorketcAct1974(HSWAct)n ControlofSubstancesHazardoustoHealthRegulations1999(COSHH)n PressureSystemsSafetyRegulations2000n ElectricityatWorkRegulations1989n LiftingOperationsandLiftingEquipmentRegulations1998(LOLER)

What needs maintenance?

Allbuildings,equipmentandplantneedtobemaintainedingoodworkingorderandingoodrepairtopreventanydangeroussituations.

Statutory testing and thorough examination

Thelawcontainssomespecificrequirementsformaintenancesuchasperiodictestingand/orthoroughexamination.Forexample:

n liftingchainsandropes-generallyeverysixmonths(althoughthiswillbedependentonthefindingsofanappropriateriskassessment);

n liftsandhoists-generallyeverysixmonths(althoughthiswillbedependentonthefindingsofanappropriateriskassessment);

n cranes-generallyevery12months(althoughthiswillbedependentonthefindingsofanappropriateriskassessment);

n steamboilers/airreceiversandpressuresystems-inaccordancewithyourcompetentperson’swrittenschemeforexaminationofpressurevessels;

n localexhaustventilation-minimumevery14months(seetheGeneralApprovedCodeofPracticefortheControlofSubstancesHazardoustoHealthRegulations1999,listedinthe‘References’sectionforChapter4).

Periodictestssuchastheseneedtobecarriedoutbyacompetentperson-thismaybeyourinsuranceengineer.

Otherexamplesofrequiredandindustryrecommendedinspectionsandchecksinclude:

n inspectionofpersonalprotectiveequipment,eghearingprotection;n weeklyinspectionofscaffolds;n monthlyexaminationofbreathingapparatus/rescueequipment;n regularvisualinspectionsofelectricalequipmentatappropriateintervals.

Practicalexperience/manufacturer’sguidancewillhelptodeterminethefrequencyatwhichinspectionandtestbyacompetentpersonisnecessary(egquarterly/annually),andthisshouldbebackedupwithmorefrequentchecksbytheusers.Keepingrecordswillhelptodeterminethefrequencies.GuidanceiscontainedinHSG107Maintaining portable and transportable electrical equipment.



Routinelubrication,serviceandoverhaulactivitiesmightinclude:

n cleaningoffloorsandmachineryaccessplatforms/walkways(egflexographicpresses);

n annualservicingoffireextinguishers.

Beguidedbythemanufacturer’srecommendationswhenworkingoutyourownmaintenanceschedulesforitemssuchasvehicles,lifttrucks,ventilationplant,ladders,portableelectricalequipment,protectiveclothingandequipmentandmachineguards.Checkthelegalrequirements,especiallyforexaminationsbyacompetentperson.

Maintenance and inspection required by PUWER 98Maintenance frequencyEquipmentmayneedtobecheckedfrequentlytomakesurethatsafety-relatedfeaturesareworkingproperly.Somefaultsinsafety-criticalsystemscouldremainundetectedunlessappropriatechecksaremade.Thefrequencyofmaintenancechecksshouldbedeterminedbyfactorssuchastheoperatingenvironment,theintensityofuse,thevarietyofoperationstheequipmentisusedfor,andtherisktohealthandsafetyfrommalfunctionorfailure.

Maintenance managementPoweredequipmentshouldbeaccompaniedbyamaintenancemanual,whichdetailsthemanufacturer’srecommendationseitherforkeepingtheequipmentinworkingorderorforsafetyreasons.Maintenancemanagementtechniquesincludeplannedpreventivemaintenance,condition-basedmaintenanceandbreakdownmaintenance.Whereyouhavesafety-criticalpartswhichcouldfailandrenderguardsorotherprotectiondevicesinoperable,youwillneedaformalsystemofplannedpreventivemaintenanceorcondition-basedmaintenance.

AgoodexampleofthemaintenancechecksrequiredunderPUWER98isthedailycheckofguardsandsafetymechanismsbymachineoperators.Itisrecommendedthatyoukeepamaintenancelogtorecordthesechecks,whichmaycompriseaseriesofcompletedguardchecklists.Thisisparticularlyimportantinthecaseofhigh-riskequipmentsuchaspower-operatedguillotinesandhand-fedplatens,butalsoappliestopressandothermachineryguarding.Whereyouhavealog,youneedtokeepituptodate.

InspectionUnderPUWER98,whereriskassessmentidentifiesthatamajorinjuryorworsecouldoccurbecauseofincorrectinstallationorre-installation,deteriorationorexceptionalcircumstancesaffectingthesafeoperationofworkequipment,inspectionisnecessary.Thepurposeofinspectionistoidentifywhethertheequipmentcanbeusedsafelyandtodetectanydeteriorationbeforeitcausesunacceptablerisk.

Inspectionwillvaryfromsimpleexternalexaminationtocomprehensiveinternalexaminationincludingdismantlingandtesting.Itshouldalwaysincludesafety-relatedparts.Individualscarryingouttheinspectionwilldetermineitsnatureandshouldhavethenecessaryknowledgeandexperience.

Exampleswhereinspectionisneededbecauseequipmentoperationiscriticallydependentonitsconditioninuseanddeteriorationwouldleadtoasignificantrisktotheoperatorinclude:

n daily/monthly/six-monthlytestingofguillotinesafetydevices(seethePIACbookletThe guide to safe use of power-operated paper-cutting guillotines);

n daily/annualtestingofhand-fedplatens(seeChapter5);



n daily/weeklytestingoftripnipbarsonsheet-fedoffsetpresseswheretheslowcrawlsafesystemofworkforcleaningisbeingused(seeChapter5).

