© Crown copyright material is produced with the permission of the Controller of HMSO and Queen's Printer for Scotland.

© Crown copyright material is produced with the permission of the Controller of HMSO and Queen's Printer for Scotland.

Updated guidance on respiratory disease and

metalworking fluids can be found on the
Metalworking Fluids Topic Pages on HSE's
Website at www.hse.gov.uk/metalworking
 AFK
HSE

Health and Safety in

ENGINEERING
7nr, r, Fr, CC13
1 1 1 1

0
© Crown copyright 1999
Applications for reproduction should be
made in writing to:
Copyright Unit, Her Majesty's Stationery
Office, St Clements House, 2-16 Colegate,
Norwich NR3 1BQ
First published 1995
Second edition 1999
Reprinted with amendments 2002
Reprinted 2004

ISBN 0 7176 1717 3

This guidance is issued by the Health and

Safety Executive. Following the guidance
is not compulsory and you are free to take
other action. But if you do follow the
guidance you will normally be doing
enough to comply with the law. Health and
Safety Inspectors seek to secure
compliance with the law and may refer to
this guidance as illustrating good practice.

2004 Reprint

In general, the amendments included in this

reprint reflect updated publications and
regulations. The overall guidance has not
changed.

HSE gratefully acknowledges the help of

Elf Oil Industrial Lubricants Division in
the preparation of the cover illustration.

0
 CONTENTS
Foreword V

Managing health and safety 1

How most accidents and cases of work-related ill health arise 2

Instant action checklist 3

Now to use this book to start your risk assessment 4

Five steps to risk assessment 6

Working in and moving around the workshop 8

The workplace 8
Lighting 9
General ventilation, temperature and toilets 10
Lifting equipment 11
Moving goods safely by hand 12
How to lift safely 13
Lifting and handling 14
Ergonomic machine operation, assembly and packing 16
Moving vehicles safely 18
Lift trucks 19
Controlling hazardous substances 20
Local exhaust ventilation 21
Electricity 23
Portable electrical equipment 24
Common problems with flexible leads, their plugs and sockets 26
Pressurised plant and systems 28

Machining 29
Now most accidents and cases of work-related ill health happen 29
Good practice, safety measures and training essentials 30
Machining 31
Computer controlled machining 32
Buying and selling machinery 34
Metalworking fluids 36
Noise 38
How to make the most of noise assessments 40
How to reduce noise 41
Vibration 43
Milling and machining centre work 44
Drilling 46
Pressing 48
Turning 50
Grinding 52
 Sawing 54
Bending 55
Guillotining 56
CNC punch pressing 57
Combination metalworking machines 58
Horizontal boring machines 59
Cleaning and degreasing 60
Vapour degreasing tanks 61

Welding and flamecutting 63

Fume control 65
Safety measures at resistance welding machines 66
Lasers used for welding and cutting 67

Radiography 68 N

Painting 69
40444

Spray painting booths and enclosures 70

Paints containing isocyanates 72
Powder coating 73
Personal protective equipment 74

Offices 76

Organising health and safety

The law 77
Accidents and emergencies 78
First aid 80
How to obtain publications and further assisstance 81
Further reading including `Key references' 82
HSE Offices 90
Some useful addresses for selecting a health and safety consultancy 91

Appendices
I Lifting and handling assessments 92
1=0

2 Metalworking fluids questionnaires 99

3 Work equipment risk assessment 101
4 Key British and European Standards and useful definitions 102
5 Fire-resistant materials for DIY spray booths 106
6 Record of examination and test of LEV plant 108
7 Answers to frequently asked questions and answers about work
in engineering workshops 114

IV
FOREWORD In this guidance:
This guidance has been written for people who
run and work in small engineering `must' denotes a legal obligation; outlines
workshops, ranging from those who of the law applying to engineering
V make their own products, workshops are provided in lined boxes on
a blue background just like this paragraph;
to those who
V maintain and repair plant and machinery V `do' and `don't', `should' and `should not'
either independently or as part of larger and other recommendations such as `use',
enterprises. `fit' and `prevent' represent good practice,
which, if adopted, will usually be what is
It is intended to help them manage their own reasonably practicable in the given
health and safety and work in safer and circumstances although there may be
healthier ways. other legally acceptable ways of achieving
the same objective.
As engineering is a wide ranging activity the
booklet does not deal with every hazard V text in italics (where it is not a reference,
which may arise or every precaution which sub-heading or caption) outlines
can be taken. It does, however, outline the requirements of Approved Codes of
most serious and frequent hazards and the Practice which have been approved by the
best ways of dealing with them. Health and Safety Commission and give
advice on how to comply with the law. If
The `Further reading' section: you are prosecuted for a breach of health
V lists HSE and other publications which give and safety law, and it is proved that you
more detail on the subjects dealt with; have not followed the relevant provisions
of the Code, a court will find you at fault,
V provides information on other sources of unless you can show you have complied
help. with the law in some other way

V tips on good practice are indicated by

phrases such as `think about' and
`consider'

V the early sections deal with how to tackle

health and safety issues common to most
engineering workshops; later sections deal
with more specific activities which may
not be carried on in all workshops.
of

_
0
 MANAGING HEALTH AND SAFETY

Successful health and safety management in small engineering workshops is about identifying the
most frequent and serious risks and adopting the right precautions, taking account of time,
money and resources.

This book identifies how most serious accidents happen and how most ill health is caused in
engineering workshops.

If you use machines or processes which are not described in this booklet, see where they are
similar to those described and work out whether they pose the same hazards and whether the
precautions suggested would be right, as well as seeking further advice.

THE MANAGEMENT OF HEALTH AND SAFETY AT WORK REGULATIONS 1999 outlined

Employers must:
assess risks to the health and safety of their employees and non-employees arising in, or from, the workshop, and
review them when there is significant change. Records of significant findings of the assessment must be kept
where there are five or more employees

plan, organise, control, monitor and review the preventative and protective measures taken as a result of the
assessment

provide health surveillance where necessary (see page 20), for example to help control health risks from
metalworking fluids

appoint any competent person(s) needed to help them comply with legal obligations, for example, when having
lifting equipment thoroughly examined

set out what should be done in case of serious and imminent danger in the workshop, such as the spillage of a
large amount of degreasing solvent

tell employees about the risks and precautions involved in their work

train employees to work safely.

You may need help beyond that given in this book. If you do, trade and employer associations, such as EEF - The
Manufacturers' Organisation, the Manufacturing Technologies Association (for machine suppliers) or local
Chambers of Commerce, offer a range of advice and support. These sources of information are given on page 81.
HSE inspectors are always willing to help (see page 90 for HSE Office details).

Employers must also consult with all their employees (including self-employed workers classed as employed persons
under health and safety law) on health and safety matters. This will involve not only giving information but also
listening to and taking account of what employees say before any health and safety decisions are taken.