Safety during maintenance work

Duringmaintenancework,conditionsareverydifferentfromthosenormallyencountered,andnewhazardsmaybeintroduced.Itisessentialthateveryoneconcernedisawareofthehazardsandofthecorrectprecautions.

Additionalpersonalprotectiveequipmentmaybeneededduringmaintenanceactivities,egoveralls,protectivefootwearandheadwear.Don’tforgetglovesforhandlinginkymachineparts,egchanginginkrollersonalithopressusingUVinks.

Safetyduringmaintenanceactivitiescanbeachievedbyusingisolation,lock-offandpermit-to-workprocedures.Generallyspeaking,simpleisolationproceduresmaybesuitableforminormaintenanceworkandformallock-offproceduresformoremajormaintenancework.

Permits to workApermit-to-worksystemisaformalwrittensystemusedtocontrolcertaintypesofpotentiallyhazardouswork.Thepermitdetailstheworktobedoneandthenecessaryprecautionstobetaken,andformsanessentialpartofmanysafesystemsofworkformaintenanceactivities,forexampleallowingworktostartonlyaftereffectiveisolationhasbeenachieved.Permitswillalwaysbeneededwhennormalsafeguardscannotbeusedorwhennewhazardsareintroducedbythework,forexamplehotworkorworkwheresomeonehastoenteraconfinedspace.

Itisessentialthatthoseaskedtodotheworkunderstandthattheycannotstartuntilthepersonincontrolofissuingapermithasfullyexplainedtheprecautionstobetakenandissatisfiedthattheyhavebeencompliedwith.Thismayincludeprovisionofeffectiveisolationandlock-off.Permitsshouldbeformalisedbymeansofawrittenhandoverprocedure,whichincludesthesignaturesofthosepeopleissuingapermitandthosedoingthework.

Permitsshouldcontainthefollowing:

n clearandunambiguousinformationandinstruction;n exactdetailsoftheitemofplantonwhichtheworkisrequired,thenatureof

thework,andtheprecautionsneededtoensurethesafetyofallpersonnel;n thestartandexpirytimeandanyconditionsunderwhichworkshouldcease

shouldbedetailed;n aplaceforthepermitissuertosignthattheyhavesatisfiedthemselvesby

personalinspectionthatallthenecessaryactionforworktocommencehasbeentakenbeforeastartismade;

n aplaceforthepermitissuertosignthattheyhavecheckedcompletionoftheworkbeforesigningthepermitoff.

Makesurethattheissuerhasenoughtechnicalknowledgeofthehazardsandprecautionstobetakenaswellastheauthoritytorequireotherresponsiblepeopletomakerecommendationswheretheyhavespecialknowledge,andtoco-ordinatethedutiesofallconcerned.

Permit-to-workprocedureswillnormallybeneededforactivitiessuchasthefollowing:



n entryintovessels,confinedspacesormachines;n hotworkwhichcouldcauseexplosionorfire;n building,maintenanceorinstallationworkbycontractors,especiallywherethis

interfaceswithnormalactivities;n mechanicalorelectricalworkrequiringisolationofthepowersource,egbefore

workinginsidelargemachines;n workonplant,mixers,boilersetcwhichmustbecutofffromthepossibleentry

offumes,gas,liquidsorsteam.

Isolation and lock-off procedures

Isolationproceduresusuallycomprisethefollowing:

n switchoff;n disconnectplugorswitchoffatisolator;n tagisolator.

Inadditiontotheabove,lock-offproceduresusuallyinvolvethefollowingsteps:

n isolatethemachinefromthemainsupplybylockingoffthepower;n useasafetylockwithonlyonekeywhichiskeptbythepersondoingthe

work;n useamultiplehaspwhereseveralpeopleareworkingsoeachcanfittheirown

lock;n putawarningnoticeontheisolator.

Accidents

Anexperiencedguillotineoperatorlostfourfingersononehandwhenarepeatstrokeoccurred.Themachinehadnotbeenmaintained,itsbrakewaswornandoilyandtheautomaticsweepawayguarddidnotoperatetoitsfullextent.PIAC-recommendedexaminationswouldhaveidentifiedthesefaultsearlyenoughtopreventanaccident.

Amachineoperatorhadhisrightindexfingerseverelycrushedwhilecleaningtheinkrollersofabagprintingmachine.Theinterlockforthehingedguardhadworkedlooseandheinadvertentlydepressedthestartbutton.Dailycheckingandmaintenanceofthesafetydevicewouldhavepreventedtheaccident.Shroudingofthestartbuttonwouldhavepreventedaccidentaloperationofthebutton.

Theoperatorofathree-knifetrimmerreceivedanelectricshockwhilepickingupaknifefromthefloorandrestingonehandonthemachine.Investigationbyanelectricianrevealedafaultyearthconnection.Regularplannedmaintenancewouldhaveidentifiedthisdefect.

Anexperiencedfitterwaskilledwhileworkingatthefeedendofapapercuttingandcreasingmachinewhentheoperator,whodidnotseehim,startedupthemachine.Therewasnosafesystemformaintenanceworkandthemachinehadnotbeenisolated.