KEY REFERENCE: Management of health and safety at work

Approved Code of Practice L21 HSE Books 2000 ISBN 0 7176 2488 9
 HOW MOST ACCIDENTS AND CASES OF

.10
WORK-RELATED ILL HEALTH ARISE

Accident and ill-health data for such a wide 'Non-movement' accidents usually arise
and varied sector is available from a from the use of machinery; these account
number of sources, including published for between 10 and 15% of all accidents.
HSE material, research papers, industry
statistics, and trade association and trade Electrical accidents are not uncommon and
union publications, although it is difficult frequently have the potential for more
to see the whole picture. The interpret- serious injuries than those recorded.
ation of the available data in this booklet is
based upon the experience of health and The most common occupational diseases are
safety inspectors gained over many years dermatitis, deafness, asthma and vibration
in dealing with the sector. white finger, and back, hand, arm,
shoulder and neck problems.
ACCIDENTS AND ILL HEALTH
There are many thousands of accidents and In any particular workshop risks which
cases of ill health reported every year in are relevant should be assessed. Those
small engineering workshops. Almost two- likely to be of most concern include:
thirds of all such accidents reported to HSE V movement of people, goods and
arise from the movement of people, goods vehicles around the workshop,
and vehicles into, around and out of particularly manual handling
workshops. Of these `movement' accidents: V machinery safeguarding
V hazardous substances, particularly
V about half involve lifting and moving metalworking fluids, degreasing solvents,
goods, and and dust or fume from welding, brazing,
V about half involve slips, trips and falls soldering,coating and painting
and hitting stationary or moving plant V noise, and
and equipment. V vibration.

Injuries in engineering industries as reported to HSE's Field Operations Directorate

and, local authorities 1998/99 - 2000/01

Non-fatal
98/99 99/00 00/01 (provisional)
Total 15 267 15 078 14 668
of which main cause involved:.
0,.

Handling and carrying 5057 (33%0) 4955.(33%) 4842 (33%)

Being struck (eg by falling 2826 (19%) 2872 (19%) 2698 (18%)
objects, moving machinery)
Slippingr and tripping 2318 (15%) 2386 (16%) 2349 (16%)
Machinery 1778 (12%) 1734 (12%) 1641 (11%)
N

Falls from height 935 (6%) 950 (6%) 910 (6%)

Workplace transport 331 (2%) 331 (2%) 360 (2%)
N

COSTS
The costs of accidents and ill health to small engineering workshops may be disproportionately high.
Many employees are `key' workers whose loss through injury or ill health severely disrupts
production and lowers profitability.
 IF YOU WANT TO START CHECKING

100

non

130
CONDITIONS RIGHT AWAY USE THIS
INSTANT ACTION CHECKLIST
CHECK INSTANT ACTION LONG-TERM SOLUTION

Are fixed machine guards in Replace discarded guards and If fixed guards are being removed
position and secured? secure them by a fixing which for frequent access (more than
needs a tool to undo it. once per shift) replace with
interlocking guards.

Are interlocking guards fitted If not, restore or repair them. Start a programme of preventative

cad
and working? maintenance.

Are all work area and Keep all areas tidy and clean, Provide non-slip floor surfaces.
passageway floors in good and avoid trailing leads. Mark gangways. Train and instruct
condition, kept clear and free Repair holes in floors and
from tripping and slipping employees to keep workplace
hazards? clear up spillages. unobstructed.
Is anyone required to lift or Mark each load with its weight See how the job may be avoided.
carry heavy or bulky items and train all employees to lift Provide mechanical aids where
and equipment unaided? and carry safely. possible.

Are any employees suffering Get them to see their GPs and Try to remove the cause, eg
from dermatitis? provide suitable gloves if these redesign the work so that handling
won't add to risks at the source of contamination is
machinery. avoided.

Do metalworking fluids smell Replace with clean fluid, after Try to find and eliminate cause of
unpleasant, particularly after cleaning the machine and contamination.
a break from machining? sump.

Is there a visible fume mist Check existing controls and Prevent fume, mist, vapour or dust
or haze in the workshop? Is ventilation, remedy and, if from being generated or capture it
there much visible dust from necessary, improve general close to source before it can be
grinding, polishing or ventilation. breathed and remove it from the
blasting? workshop.

If you can't hear someone Make sure noise/machine Assess, remove, reduce or enclose
2 m away talking in a normal enclosures are closed and noise at source.
voice. hearing protection is being
worn.

Are vibration levels of hand- Check suppliers' data on Buy and use reduced-vibration
held tools as low as possible? vibration levels. Keep tools wherever possible.
equipment maintained.

If all vehicles (including fork- Ensure that all drivers on site Review all transport movements,
lift trucks) and pedestrians are properly trained and fork- including delivery and customer
are kept. lift truck operators authorised. vehicles. Consider one-way
Enforce speed limits and systems and clearly mark and sign
reduce the need for reversing, traffic routes.

L'J
 HOW TO USE THIS BOOK TO START
YOUR RISK ASSESSMENT

Here are some questions for finding out how dangerous or unhealthy your workshop might be,
and what to do about it.

GENERALLY IF THE ANSWER IS `YES'

Think about the times when people have been Investigate the possible causes further.
off work recently: The most likely ones are outlined in this
V Could their absences be put down to booklet.
conditions at work?
V Is there a pattern to any of them?
V Have the lessons of any recent accidents,
near misses or cases of work-related ill-
health been missed?
V Are there health or safety aspects of any
processes/operations you feel uneasy about?

THE WORKSHOP ITSELF

Are there any parts which are: See pages 8-9 for details of the standards
V dirty required.
V dark
V obstructed
V poorly ventilated
040

V unnecessarily wet, or
V otherwise dangerous or unhealthy to move
around or work in?

MOVING AND WORKING WITH

ARTICLES BY HAND;
LOADING/UNLOADING
MACHINES; ASSEMBLY AND
PACKING
Has anyone complained about or been off Complete the more detailed questionnaire
work with a bad back, or persistent hand, on pages 92-93 (for lifting) and pages 94-98
arm, shoulder or neck problems which (for handling). If you have problems, the
could be put down to work? solutions suggested on pages 12-17 may
help.
What about the loads being moved?
Are they too:
V heavy
V sharp
V large
V awkward
V hot or cold?
Does the job involve a lot of frequent,
forceful or awkward movements?
VEHICLES (INCLUDING FORK-LIFT IF THE ANSWER IS `YES'
TRUCKS) This may indicate too fast/careless driving or
Is there any damage to the workshop or plant a poorly laid out workplace and also
and machinery from vehicles? potential for injuries. Investigate further.
Do vehicles operate close to pedestrians?
Are vehicles required to reverse?
Does anyone use vehicles without being See pages 18-19 for advice on the selection
properly selected and trained? and training of drivers.
Are the conditions in which they operate too See pages 8-9 for the minimum standards
dark, obstructed, wet or otherwise dangerous? required for workshops.

METALWORKING -
MACHINING AND WELDING
Is it difficult to hear someone talking (in a Carry out a noise assessment - pages 38-42 tell
normal voice) 2 m away at any point in the you how to do this and make the most of it and
workshop? how to reduce and control excessive noise.
Is it possible to reach (DON'T TRY!) any See the individual machining sections of this
pressing, shearing, rotating, cutting or sawing booklet, pages 44-59, for advice on how to
tools especially when: loading/unloading guard machinery.
components; removing swarf; or making
adjustments?

Is there any visible fume, dust, mist or spray, or Viewing any suspected source with a strong
can it be smelt? light (eg a Tyndall beam or video light) behind
it will show where the fume is. See pages 20-22
on how to avoid or control harmful fume,
dust, mist and spray. See pages 99-100 for
guidance on checking the health of people
working with metal cutting fluids.
Do some operators frequently have to manipulate See pages 12-17 for advice on lifting and
or load/unload components which are too handling.
heavy, hot, awkward or sharp?
Do you machine, weld or work with See pages 20-22 for advice on how to control
components containing cadmium, lead, exposures to hazardous substances.
chrome or similarly hazardous substances?
Do employees complain about numb or tingling See page 43 for advice on how to deal with
fingers, `dead hands' on cold days or finger hand-arm vibration.
blanching.

CLEANING AND FINISHING

Do you use:
V a vapour degreaser? See pages 61-62 for how to maintain it and
prevent the need to get in and clean it.
V other means of degreasing? See page 60 for how to avoid and control
exposures to harmful cleaners.
Do you paint components, or use coating See pages 69-73 for how to avoid and control
powders? exposures to harmful substances in paints and
coating powders.
 FOR A LONGER LOOK,
TAKE 5 STEPS TO YOUR RISK ASSESSMENT

The Five Steps

V Look for the hazards
V Decide who might be harmed and how
V Evaluate the risks and decide whether precautions are adequate or more should be done
V Record your findings
V Review you assessment from time to time and revise it if necessary

Using the information on the preceding pages and the rest of this booklet, identify:

POSSIBLE HAZARDS (CHANGE AND/OR WHO MIGHT BE HARMED

INSERT YOUR OWN AS NECESSARY)

HANDLING

TRANSPORT and
VEHICLE MOVEMENTS

METALWORKING
FLUIDS

CLEANING and
DEGREASING
SOLVENTS

MACHINERY
(including setting
and maintenance)

WELDING PROCESSES and MATERIALS

NOISE

VIBRATION
 YOUR RISK ASSESSMENT CONTINUED

The Five Steps

V Look for the hazards
V Decide who might be harmed and how
V Evaluate the risks and decide whether precautions are adequate or more should be done
V Record your findings
V Review you assessment from time to time and revise it if necessary

WHETHER EXISTING WHAT MORE NEEDS TO DATE OF THE NEXT

<-I
MEASURES ARE BE DONE REVIEW
ADEQUATE

KEY REFERENCE: 5 Steps to risk assessment INDG163(revl)

(single copy free or priced packs of 10 ISBN 0 7176 1565 0)

r1
L"J
WORKING IN AND MOVING AROUND THE WORKSHOP
About two thirds of all accidents in small engineering workshops happen during the movement of
vehicles, people and goods. A safe, well-lit, clean workplace can help prevent many of these.

WORKPLACE (HEALTH, SAFETY AND WELFARE) REGULATIONS 1992 and

APPROVED CODE OF PRACTICE outlined

A safe place of work Safe movement

You must have: You must have:

buildings in good repair safe passage for pedestrians and vehicles - you may
precautions such as fences or rails to stop people or need separate routes
materials falling from open edges* level, even surfaces without holes or broken boards
space for safe movement and access, eg to handrails on stairs and ramps where necessary
machinery safe doors, eg vision panels in swing doors
safe glazing where necessary, marked to make it surfaces which are not slippery
easy to see well lit outside areas.
floors, corridors and stairs free of obstruction
good drainage at wet processes such as washing Workstations
and cleaning Work stations and seating must fit the worker
windows that can be opened (if openable) and and the work. Make sure that:
cleaned safely. They should be designed to stop back rests support the small of the back and foot
people falling out or bumping into them when rests are provided where necessary
open. You may need to fit anchor points if window work surfaces are at a sensible height
cleaners have to use harnesses. there is easy access to controls.
outdoor routes kept safe during icy conditions, eg
salted/sanded and swept. Cleanliness
You must:
provide clean floors and stairs, which are drained
where necessary and not slippery
provide clean premises, furniture and fittings
provide containers for waste materials
remove dust, refuse and trade-waste regularly
clear up spillages promptly
keep internal walls/ceilings clean. They may need
painting to help easy cleaning.

*particularly on the flat roofs of offices provided in small industrial units, which are often used for storage; proper
stairs should be provided for frequent access to these areas

MAINTENANCE
Maintaining the workshop and the equipment in it may pose different hazards from those encountered in the normal run of
production work. Contractors as well as your own employees may be at increased risk, particularly during the repair and cleaning
of plant containing toxic, flammable or hazardous materials, machinery and during work at heights or in confined spaces.

KEY REFERENCE: Workplace health, safety and welfare Approved Code of Practice and Guidance
on Regulations HSE Books ISBN 0 7176 0413 6
 LIGHTING
Poor lighting is often a factor in accidents and can also increase visual fatigue.

THE LAW* ON LIGHTING outlined

You must provide:

good light - use natural light where possible but try to avoid glare
a good level of local lighting at work stations where necessary
suitable forms of lighting (fluorescent tubes operating at mains frequency may be dangerous with rotating
machinery when the rotating part can appear to have stopped)
special fittings for flammable and explosive atmospheres, eg in spray booths, to reduce risks of ignition and explosion.

* Workplace Health, Safety and Welfare Regulation 1992

Problems Typical activity Average illuminance Minimum measured illuminance

lux (lx) in work areas (lx) at any point or a suitable place

General hazards from the General work in the 100 50

movement of people, workshop, assembly of

machines and vehicles in and large components
around the workshop and
visual fatigue from work
requiring limited perception of
detail

Visual fatigue from work Sheet metal work, 200 100

requiring perception of detail general machining,

office work

Visual fatigue from work Drawing office work, 500 200

requiring perception of fine assembly of electronic

detail and other fine
components

Avoid:
V large differences in the lighting of adjacent areas
V glare from direct sunlight by providing blinds, for example, and from directly visible lamps by
excluding them sufficiently from lines of sight when necessary
V strobe effects by:
supplying adjacent runs of light fittings from different phases
providing a high frequency supply
washing out the effect with local tungsten filament lighting
if high intensity tungsten halogen or mercury lamps are used to provide local lighting,
manufacturers' filters should always be kept in place.

For the electrical safety of lighting systems see pages 23-27.

KEY REFERENCE: Lighting at work HSG38 1997 HSE Books ISBN 0 7176 1232 5
 GENERAL VENTILATION, TEMPERATURE
AND TOILETS

Fans and/or additional air inlets (at low level) THE LAW ON TOILETS AND WASHING
and outlets (at high level) may be needed FACILITIES outlined
in workshops where there are no means of
ventilation other than air leaking in and You must provide:
out (particularly in units on some factory suitable and sufficient (and adequately ventilated
estates) and where: and lit) sanitary conveniences and (nearby)
washing facilities kept clean and orderly, in the
work generates hazardous minimum numbers outlined below
airborne pollutants separate rooms for men and women, except where
workshops have been sealed to they are for the use of one person and are capable
conserve energy. of being secured from the inside
hot and cold, or warm water with means of
Provide at least cleaning and drying.

cad
Five litres/second per occupant (eight is
recommended for comfort) and air
movement in the workshop of at least 0.1 No of people No of WCs
to 0.15 metres/second. in workshop and wash stations
1-5 1

Measure velocities, using specialist help if 6-25 2

needed, at inlet ducts (to calculate air 26-50 3
flows inwards) and inside the workshop 51-75 4
(to calculate air movements). 76-100 5
Alternatively, for sanitary accommodation used
THE LAW ON TEMPERATURE outlined only by men, the following numbers are
recommended:
You must provide:
a reasonable temperature and a thermometer No of No of WCs No of
inside workshops. men urinals
1-15 1 1

The temperature should be at least 160C unless work 16-30 2 1

involves severe physical effort, in which case the 31-4S 2 2

minimum should be 130C. 46-60 3 2

61-75 3 3
76-90 4 4
91-100 4 4
Make separate calculations where groups such as
office workers have separate accommodation.