Appendix 1 Safeguarding termsAudible pre-start warning device-adevice(normallyautomaticondepressionofastartorslowcrawlcontrolonlargermachinery)thatdeliversaclearlyaudiblesignalbeforestart-upofthemachine.(Seeguidanceanddiagramsunder‘Machinecontrols’inthe‘Safetyhazardsbyprocesssection’ofChapter5.)

Contra-rotating rollers/cylinders-rollers/cylindersthatrotatetowardseachother.

Crawl-slowspeed,wheremachinescanrunatcrawlspeedswithguardsopentheyshouldbecapableofrunningatslowcrawlonly(see‘Slowcrawl’).Wheremachinesrunatcrawlspeedswithguardsinposition/closed,thecrawlspeedscanbeinexcessofthosesetoutforslowcrawlasthecrawlinthiscontextisnotdesignedtobeasafetyfeature.

Electrosensitive safety system-electrosensitiveprotectiveequipment,egphotoelectricsafetysystem.

Emergency stop device-readilyaccessiblestopcontrolsintendedtoeffectarapidresponsetoapotentiallydangeroussituation.Notdesignedforuseasastopduringnormalday-to-dayoperation.Commontypesincludemushroom-headedbuttons,pushbars,pullwireandkickplates.

Fail to danger-anyfailureofthemachinery,itsassociatedsafeguards,controlsorpowersupplythatleavesamachineinadangerousorunsafecondition.

Fail to safety/fail-safe-anyfailureofthemachinery,itsassociatedsafeguards,controlsorpowersupplythatleavesthemachineinasafecondition.

Fixed guard-guardsthatrequireatoolforremoval,eganAllenkeyorspanner.Wingnutsorsimilararenotacceptable.OpeningsinfixedguardsarepermissibleprovidedsafetyreachdistancesaremaintainedinaccordancewithBSEN294(see‘Machinerystandards’intheReferencessection).

Gap covers-usuallycurvedmetalsectionsdesignedtobefittedinthegapsofplateandblanketcylinderstocreateacylinderofsmoothcircumference.

Guard-aphysicalbarrierthatpreventsorreducesaccesstoadangerpointorarea.

Guard locking-anadditionalsafetyfeatureofcertaininterlockedguardingformachineswithlongrundowntimeswhichpreventstheguardsfrombeingopeneduntildangerousmovementwithintheguardedareahasstopped.

Hickey picking-removalofhickeys(piecesofflufforotherforeignbodies),usuallyfromthesurfaceofprintingcylinders.

Hold-to-run controls(deadman’scontrol)-permitmovementofamachineonlyoncontinuedactivationofacontrol.Hold-to-runcontroldevicesshouldbedesignedtoallowmovementlimitedtoamaximumof25mmorwithamaximumoperatingspeedof1m/minorwherethiswouldreducetheabilityofthemachinetoperformitsfunctionandtherewouldbenosubstantialincreaseinhazardmovementlimitedtoamaximumof75mmorwithamaximumoperatingspeedof5m/min.



Inch-limitedmovement.Movementshouldbelimitedto25mm,or75mmwherethisisnotpossibleanddoesnotincreasethehazardssubstantially.Inchingisnotcontinuousmotionunderhold-to-runcontrol.

In-running nip-trappinganddrawing-inhazardcreatedbyrotatingrollersorcylinders.Canoccurbetweentwocontra-rotatingrollers(poweredornon-powered);onerotatingrollerandastationaryrolleroradjacentfixedpartofthemachine;rollersrotatinginthesamedirectionbutwithdifferentperipheralspeedsorsurfaceproperties(friction);guiderollersanddrivingbelts,conveyorbeltsandpossiblytheweb.

Integrity-theabilityofdevices,systemsandprocedurestoperformtheirfunctionwithoutfailureordefeat.

Interlock-asafetydevicethatinterconnectsaguardwiththecontrolsystemorthepowersystemofthemachine.

Interlocked guard-aguardthatwhenopenedoperatesaninterlocktostopmovementofdangerouspartsbeforetheycanbereachedbyanoperatororotherperson.

Isolate-theremovalofallsourcesofenergyinasecuremanner,iebyensuringthatinadvertentreconnectionisnotpossible.

Lift out/pop out rollers-rollersthatarenotfixedinpositionandarelightenoughtoliftoutofpositionifablockageorentanglementoccurswithoutcausinginjury.

Multi-operator presses-pressesdesignedtobeoperatedbymorethanoneperson.

Nip bar-fixedsection,normallymetal,eitherroundorangled,runningalongthelengthofrollersorcylinderssituatednomorethan6mmfromthecylinderorrollersurfacedesignedtominimisetheriskofentanglementbythenipcreatedbycontra-rotatingrollers.

Safe by position-outofreach.SeealsosafetyreachdistancesinBSEN294(see‘Machinerystandards’intheReferencessection).

Safe system of work or safe working practice-amethodofworkingthateliminatesorreducestheriskofinjury.

Safety device/protective device-adeviceotherthanaguardthateliminatesorreducesdanger.

Safety reach distance-safetydistancethatshouldpreventdangerouspartsfrombeingreachedbyoperatorsorothers.

Slow crawl-safety-relatedrestrictedoperatingspeed.Asarule,theslowcrawlspeedshouldbesetatamaximumoperatingspeedof1m/min,or5m/minwherethisisnotpossiblebecauseitwouldreducetheabilityofthemachinetoperformitsfunctionandwheretherewouldbenosubstantialincreaseinhazard.