KEY REFERENCE: Workplace Health, Safety and Welfare Regulations 1992

Approved Code of Practice and Guidance on Regulations L24 HSE Books ISBN 0 7176 0413 6
 PB

LIFTING EQUIPMENT

Although lifting, supporting and handling THE LAW* ON LIFTING EQUIPMENT outlined
equipment can lighten the load of manual
handling when properly used, many The same regulations now apply to all lifting
accidents happen when loads are dropped equipment, which includes any equipment used at
from lifting equipment, either because of work for lifting or lowering loads, and lifting
poor slinging, or equipment failure or accessories such as chains, slings, eyebolts etc.
overloading.
You should ensure that:
Always: lifting equipment is sufficiently strong, stable and
V maintain all lifting equipment, including suitable for the proposed use, and marked to
that used only occasionally, such as indicate its safe working load;
attachments to fork lift trucks
V train all users, particularly in the use of lifting equipment is positioned or installed to
slings where necessary minimise the risk of injury, eg from the equipment
V plan lifts in advance or the load falling or striking people;
V ensure that the weight and the distribution
of any load is not beyond the capacity of every part of a load (including, for example, pallets
the equipment being used and stillages) and anything attached to the load
V provide safe places of work from which to and used in lifting (including for example the
maintain hoists and lifts, particularly at lifting points on skips) is of adequate strength;
heights; do not allow overhead travelling
cranes to work within 6 m of persons on lifting operations are planned, supervised and
crane tracks carried out in a safe manner by people who are
V check the condition, type and size of any competent;
eyebolts used and ensure that the thread
type matches the hole into which it is to be lifting equipment (including accessories) is
screwed. thoroughly examined for any defect before it is put
into service for the first time (unless it is new and
is covered by an EC declaration of conformity
which is less than 12 months old). Where the safety
of lifting equipment depends on installation
conditions, it must be thoroughly examined after
installation and before being put into use for the
first time. Periodic thorough examinations are also
required at six-monthly intervals for accessories
and equipment used for lifting people, and at least
annually for all other equipment; or at intervals
laid down in an examination scheme drawn up by
a competent person.

* Lifting Operations and Lifting Equipment Regulations 1998

KEY REFERENCE: Safe use of lifting equipment: Lifting Operations and Lifting Equipment
Regulations 1998 L113 HSE Books ISBN 0 7176 1628 2
 MOVING GOODS SAFELY BY HAND

The unsafe movement of goods by hand, Sharp edges

'"J
either by lifting or handling causes more These cause as many as a third of all

.'1
accidents and ill health in small accidents in some engineering workshops,
engineering workshops than any other resulting in cuts, abrasions, infected
single activity, especially to those most at wounds, dermatitis, amputations and

'ate

.ti
risk, including the younger more occasionally fractures.

r°=
inexperienced employees, the older and/or
less physically fit, and those who may Those working with sheet metal, either flat
make an existing injury worse. or coiled, heavy sharp items, such as tools
and cutters, and scrap metal and swarf are
Back injuries are very common as are hand, most at risk.
arm, shoulder and neck injuries,
particularly from unsafe, highly repetitive Consider how to avoid handling sharp
work. Cuts and abrasions from sharp edges, and if this is not reasonably
edges are also very numerous. practicable, reduce exposure to them.

MANUAL HANDLING OPERATIONS Reducing the risks

REGULATIONS 1992 outlined V Ask your supplier to remove or protect
om,

sharp edges, eg by machining out sharp

Employers must: edges or fitting plastic covers or padding.
avoid the need for hazardous manual lifting and
handling if reasonably practicable V Remove sharp edges or protect them
assess the risk of injury from any hazardous before handling.
manual lifting and handling which cannot be
avoided; and V Avoid handling by using, for example,
reduce the risk of injury accordingly. trays, jigs, holders or baskets.

Employees must: V Minimise handling by automating

follow safe systems of work laid down processes by using, for example,
by their employers conveyors, feed and discharge
1, use mechanical aids provided by their chutes.
employers properly
remember to use the training
provided on lifting.

Use personal protective

equipment such as gloves,
gauntlets and aprons, but
only where these do not
add to other risks from
machinery, such as
entanglement.

0
KEY REFERENCE: Manual Handling Operations Regulations 1992
Guidance on Regulations L23 1998 HSE Books ISBN 0 7176 2415 3

12
 HOW TO LIFT SAFELY

Here are some important points, using a basic Try to keep the arms within the boundary
lifting operation as an example. formed by the legs. The best position and
type of grip depends on the circumstances
Plan the lift. Where is the load to be placed? and individual preference; but it must be
Use appropriate handling aids if possible. secure. A hook grip is less tiring than
Do you need help with the load? Remove keeping the fingers straight. If you need to
obstructions such as discarded wrapping vary the grip as the lift progresses, do it as
materials. For a long lift, such as floor-to- smoothly as possible.
shoulder height, consider resting the load
mid-way on a table or bench in order to Keep close to the load
change grip. Keep the load close to the trunk for as long as
possible. Keep the heaviest side of the load
Position the feet next to the trunk. If a close approach to
Feet apart, giving a balanced and stable base the load is not possible, slide it towards
for lifting (tight skirts and unsuitable you before trying to lift.
footwear make this difficult). Leading leg
as far forward as is comfortable. Lift smoothly, keeping control of the load.

Adopt a good posture Don't twist the trunk when turning to the side.
When lifting from a low level, bend the knees.
But do not kneel or overflex the knees. If precise positioning of the load is necessary,
Keep the back straight (tucking in the chin put it down first, then slide it into the
helps). desired position.

Lean forward a little over the load if necessary TRAINING FOR LIFTING AND HANDLING
to get a good grip. Keep the shoulders This should cover:
level and facing in the same direction as V how to recognise harmful manual
the hips. handling
.f'

V appropriate systems of work

V use of mechanical aids
V good handling technique.

(d) Pull the load in

close to your body

(a) Plan the lift

(b) Determine the best
lifting technique

(c) Get a secure grip

13
 LIFTING AND HANDLING
Assessing risks
Assessment Job
Some of the important
questions to ask

Loading/unloading
--ON-
Job: Too high to lorries/vans by hand
lift/lower?
Too rushed?
Too far to carry? '
Too repetitive?
Too much twisting
involved? Moving materials
to/from machines

Load: Too heavy?

Too large?
Too unstable?
Too hot/cold?
Too sharp?
f,
.&
- Sorting/counting
components

Too difficult to
grasp? ! a, o
Loading/unloading
machines
Work area: Too dark?
Too slippery?
Too obstructed?
Too many steps?

Assembling and
MMO-
packing

Individual: Fit for the job?

In need of special
consideration or
training? Preparing,
maintaining, moving
and repairing
machinery

14
 Taking action
Short-term action Long-term solution

Provide help for heavy Palletise load(s). Use fork lift

loads. Use the right trucks
person for the job

Break down loads into Use conveyors/hoists/fork lift

easily handled trucks
units/containers

Use appropriate trained, Ask suppliers to pre-sort

fit, personnel before delivery. Weigh instead
of count. Automate sorting

Raise stillages/bins to Automate load/unload

right height/position/ operations. Use hoists and/or
mechanical aids
9

Use appropriate fit, Provide good working

MMOP-
trained, personnel at the environment, well lit and
right place. Rotate the appropriate mechanical aids
work to prevent too and tools to do the work
much repetition without undue strain. `Design
out' the need for manual
assembly and packing

Use appropriate fit, Provide unobstructed access

trained personnel and mechanical aids as
necessary
 ERGONOMIC MACHINE OPERATION,
ASSEMBLY AND PACKING

TO MINIMISE RISKS Most ILL HEALTH arises from:

V avoid applying too much force for too long V prolonged forceful or repetitive gripping,

4rOv
or too frequently using an awkward twisting, reaching or other movement
posture of the hand, wrist or arm. without enough rest or recovery. This
causes pain, a restriction of joint
CONSIDER movement and soft tissue swelling, leading
REDUCING THE FORCE INVOLVED sometimes to permanent disability, mostly
by, for example: in the hands, arms and shoulders
V keeping cutting tools sharp
V providing a larger gripping area V lifting and handling goods unsafely by
V supporting tools by means of balancers or hand.
tensioners (which may also help minimise
vibration)

A modified handle design can lead to a more comfortable hand position

REDUCING HIGHLY REPETITIVE

MOVEMENTS by, for example:
V restructuring jobs so they contain more
varied work
V automation

REDUCING THE NEED FOR AWKWARD

POSTURES by, for example:
V changing the orientation of the part being
worked upon to enable the wrist to be straight
V moving the operator so work is more
comfortable

TRAINING IS VITAL, particularly: Consider workstations where both standing

T to prevent the repetition of old, bad ways of and sitting is possible. In general it is less
working physically stressful to sit, provided there
V to protect newer employees from working too are opportunities for moving around.
quickly too soon

KEY REFERENCE: Upper limb disorders in the workplace

HSG60 HSE Books ISBN 0 7176 197S 8

16
 ERGONOMIC ASPECTS TO FOR PROCESS OR ASSEMBLY WORK
CONSIDER arrange the work in a semi-circle
FOR OPERATING MACHINERY provide a swivel chair
V make frequently operated hand controls bring the work to the worker
easy to reach and work consider chairs with forward- tilting seats
V if seats are provided leave sufficient room and backrests to help workers reach
for knees and legs further without loss of support, and
avoid bending and twisting to load/unload consider work surfaces and component
machines by having material/bins on racks trays which slope towards the worker
which can be raised and lowered to keep racks for material and finished items
them at waist height should be adjustable so that work is
consider 'lean-on' or 'sit-stand', wheeled, comfortable to reach and put away.
sliding, suspended or fixed seats
see
LI page 76 for
normal
chairs.

FOR PRECISION WORK

To avoid tense postures, a forward tilting
seat and a work surface which slopes to
the worker may be particularly helpful
Foldaway seat

Zone of
400

400

convenient
reach
300

300

Normal
200

200

working
area
100

100

100 0 100

Horizontal reach -
distances in millimetres

KEY REFERENCE: Seating at work HSG57 1997

HSE Books ISBN 0 7176 1231 7
 MOVING VEHICLES SAFELY

Lorries, vans, cars and other vehicles and V Do not allow untrained drivers to drive
mobile plant are involved in many vehicles
accidents, when reversing and manoeuvring V Avoid reversing (eg by suitable traffic
in or around small workshops. These routing for example) or provide help for
accidents cause injuries and occasionally reversing drivers if possible (eg a guide)
deaths when victims are run over or Use speed bumps to limit traffic speeds
crushed. where necessary and make sure there are
gaps for any lift trucks which have to cross
To reduce risks: them
V Identify and clearly mark safe routes and V Select and train your own drivers with
locations for deliveries and despatches care.
which are:
LOADING AND UNLOADING
away from pedestrians as much as VEHICLES
possible Accidents frequently happen when people fall
in good condition from vehicles. Avoid the need to climb on
well lit at all times when being used loads (by using curtains on the sides of
away from vulnerable plant vehicles or mechanical or proprietary
marked clearly with suitably low speed sheeting systems), or provide safe access
limits. and safe systems of work. If it is necessary
to walk on the top of high loads, safety
V Provide loading bays with an lines and harnesses should be provided and
exit from low level or a refuge worn.
to prevent crushing STOP

Right Left

Move away Move towards

KEY REFERENCE: Workplace transport safety HSG136 HSE Books ISBN 0 7176 0935 9
Managing vehicle safety at the workplace INDG199 HSE Books (single copies free)
 LIFT TRUCKS

HOW MOST ACCIDENTS HAPPEN APPROVED CODE OF PRACTICE ON

Lift trucks, (powered and non-powered, RIDER OPERATED LIFT TRUCKS -
pedestrian and rider-operated,) are involved OPERATOR TRAINING outlined
in many accidents in small engineering Employers to provide basic training by
workshops. These are frequently caused by recognised instructors
reversing unsafely, speeding, overloading, Trainees to pass a test of their competence
carrying passengers or lifting personnel the Records to be kept of training.
truck was not designed for, or drivers not
being trained, and result in many serious
injuries and some deaths every year when S A F E L I F T T R U C K
victims are run over or crushed. O P E R A T I O N

Most ILL HEALTH arises from: Get the right truck for the job
V using diesel trucks in enclosed confined Maintain all lift trucks regularly in
working areas, leading to breathing problems accordance with the manufacturer's
V poor seating and controls leading to back instructions, ensure seats are maintained to
and upper limb disorders minimise unhealthy postures and vibration
V poor roadways which may cause vibration Select only suitable personnel for training as
leading to back problems. operators/drivers, authorise operators/drivers
in writing
THE LAW* ON MOBILE WORK EQUIPMENT outlined Avoid routes near vulnerable plant, eg
flammable liquid stores, or protect such plant
mobile work equipment includes fork lift trucks and Segregate busy lift truck areas/routes from
any other work equipment which carries out work pedestrian and working areas as much as
while it is travelling or which travels between different possible, pay particular attention to
locations where it is used to carry out work. barriers, layout, visibility, lighting and
Los

where mobile work equipment is used for carrying warnings where lift trucks and people work
people, it must be suitable for this purpose. alongside each other; enforce rules for low
Measures must be taken to reduce the risks to the speed and safe reversing
safety of people being carried, the operator, and Ensure operating surfaces are strong enough,
anyone else. These include measures to reduce the well maintained and gradients are not too steep
risks from equipment rolling over (most counter- Train all employees on lift truck movements,
balanced, seated centre-control fork lift trucks if the lift truck is used on the road (to load
have a vertical mast which prevents them rolling and unload, for example) provide a second
more than 900 ). Measures, such as fitting person to help with traffic, as necessary
restraining systems, eg seat belts, must also be Rider operated lift trucks used regularly
taken to reduce the risk of anyone being crushed on the road for long periods, and their
between any part of the equipment and the ground drivers, must be licensed by the
if it rolls over or overturns. Department of Transport
you must ensure that self-propelled work equipment Keep keys secure when trucks not being
(ie work equipment which is propelled by its own motor used
mechanism) has appropriate facilities to ensure the Do not use forks, pallets or bins to lift
safety of people in the workplace, including facilities for persons to work at heights unless these are
preventing its being started by an unauthorised person. suitably modified; use properly designed
* Provision and Use of Work Equipment Regulations 1998 mobile work platforms if possible.