Slow speed-productioncrawl(withguardsinposition)-seealso‘Crawl’.

Trip devices-deviceswhichbringdangerouspartsofmachinerytorestwhenactivated(egknocked)byoperatorsorotherpeople.



Trip nip bar-similartoafixednipbarbutwhendeflectedactstocutthepowersupplytothemotor,causingthepresstocometoarapidbutcontrolledstop.Thewithdrawalpath/deflectionofthetripbarshouldbelongerthanthestoppingpathofthehazardousmovement.

Tunnel guard-fixedorinterlockedguardthatpreventsaccesstodangerouspartsusingtheprinciplesofsafetyreachdistancesinconstructionoftheguard,oftenusingatunnelshape.

Two-hand control-controlsdesignedsothatsimultaneousoperationofthecontrols(withinapproximately0.5seconds)isrequiredbeforethemachinewilloperate.Operationofthemachinebysuchcontrolsshouldusuallyallowlimitedmovement,egasinglestrokeofaguillotine,ormovementatslowcrawlspeedsonly.Hazardousmovementshouldstopwheneitheractuator/controlisreleased.

Wander lead control/pendant control-portablecontrolpanelusuallyonflexiblearmouredcableleadallowingoperationofthemachinefromdifferentpositions.Ifthecontrolallowsoperationofthemachinewithguardsopenitshouldoperateasatwo-handcontrol(see‘Two-handcontrol’).

Web-driven rollers-non-poweredrollersthatactasifpoweredduetothedrivingforceoftheweb.

Zoning-eachcontrolonlyallowsoperationofalimitedpressorassociatedareawithaguardopenwhenguardselsewherethatarenotclearlyvisibleareclosed,egatprintunitsoflargerpresses.



Appendix 2 Example risk assessment form

Thisisasuggestedriskassessmentform.Youdonothavetousethis-itismerelyanexampleofthe

sortofformyoumayuse

RISK ASSESSMENT NO

Site Area

Operationscoveredbytheassessment

Maximumnumberofpeopleexposed:

Frequencyanddurationofexposure:

Hazards

Actiontakentoreducerisk Residual risk

Likelihood Severity

Hazardsstilloutstanding

Assessmentofresidualrisk:low/medium/high

Furtheractionsrequired: Person Dateresponsible completed

Signed: Date Reviewdate

Position:

DateResponsibleDirector’sapproval



Appendix 3 Assessing hazards in a small print works



ReferencesChapter 1 Managing health and safety

Management of health and safety at work. Management of Health and Safety at Work Regulations 1999. Approved Code of Practice and guidanceL21(Secondedition)HSEBooks2000ISBN0717624889

Homeworking: Guidance for employers and employees on health and safetyLeafletINDG226HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN071761204X)

Working alone in safety: Controlling the risks of solitary workLeafletINDG73(rev)HSEBooks1998(singlecopyfreeorpricedpacksof15ISBN0717615073)

RIDDOR explained: Reporting of Injuries, Diseases and Dangerous Occurrences RegulationsLeafletHSE31(rev1)HSEBooks1999(singlecopyfreeorpricedpacksof10ISBN0717624412)

A guide to the Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1995L73(Secondedition)HSEBooks1999ISBN0717624315

RIDDOR reporting: Information about the new incident centreLeafletMISC310HSEBooks2001

First aid at work. The Health and Safety (First Aid) Regulations 1981. Approved Code of Practice and guidanceL74HSEBooks1997ISBN0717610500

First aid at work: Your questions answeredLeafletINDG214HSEBooks1997(singlecopyfreeorpricedpacksof15ISBN0717610748)

Basic advice on first aid at workLeafletINDG215(rev2)HSEBooks1999(singlecopyfreeorpricedpacksof20ISBN0717624234)

Health and safety in construction. Construction (Design and Management) Regulations 1994. Approved Code of PracticeHSG150HSEBooks2001ISBN0717621065

Having construction work done? Duties of clients under the Construction (Design and Management) Regulations1994LeafletMISC193HSEBooks1999

A guide to the Construction (Health, Safety and Welfare) Regulations1996LeafletINDG220HSEBooks1996(singlecopyfreeorpricedpacksof10ISBN0717611612)

Consulting employees on health and safety: A guide to the lawLeafletINDG232HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN0717616150)

A guide to the Health and Safety (Consultation with Employees) Regulations 1996. Guidance on RegulationsL95HSEBooks1996ISBN0717612341

Safety representatives and safety committeesL87(Thirdedition)HSEBooks1996ISBN0717612201

Essentials of health and safety at workHSEBooks1994ISBN071760716X



Health and safety law: What you should knowLeafletHSEBooks1999(pricedpacksof25ISBN0717617025)

Successful health and safety managementHSG65(Secondedition)HSEBooks1997ISBN0717612767

Five steps to risk assessmentLeafletINDG163(rev1)HSEBooks1998(singlecopyfreeorpricedpacksof10ISBN0717615650)

A guide to risk assessment requirements: Common provisions in health and safety lawLeafletINDG218HSEBooks1996(singlecopyfreeorpricedpacksof5ISBN0717612112)

Working together: Guidance on health and safety for contractors and suppliersLeafletINDG268HSEBooks1998(singlecopyfreeorpricedpacksof10ISBN0717615480)

Managing health and safety: Five steps to successLeafletINDG275HSEBooks1998

Chapter 2 Training

PUWER 1998: Provision and Use of Work Equipment Regulations 1998. Open learning guidanceHSEBooks1999ISBN0717624595

LOLER 1998: Lifting Operations and Lifting Equipment Regulations 1998. Open learning guidanceHSEBooks1999ISBN0717624641Managing health and safety: An open learning workbook for managers and trainersHSEBooks1997ISBN0717611531

The training of first aid at work: A guide to gaining and maintaining HSE approvalHSG212(Secondedition)HSEBooks2000ISBN071761896X

Five steps to information, instruction and trainingLeafletINDG213HSEBooks1996(singlecopyfreeorpricedpacksof10ISBN071761235X)

Printing industry: Health and safety training package. An open learning packagePIAC/HSEBooks1998ISBN0717614816

Chapter 3 Workplace and transport safety

Workplace health and safety

Workplace health, safety and welfare. Workplace (Health, Safety and Welfare) Regulations 1992. Approved Code of PracticeL24HSEBooks1992ISBN0717604136

Workplace health, safety and welfare: A short guide for managersLeafletINDG244HSEBooks1997(singlecopyfreeorpricedpacksof10ISBN0717613283)

Lighting at workHSG38(Secondedition)HSEBooks1997ISBN0717612325

Display screen equipment work. Health and Safety (Display Screen Equipment) Regulations 1992. Guidance on RegulationsL26HSEBooks1992ISBN0717604101



Working with VDUsLeafletINDG36(rev1)HSEBooks1998(singlecopyfreeorpricedpacksof10ISBN0717615049)

Seating at workHSG57(Secondedition)HSEBooks1997ISBN0717612317

Young people at work: A guide for employersHSG165(Secondedition)HSEBooks2000ISBN0717618897

Thermal comfort in the workplace: Guidance for employersHSG194HSEBooks1999ISBN0717624684

Slips and trips: Guidance for employers on identifying hazards and controlling risksHSG155HSEBooks1996ISBN0717611450

Preventing slips, trips and falls at workLeafletINDG225HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN0717611833)

Safe movement of vehicles

Managing vehicle safety at the workplace: A short guide for employersLeafletINDG199HSEBooks1995(singlecopyfreeorpricedpacksof10ISBN0717609820)

Rider-operated lift trucks. Operator training. Approved Code of Practice and guidanceL117HSEBooks1999ISBN0717624552

Safety in working with lift trucksHSG6(Thirdedition)HSEBooks2000ISBN0717617815

Safe use of lifting equipment. Lifting Operations and Lifting Equipment Regulations 1998. Approved Code of Practice and guidanceL113HSEBooks1998ISBN0717616282

Workplace transport safety: Guidance for employersHSG136HSEBooks1995ISBN0717609359Reversing vehiclesLeafletINDG148HSEBooks1993(singlecopyfreeorpricedpacksof15ISBN0717610632)

Asbestos

Managing asbestos in premisesLeafletINDG223(rev2)HSEBooks2001(singlecopyfreeorpricedpacksof10ISBN0717620921)

Chapter 4 Health risks

Need help on health and safety? Guidance for employers on when and how to get advice on health and safetyLeafletINDG322HSEBooks2000(singlecopyfreeorpricedpacksof10ISBN0717617904)

Health surveillance at workHSG61(Secondedition)HSEBooks1999ISBN071761705X

Understanding health surveillance at work: An introduction for employersLeafletINDG304HSEBooks1999(singlecopyfreeorpricedpacksof15ISBN0717617122)



Hazardous substances

General COSHH ACOP (Control of substances hazardous to health) and Carcinogens ACOP (Control of carcinogenic substances) and Biological agents ACOP (Control of biological agents). Control of Substances Hazardous to Health Regulations 1999. Approved Codes of PracticeL5(Thirdedition)HSEBooks1999ISBN0717616703

COSHH a brief guide to the regulations: What you need to know about the Control of Substances Hazardous to Health Regulations 1999 (COSHH)LeafletINDG136(rev1)HSEBooks1999(singlecopyfreeorpricedpacksof10ISBN0717624447)

Control of chemicals in printing: COSHH essentials for printersPIAC/HSEBooks2000ISBN0717618358

COSHH essentials: Easy steps to control chemicals. Control of Substances Hazardous to Health RegulationsHSG193HSEBooks1999ISBN0717624218

Safe use of printing chemicals: COSHH and substitutionVideoHSEBooks1998ISBN0717618587

A step by step guide to COSHH assessmentHSG97HSEBooks1993ISBN0717614468

Seven steps to successful substitution of hazardous substancesHSG110HSEBooks1994ISBN0717606953

Why do I need a safety data sheet?LeafletINDG182HSEBooks1994(singlecopyfreeorpricedpacksof10ISBN0717608956)

Working safely with solvents: A guide to safe working practicesLeafletINDG273HSEBooks1998

Health risk management: A guide to working with solventsHSG188HSEBooks1998ISBN0717616649

Occupational exposure limits 2002GuidanceNoteEH40HSEBooks2002ISBN0717620832

Specific process health hazards

Safety in the use of inks, varnishes and lacquers cured by ultraviolet light or electron beam techniquesPIAC/HSEBooks1993ISBN0118820451