KEY REFERENCE: Rider operated lift trucks - operator training L117 HSE Books
ISBN 0 7176 2455 2; Safety in working with lift trucks HSE Books 2000 ISBN 07176 1781 5

19
 CONTROLLING HAZARDOUS SUBSTANCES

Exposure to hazardous substances most The most common health effects from
frequently occurs when: hazardous substances are:
V skin diseases such as dermatitis from
V machining (see page 30 for general control of metalworking fluids and oils
hazardous substances and pages 36-37 for the V lung problems, such as asthma, from
control of metalworking fluids) isocyanate paints and glues
V welding (see page 63) V poisonings, such as lead poisoning, and
V painting (see page 69) and V very rarely cancer, such as skin cancer
V cleaning and degreasing (see page 60). from certain mineral oils.

The control of dust, fume, spray and vapour- and THE CONTROL OF SUBSTANCES
the prevention of skin contact by adequate HAZARDOUS TO HEALTH REGULATIONS
personal protection - will minimise risks of outlined
adverse health effects, but pay particular
attention to precautions when machining, You must:
welding, polishing or grinding: assess risks to health
prevent exposure, for example by using
V nickel-copper and nickel-chrome alloys (found a less hazardous substance
in coins, magnets, chemical and food process a different process
equipment and in the aerospace industry) where prevention is not reasonably practicable,
V stainless steel and nickel alloys; stainless steel control exposure by, for example, isolating or
and chromium alloys enclosing the process or, if this is not reasonably
V lead and lead alloys practicable, local exhaust ventilation, and
V copper alloys containing beryllium (commonly where prevention or control is insufficient on its
found in the electrical industry and in high own, provide personal protective equipment
definition tools and dies - used, for example, in inform, instruct and train employees
plastic injection moulding machines) carry out air monitoring and health surveillance
V cadmium-plated articles. where necessary.

THE HEALTH AND SAFETY AT WORK ETC ACT

1974, SECTION 6 IN RELATION TO THE SUPPLY A hazard may be defined as something that
OF SUBSTANCES FOR USE AT WORK outlined can cause harm - such as the chemicals in a
tin of paint - while a risk may be seen as the
Suppliers must: chance of harm actually being done - which
ensure so far as is reasonably practicable that the can vary with how the paint is actually
substance will be safe and without risks to health used; spraying in an uncontrolled
provide adequate information about any risks to environment without personal protection
health or safety to which the inherent properties could pose high levels of risk.
of the substance may give rise.

Labels and safety data sheets supplied with

hazardous chemicals contain important
information about hazards (see CHIP
reference page 84) to help you use them
safely.

KEY REFERENCE: Control of Substances Hazardous to Health Regulations 2002. Approved

Code of Practice and guidance L5 (Fourth edition) HSE Books 2002 ISBN 0 7176 2534 6
 LOCAL EXHAUST VENTILATION (LEV)

SELECTION AND USE THE LAW* ON MAINTENANCE,

LEV is a frequently used way of controlling EXAMINATION AND TESTING OF LEV outlined
exposure to hazardous substances by
drawing them away from the breathing In most small engineering workshops, employers
zones of workers into a hood and ductwork must ensure that thorough examinations and tests
connected to an extract fan. are carried out:
every 14 months for most processes
In many circumstances LEV may be cheaper every six months where metal articles are abraded
and more effective than dilution or polished for more than 12 hours a week.
ventilation. (Dilution ventilation works by
introducing fresh air into the workplace to Employers must also keep appropriate records for at
lower the general level of the hazardous least five years.
substances in the air).
See Appendix 6 for details which should be recorded.
Heat losses from LEV may be minimised by
heat recovery systems or recirculation of * Control of Substances Hazardous to Health Regulations, regulation 9

filtered air, but the latter only after

specialist advice to prevent the Someone with sufficient training, knowledge,
recirculation of hazardous materials in skills and experience is required for the
harmful quantities. maintenance, examination and testing of
LEV, and insurance companies frequently
have the competence required.

To make the most of LEV

Get an expert to design and install the
most appropriate system, with the right
hoods/enclosures, ductwork, air velocities
and cleaning and filtration systems

V Make sure partial enclosures are

large enough to contain the work
and that sprayers do not stand
between the workpiece and point
of extraction; consider a turntable
for heavy items

LEV used to help draw welding fume from the

breathing zone of a welder

( 21
 %J%

LOCAL EXHAUST VENTILATION (LEV)

V Check and maintain the system, V damaged and/or blocked ductwork

regularly particularly flexible
ductwork V blocked, damaged, unsuitable or
incorrectly installed filters
V Provide sufficient lighting (suitably
protected) within the enclosure to V too high/low water levels in wet collectors
encourage work to be done within the
extracted area. V wear or corrosion of fan blades leading to
build up of contaminant on blades
Common causes of LEV failure, which you can
check easily and frequently yourself to V slipping drive belts to fans
keep it working properly include:
V poor lubrication of fan bearings.
V physical damage to and poor positioning of
hoods and booths It helps to keep a record of these checks.

Spraying in the direction of exhaust ventilation air

movement; a turntable can help a sprayer avoid standing
between the item being sprayed and the point of air
extraction from the booth

KEY REFERENCE: Introduction to local exhaust ventilation HSG37

HSE Books ISBN 0 7176 1001 2

22
 ELECTRICITY

HOW MOST ACCIDENTS HAPPEN PRECAUTIONS necessary to prevent

V Most accidents arise from contact with live accidents require everyone in the
conductors or equipment made live by workshop (including the self-employed) to
faulty wiring and connections. use equipment safely and co-operate with
the employer where necessary.
V Equipment using 240v AC may be as
dangerous as that using 415v AC, Employers in particular need to:
depending on circumstances. V develop a suitable system of maintenance
for both fixed installations and portable
Each year, the use of electricity causes fatal equipment - advice from a competent
and other injuries (eg burns) from electric person may be required
shock and fire.
V ensure that electrical contractors are
THE LAW* ON `LIVE' ELECTRICAL WORK competent for the work they are expected
outlined to do; for example, are they registered with
such organisations as the National
No electrical work should be carried out `live' where Inspection Council for Electrical
there is a possibility of contact with a potentially Installation Contracting or equivalent?
dangerous live conductor unless:
V select equipment which is suitable for the
it is unreasonable in all the circumstances job (using reduced low-voltage equipment
for the equipment to be dead; and lowers the risk of serious injury)
it is reasonable in all the circumstances
for the work to be carried out on or near V check that wiring and equipment is sound
it while it is live; and and properly installed, especially so that
suitable precautions (including, where protection equipment such as fuse and
necessary, suitable protective equipment) switchgear will operate adequately in the
have been taken to prevent injury, such case of faults. Universally accepted
as proper work planning and the use of standards are described in BS 7671
adequately trained and supervised staff. Requirements for electrical installations

* See Key Reference V ensure any electricians working for you are
competent. Levels of qualification
established by the Electrical Joint
Industries Board may be of help here, but
check that qualifications are relevant; a
fully qualified TV technician may not be
competent to re-wire a building.