Ozone: Health hazards and precautionary measuresGuidanceNoteEH38(rev)HSEBooks1996ISBN0717612066

Electrical risks from steam/water pressure cleanersGuidanceNotePM29(Secondedition)HSEBooks1995ISBN0717608131

Monitoring strategies for toxic substancesHSG173HSEBooks1997ISBN0717614115

Organic isocyanates in airMDHS25/3HSEBooks1999ISBN0717616681



Isocyanates: Health hazards and precautionary measuresGuidanceNoteEH16(Fourthedition)HSEBooks1999ISBN0717617017

Safe use of isocyanates in printing and laminatingPIAC/HSEBooks1997ISBN0717613127

Noise

Reducing noise at work. Guidance on the Noise at Work Regulations 1989L108HSEBooks1998ISBN0717615111

Noise at work: A guide for employeesLeafletINDG99(rev)HSEBooks1991(singlecopyfreeorpricedpacksof20ISBN0717609626)

Ear protection: Employers’ duties explainedLeafletINDG298HSEBooks1999(singlecopyfreeorpricedpacksof5plus5postersMISC185and30pocketcardsINDG299ISBN0717624846)

Protect your hearingPocketcardINDG299HSEBooks1999(singlecopyfreeorpricedpacksof25ISBN0717619249orpricedpackof30plus5postersMISC185and5leafletsINDG298ISBN0717624846)

Noise reduction at buckle folding machinesPIAC/HSEBooks1986ISBN0118838490

Noise reduction at web-fed pressesPIAC/HSEBooks1988ISBN0118839721

Health surveillance in noisy industries: Advice for employersLeafletINDG193HSEBooks1995(singlecopyfreeorpricedpacksof10ISBN0717609332)

A guide to audiometric testing programmesGuidanceNoteMS26HSEBooks1995ISBN0717609421

Introducing the Noise at Work Regulations: A brief guide to the requirements for controlling noise at workLeafletINDG75(rev)HSEBooks1989(singlecopyfreeorpricedpacksof15ISBN0717609618)

Keep the noise down: Advice for purchasers of workplace machineryLeafletINDG263HSEBooks1997(singlecopyfreeorpricedpacksof15ISBN0717614808)

Manual handling

Manual handling. Manual Handling Operations Regulations 1992. Guidance on RegulationsL23(Secondedition)HSEBooks1998ISBN0717624153

Handling the news: Advice for employers on manual handling of bundlesPIACLeafletIACL105HSEBooks1999

Handling the news: Advice for newsagents and employees on safe handling of bundlesPIACLeafletIACL106HSEBooks1999

What the papers weigh: Safe handling of bundlesVideoHSEBooks1999ISBN0717619486

Back in work: Managing back pain in the workplace - A leaflet for employers and workers in small businessesLeafletINDG333HSEBooks2000



Work-related upper limb disorders in the printing industryLeafletIACL91HSEBooks1994

Work related upper limb disorders: A guide to preventionHSG60HSEBooks1990ISBN0717604756

Manual handling: Solutions you can handleHSG115HSEBooks1994ISBN0717606937

Getting to grips with manual handling: A short guide for employersLeafletINDG143(rev1)HSEBooks2000(singlecopyfreeorpricedpacksof15ISBN0717617548)

Radiation

Laser safety in printingHSEBooks1990ISBN0118854364

BSEN60825-1:1994,IEC60825-1:1993Safety of laser products. Equipment classification, requirements and user’s guideBritishStandardsInstitution

Skin disease

Assessing and managing risks at work from skin exposure to chemical agents: Guidance for employers and health and safety specialistsHSG205HSEBooks2001ISBN0717618269Choice of skin care products for the workplace: Guidance for employers and health and safety specialistsHSG207HSEBooks2001ISBN0717618250

Preventing dermatitis at work: Advice for employers and employeesLeafletINDG233HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN0717612465)

Skin problems in the printing industryPIACLeafletIACL101(rev1)HSEBooks2002

Other health issues

Tackling work-related stress: A managers’ guide to improving and maintaining employee health and well-beingHSG218HSEBooks2001ISBN0717620506

Work-related stress: A short guideLeafletINDG281(rev1)HSEBooks2001(singlecopyfreeorpricedpacksof10ISBN071762112X)

Stress at work: A guide for employersHSG116HSEBooks1995ISBN071760733X

New and expectant mothers at work: A guide for employersHSG122HSEBooks1994ISBN0717608263

Drug misuse at work: A guide for employersLeafletINDG91(rev2)HSEBooks1998(singlecopyfreeorpricedpacksof10ISBN0717624021)

Don’t mix it: A guide for employers on alcohol at workLeafletINDG240HSEBooks1996(singlecopyfreeorpricedpacksof10ISBN0717612910)

Passive smoking at workLeafletINDG63(rev1)HSEBooks1992(singlecopyfreeorpricedpacksof10ISBN0717608824)



Legionnaires’ disease. The control of legionella bacteria in water systems.Approved Code of Practice and guidanceL8(Secondedition)HSEBooks2000ISBN0717617726

Legionnaires’ disease: A guide for employersLeafletIAC27(rev2)HSEBooks2001(singlecopyfreeorpricedpacksof15ISBN0717617734)

A guide to the Asbestos (Licensing) Regulations 1983 as amended. The Asbestos (Licensing) Regulations 1983. Guidance on Regulations L11(Secondedition)HSEBooks1999ISBN0717624358

The control of asbestos at work. Control of Asbestos at Work Regulations 1987. Approved Code of PracticeL27(Thirdedition)HSEBooks1999ISBN0717616738

Work with asbestos insulation, asbestos coating and asbestos insulating board. Control of Asbestos at Work Regulations 1987. Approved Code of PracticeL28(Thirdedition)HSEBooks1999ISBN0717616746

Local exhaust ventilation

An introduction to local exhaust ventilationHSG37(Secondedition)HSEBooks1993ISBN0717610012

Maintenance, examination and testing of local exhaust ventilationHSG54(Secondedition)HSEBooks1998ISBN0717614859

Personal protective equipment

Personal protective equipment at work. Personal Protective Equipment at Work Regulations 1992. Guidance on RegulationsL25HSEBooks1992ISBN0717604152

Cost and effectiveness of chemical protective gloves for the workplace: Guidance for employers and health and safety specialistsHSG206HSEBooks2001ISBN0717618285

Selecting protective gloves for work with chemicals: Guidance for employers and health and safety specialistsLeafletINDG330HSEBooks2000(singlecopyfreeorpricedpacksof15ISBN0717618277)

Preventing asthma at work. How to control respiratory sensitisersL55HSEBooks1994ISBN0717606619

Respiratory sensitisers and COSHH: Breathe freely - An employers’ leaflet on preventing occupational asthmaLeafletINDG95(rev2)HSEBooks1995(singlecopyfreeorpricedpacksof15ISBN0717609146)

BSEN166:1996Personal eye-protection. SpecificationsBritishStandardsInstitution

BSEN345-1:1993Safety footwear for professional use.SpecificationBritishStandardsInstitution

BSEN345-2:1997Safety footwear for professional use. Additional specificationsBritishStandardsInstitution

BSEN346-1:1993Protective footwear for professional use. SpecificationBritishStandardsInstitution



BSEN346-2:1997Protective footwear for professional use. Additional specificationsBritishStandardsInstitution

BSEN352-1:1993Hearing protectors. Safety requirements and testing. Ear-muffsBritishStandardsInstitution

BSEN352-2:1993 Hearing protectors. Safety requirements and testing. Ear-plugsBritishStandardsInstitution

BSEN352-3:1997Hearing protectors. Safety requirements and testing. Ear-muffs attached to an industrial safety helmetBritishStandardsInstitution

Chapter 5 Process safety

Safe use of work equipment. Provision and Use of Work Equipment Regulations 1998. Approved Code of Practice and guidanceL22(Secondedition)HSEBooks1998ISBN0717616266

The Supply of Machinery (Safety) Regulations 1992SI1992/3073TheStationeryOffice1992ISBN0110257197

The Supply of Machinery (Safety) (Amendment) Regulations 1994SI1994/2063TheStationeryOffice1994ISBN0110450639

VDUs: An easy guide to the regulationsHSG90HSEBooks1994ISBN0717607356

The guide to safe use of power-operated paper-cutting guillotines(Secondedition)PIAC/HSEBooks1999ISBN0717617076

Application of electro-sensitive protective equipment using light curtains and light beam devices to machineryHSG180HSEBooks1999ISBN0717615502

Pressure systems: Safety and youLeafletINDG261(rev1)HSEBooks2001(singlecopyfreeorpricedpacksof15ISBN0717615626)

Supplying new machinery: A short guide to the law and some information on what to do for anyone supplying machinery for use at workLeafletINDG270HSEBooks1998(singlecopyfreeorpricedpacksof15ISBN071761560X)

Buying new machinery: A short guide to the law and some information on what to do for anyone buying new machinery for use at workLeafletINDG271HSEBooks1998(singlecopyfreeorpricedpacksof15ISBN0717615596)

Using work equipment safelyLeafletINDG229HSEBooks1997(singlecopyfreeorpricedpacksof5ISBN0717613267)

Safe systems of work for cleaning sheet-fed offset lithographic printing pressesPrintingInformationSheetPIS1HSEBooks2000

Safe systems of work for cleaning web-fed offset lithographic printing pressesPrintingInformationSheetPIS2HSEBooks2000

Safe systems of work for cleaning flexographic, rotary letterpress and gravure printing presses PrintingInformationSheetPIS3HSEBooks2000



Safety at power-operated paper cutting guillotines: Your responsibilitiesPIACLeafletINDG282HSEBooks1998

Machinery standards

ThecurrentENStandardsgivespecificationsfornewmachines.However,someoftheprecautionsmayberelevanttoexistingmachineswhenitisreasonablypracticabletofitthem.