KEY REFERENCES: Memorandum of guidance on the Electricity at Work Regulations 1989

HSR25 HSE Books ISBN 0 7176 1602 9; Electrical safety and you INDG231 (single copies free)

23
 PORTABLE ELECTRICAL EQUIPMENT

Use this list to check whether you are managing the risks from
portable electrical equipment. Have you:
prepared and implemented a system of maintenance for portable (and transportable)
electrical equipment

made sure that all items of portable electrical equipment are included in the maintenance
cad

system

decided how to deal with `unauthorised' equipment brought in by employees, eg portable,

mains-operated radios

collected information on where and how equipment is used. This information will help you
decide what sort of checks/inspections/tests are required and at what frequencies

it provided straightforward training and information for all users (including yourself) to help
them carry out user checks when equipment is used

made sure that all equipment receives a formal visual inspection at appropriate intervals,
cad

carried out by someone who has been trained in what to look for

considered preparing brief written guidance relating to visual inspection, what to look for,
and procedures to follow when faults are found (and when unauthorised equipment is found)

identified equipment which will need periodic combined inspection and testing

established how often combined inspection and testing is appropriate (based on the type of
equipment, how it is used, where it is used and the results of any previous
checks/inspections/tests)

appointed someone with the appropriate knowledge, training and experience to carry out
the inspection and testing

reviewed the results of checks/inspections/tests to identify any common trends and to

confirm that the chosen inspection/test frequencies are appropriate

made sure that the arrangements which you have made are being put into practice and that
follow-up action is being taken?

REMEMBER THAT CHOOSING THE RIGHT EQUIPMENT AND CARRYING

OUT VISUAL INSPECTIONS ARE PERHAPS THE MOST IMPORTANT WAYS
TO MINIMISE THE RISKS.

24
 ACTIVITY PREFERRED EQUIPMENT

Work inside metal tanks which may be Use pneumatic power tools. Lighting, if
damp or humid (through condensation, for essential, should be 25V dc CTE* max and
example) fixed out of reach.

Use equipment operating at voltages of 50V

*Work on apparatus where water may be ac, 120V dc or less. Higher-voltage
present (on a metalworking fluid equipment should be built to waterproof
circulation system on a machine tool) standard, eg BS EN 60529: 1992
Specification for degrees of protection
provided by enclosures. The supply to
Work in close contact with metalwork in earthed equipment should incorporate
cool dry conditions back-up protection which automatically
disconnects the supply in the event of a
fault, preferably earth monitoring.
Ad hoc maintenance work and outside
work in good weather Use equipment operating at voltages of 50v
ac, 120v dc or less (110v ac CTE may be
used in conjunction with all-insulated or
double/insulated tools). Frequent cleaning
of ventilation louvres is necesary.

Reduced low-voltage equipment is

preferred such as 110 volt CTE.

* CTE: centre tapped to earth

KEY REFERENCE: Maintaining portable and transportable electrical equipment

HSG107 HSE Books ISBN 0 7176 0715 1

25
 COMMON PROBLEMS WITH
FLEXIBLE LEADS, THEIR PLUGS AND SOCKETS
AND HOW TO AVOID THEM
Many accidents causing burn and shock injuries which are sometimes fatal
arise from poorly maintained and damaged leads, plugs and sockets.

PROBLEM PRECAUTION

Failure to select the right equipment for the Choose the right equipment. For example
job/environment in a heavy fabrication shop, armoured,
heat-, oil- and fire-resistant leads will
often be necessary. Select reduced low
voltage equipment (110V AC CTE max)
whenever possible.

Failure to give adequate support to suspended Use a wire or chain to relieve the cable of
cables (such as on pendant control leads for tension.
overhead cranes)

Poor joints in cables Replace cables rather than repair them,

particularly. those used for a long time, or
for short lengths when the cost of repair
may, be more than replacement; for longer
lengths cut off the damaged part if it is
close to an end or use a proprietary plug/
socket which provides both electrical and
mechanical protection for cables. (If a
coupler is used the socket must be on the
supply side and the plug on the cable
connected to the apparatus.)

Repairs should be carried out only by

competent personnel; insulation and
sheath damage can be repaired by
vulcanising or using compatible
proprietary self-sealing material together
with a heat shrinkable plastic sleeve to give
the finished joint necessary insulating
value, strength and waterproofing.
Insulating tapes alone are unsatisfactory.

Leads trailing too long may prevent circuit Provide more convenient sockets, closer to
protection from operating within designed work.
limits
Where liable to damage, for example in a
Cables and conductors insufficiently protected busy area, re-route or provide a suitable
and liable to damage cover, eg a conduit.

26
 PROBLEM PRECAUTION

Cables and conductors too often flexed, which Check regularly, especially where the cable
may cause damage to the insulating sheath or is terminated into the apparatus concerned,
conductor and repair or replace as necessary.

Damage to cables and conductors by portable Secure leads as far as possible out of harms
equipment suchas soldering irons and way, where risk of damage is minimised.
portable grinders

Arcing when plugs withdrawn on load Above 16A provide a switch (interlocked
with plug if possible) to enable currents
to be safely broken before withdrawing
plug.

Weight and leverage of adaptors Do not use adaptors or other plug-in

damaging socket outlets devices where their weight and leverage
may damage socket outlets. Provide
sufficient socket outlets or, if necessary, use
purpose made, portable multi-socket
outlets.

Failure of plug cord grips Ensure that it is the sheath which is being
gripped not the conductors; do not remove
plugs by pulling leads.

Use the correct type of plug (particularly

for armoured lead). Consider heavy-duty
industrial plugs. Ensure it is terminated as
per the manufacturer's instructions.

Loss of securing screws for plugs Check them regularly, and replace missing
ones.

Screened and armoured flexible cables Secure the whole cable using purpose-
incorrectly terminated in smaller portable made glands/termination fitted by a
equipment skilled person where necessary.

Overheated extension lead drums Unwind lead from drum completely before
use.