BSEN292-1:1991Safety of machinery. Basic concepts, general principles for design. Basic terminology, methodologyBritishStandardsInstitution

BSEN292-2:1991Safety of machinery. Basic concepts, general principles for design. Technical principles and specificationsBritishStandardsInstitution

BSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbsBritishStandardsInstitution

BSEN349:1993Safety of machinery. Minimum gaps to avoid crushing of parts of the human bodyBritishStandardsInstitution

BSEN811:1997Safety of machinery. Safety distances to prevent danger zones being reached by the lower limbsBritishStandardsInstitution

BSEN953:1998Safety of machinery. Guards. General requirements for the design and construction of fixed and movable guardsBritishStandardsInstitution

BSEN954-1:1997Safety of machinery. Safety related parts of control systems. General principles for designBritishStandardsInstitution

prEN1010:1998 (Draft) Safety of machinery: Safety requirements for the design and construction of printing and paper converting machinery

BSEN1050:1997Safety of machinery. Principles for risk assessmentBritishStandardsInstitution

BSEN1088:1996Safety of machinery. Interlocking devices associated with guards. Principles for design and selectionBritishStandardsInstitution

BSEN1539:2000Dryers and ovens in which flammable substances are released. Safety requirementsBritishStandardsInstitution

BSEN60204-1:1993Safety of machinery. Electrical equipment of machines.Specification for general requirements British Standards Institution

BSEN61496-1:1998,IEC61496-1:1997Safety of machinery. Electro-sensitive protective equipment. General requirements and testsBritishStandardsInstitution

Chapter 6 Electricity

Memorandum of guidance on the Electricity at Work Regulations 1989. Guidance on RegulationsHSR25HSEBooks1989ISBN0717616029

Your guide to the essentials of electrical safetyCDROMHSEBooks2000ISBN0717617149



Do you use a steam/water pressure cleaner? You could be in for a shock!LeafletINDG68(rev)HSEBooks1997

Electricity at work: Safe working practicesHSG85HSEBooks1993ISBN071760442X

Electric storage batteries: Safe charging and useLeafletINDG139HSEBooks1993

Electrical safety and youLeafletINDG231HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN0717612074)

Maintaining portable electrical equipment in offices and other low-risk environmentsLeafletINDG236HSEBooks1996(singlecopyfreeorpricedpacksof10ISBN0717612724)BS7671:1992Requirements for electrical installations. IEE Wiring Regulations. Sixteenth editionBritishStandardsInstitution

Chapter 7 Fire and explosion

Fire safety: An employer’s guideHSEBooks1999ISBN0113412290

The storage of flammable liquids in containersHSG51(Secondedition)HSEBooks1998ISBN0717614719

Safe use and handling of flammable liquidsHSG140HSEBooks1996ISBN0717609677

Safe working with flammable substancesLeafletINDG227HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN071761154X)

The storage of flammable liquids in tanksHSG176HSEBooks1998ISBN0717614700

Control of fire in the printing industryPIAC/HSEBooks1992ISBN0118863754BSEN1539:2000Dryers and ovens in which flammable substances are released. Safety requirementsBritishStandardsInstitution

BS6133:1995Code of practice for safe operation of lead-acid stationary batteriesBritishStandardsInstitution

PrEN12753(Draft) Thermal cleaning systems for exhaust gas from surface treatment equipment - Safety requirementsBritishStandardsInstitution

BSEN50018:2000Electrical apparatus for potentially explosive atmospheres. Flameproof enclosure ‘d’BritishStandardsInstitution

BSEN50019:2000Electrical apparatus for potentially explosive atmospheres. Increased safety ‘e’BritishStandardsInstitution

BSEN50021:1999Electrical apparatus for potentially explosive atmospheres. Type of protection ‘n’BritishStandardsInstitution



Chapter 8 MaintenanceMaintaining portable and transportable electrical equipmentHSG107HSEBooks1994ISBN0717607151

Improving maintenance: A guide to reducing human errorHSEBooks2000ISBN0717618188

Permit-to-work systems LeafletINDG98(rev3)HSEBooks1997(singlecopyfreeorpricedpacksof15ISBN0717613313)

Whileeveryefforthasbeenmadetoensuretheaccuracyofthereferenceslistedinthispublication,theirfutureavailabilitycannotbeguaranteed.

Seethe‘FurtherInformation’sectionfordetailsofhowtoobtainpublications.



Further informationHSE publications

Printing Industry Advisory Committee (PIAC)

TheSecretaryPIACHealthandSafetyExecutive3EastGrinsteadHouseLondonRoadEastGrinsteadWestSussexRH191RRTel:01342334200Fax:01342334222

Graphical, Paper and Media Union

Graphical,PaperandMediaUnionKeysHouse63/67BromhamRoadBedfordMK402AGTel:01234351521Fax:01234270580Website:www.gpmu.org.uk

British Printing Industries Federation

BritishPrintingIndustriesFederationFarringdonPoint29-35FarringdonRoadLondonEC1M3JFTel:02079158300Fax:02074057784Website:www.bpif.org.uk

Institute of Occupational Health and Safety (IOSH)

IOSHTheGrangeHighfieldDriveWigstonLeicestershireLE181NNTel:01162573100Fax:01162573101Website:www.iosh.co.uk

Royal Society for the Prevention of Accidents (RoSPA)

RoSPAEdgbastonPark353BristolRoadEdgbastonBirminghamB57STTel:01212482000Fax:01212482001Website:www.rospa.co.uk



British Safety Council

BritishSafetyCouncil70ChancellorsRoadLondonW69RSTel:02087411231Fax:02087414555Website:www.britishsafetycouncil.org

ForinformationabouthealthandsafetyringHSE’sInfolineTel:08453450055Fax:08454089566Textphone:08454089577e-mail:[email protected],CaerphillyBusinessPark,CaerphillyCF833GG.

HSEpricedandfreepublicationscanbeviewedonlineororderedfromwww.hse.gov.ukorcontactHSEBooks,POBox1999,Sudbury,SuffolkCO102WATel:01787881165Fax:01787313995.HSEpricedpublicationsarealsoavailablefrombookshops.

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.

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