27
 PRESSURISED PLANT AND SYSTEMS

THE LAW* ON PRESSURISED PLANT AND INJECTION INJURIES

SYSTEMS outlined Injuries, occasionally fatal, may be caused
by accidental or deliberate injection of
All plant and systems must be designed, material and/or compressed air either
constructed and installed to prevent danger through the skin or into a body orifice
Systems must be properly maintained Ordinary working clothes do not
Modifications or repairs must not cause danger significantly resist the penetration of
There must be a written scheme for examination compressed air into the body
of certain pressure vessels, such as air receivers, High-pressure fluid guns may inject
steam boilers, fittings and pipework, drawn up by material at 3-7000psi and cause serious
a competent person injuries. Care should be taken to avoid
Examinations as set out in the written scheme accidental injections
must be carried out by a competent person `Horseplay' should be strictly forbidden
Records must be kept in most cases Because the degree of injury may not
always be immediately apparent, medical
advice should always be sought after
PRESSURE TESTING compressed air penetration occurs or is
Accidents, some fatal, occur during suspected.
pressure testing when the energy
contained in the vessel under test is
released with explosive force
Wherever practicable, avoid using
compressed air, steam or gas (which
contains more than 200 times the energy
of water of the same volume)
Use hydraulic (liquid) pressure with
suitable precautions and always, if
possible, before leak testing (using air,
steam or inert gas) components not
intended as pressure vessels, eg vehicle
fuel tanks, radiators, small castings,
storage tanks and oil drums

KEY REFERENCE: *Safety of pressure systems. Pressure Systems Safety Regulations 2000.
Approved Code of Practice HSE Books ISBN 0 7176 1767 X
Compressed air safety HSG39 HSE Books ISBN 0 7176 1531 6

28
 MACHINING

HOW MOST ACCIDENTS HAPPEN Most ILL HEALTH arises from:

Most accidents at all types of machine, V unsafe loading/unloading and handling of
including automatic and CNC machines, components, in particular when highly
happen to operators during normal repetitive, which may cause back injuries
operation when: and upper limb disorders
V loading/unloading components V skin contact with metalworking fluids, for
V removing swarf example when preparing fluids or handling
V taking measurements and making components, which may cause skin
adjustments (to the coolant supply in irritation and dermatitis
particular). V breathing in aerosols, oil mists and fumes
from metalworking fluids during
On manually operated machines, the most machining which may cause irritation of
dangerous machine movements are the the eyes, nose and throat, and occasionally
rotating, cutting, shearing, sawing or breathing difficulties such as bronchitis
pressing movements of tools, particularly on: and asthma
V presses V sharp edges and swarf which may cause
V drilling machines cuts which exacerbate dermatitis
V milling machines V high noise levels which may cause deafness
V lathes most frequently at machines which
V metal cutting saws generate impacts when operating, higher
V guillotines and speed machines or groups of machines
V grinding machines. running together
V vibration, particularly when grinding.
Hands are most frequently injured, the most
numerous injuries being cuts and
abrasions, many of which are severe.
Broken bones and dislocations are
numerous. Amputations of fingers and
hands are not infrequent and there are
some fatalities, often arising from
entanglements, every year. Eye injuries are
also common.

On automatic and computer controlled

machinery, a larger proportion of
accidents happens at automatically and
computer controlled clamps, axes, tables,
swarf removal equipment, chucks and
other work handling equipment.

At all types of machinery a large number of

accidents happen to setters, electricians
and maintenance personnel during set-up,
inspection, fault-finding, maintenance and
repair.

29
 JJ

MACHINING
GOOD PRACTICE

SAFETY MEASURES TRAINING ESSENTIALS

To prevent access to dangerous movements Operators should know:
during batch production at manually what the main dangers are, how the main
operated machines use fixed guards with: safeguards work and who should be notified
jigs and fixtures (such as sliding trays) to of defective ones
load and unload components away from how to start, operate and stop the machine safely
the tools what to wear (eg protective equipment) and
safe means of removing swarf (such as a what not to wear (eg loose clothing at some
hook or rake which may be inserted machines)
through small openings in fixed guards) how to
and adjusting coolant (such as taps load and unload components
outside fixed guards). remove swarf, and
Use fixed and interlocking guards or safety adjust coolant flow safely
devices providing equivalent protection at V not to clean machines using compressed air
automatic and CNC machines to ensure all to blow material away - industrial vacuum
dangerous movements, not only tools, are cleaners or brushes should be used
guarded (see page 32 and individual how to work safely with any metalworking
machines for further guidance on guarding fluids used.
CNC machines).
Control noise by engineering means at source Maintenance and setting personnnel should
or adapt and extend guards to serve as noise know:
enclosures (eg by lining them with noise that before inspection, cleaning,

(IQ
absorbent materials). (See pages 40-42). maintenance and repair, machines must in
Use guards to help enclose and control general be switched off and isolated
hazardous substances with LEV where where power is necessary, how to work
appropriate. safely, for example by using:
V Manually operated machines used written systems of work
infrequently for one-off operations such as permits to work on complex or hazardous
those often found in toolrooms may require plant, and
constant adjustment and close observation; warning signs
guards may also need to be readily how to maintain metalworking fluids to
adjustable and allow close observation. minimise health risks.

THE PROVISION AND USE OF WORK EQUIPMENT REGULATIONS 1998 outlined (equipment includes machinery)
Employers and others must ensure that:
suitable equipment is provided for the jobs involved
information and instruction are adequate
equipment is maintained in good working order and repair
training is provided for operators and supervisors
equipment is safeguarded to prevent risks from mechanical and other specific hazards
equipment is provided with appropriate and effective controls
maintenance is carried out safely
some work equipment is subject to inspection to ensure that is safe to use (see page 31).
The Regulations also contain requirements relating to mobile work equipment (see page 19) and power presses
(see page 48).

KEY REFERENCE: Provision and Use of Work Equipment Regulations 1998

ACOP and Guidance on Regulations L22 HSE Books ISBN 0 7176 1626 6
 MACHINING

The Provision and Use of Work Equipment Inspection will be necessary when equipment or
Regulations 1998 impose requirements parts of equipment deteriorate and lead to
relating not just to preventing access to danger and where this will not be
dangerous parts of machinery, but also to adequately controlled through operator
the following: checks and normal servicing regimes. It will
not therefore apply to everyday risks at
V information and instruction work equipment, which can be detected and
V inspection rectified during routine operator checks and
V safe maintenance operations maintenance.
V starting and stopping machines safely
(including emergency stops) The purpose of an inspection is to identify
V control systems whether the equipment can be operated,
V means of isolating work equipment from adjusted or maintained safely and that any
sources of energy deterioration (such as damage or wear) can
V stability be detected and remedied before it results
V lighting in unacceptable risks.
V markings
V warning devices. Inspections should include visual and
functional checks of the equipment, and
You will need to carry out risk assessments on sometimes testing. This will depend on the
your existing machinery in order to identify complexity of the equipment, on where and
whether it complies with all of the how it is used, and on what the risks to
requirements. You can use the risk health or safety could be if the equipment is
assessment proforma in Appendix 3 to help. operated in an unsafe condition.

INSPECTION OF WORK A risk assessment should be carried out to

EQUIPMENT determine whether an inspection is
Inspection of work equipment should be carried necessary and, if so, what form it should
out where a significant risk of injury (one which take. The assessment should also state the
could foreseeably result in a major injury or intervals at which inspections should be
worse) may result from: carried out. Records of the assessment and
the inspections should be kept.
V incorrect installation or reinstallation of the
equipment Some examples of equipment which is
V deterioration of the work equipment likely to be subject to inspection:
leading to danger, or
V as a result of exceptional circumstances Hydraulic presses and press brakes
which could affect the safe operation of the Non-lifting parts of fork lift trucks
work equipment (for example, if it is Die-casting machines
damaged).
 COMPUTER CONTROLLED (CNC) MACHINING

HOW MOST ACCIDENTS HAPPEN Most ILL HEALTH arises in the same ways
From trapping at, or contact with, tools, clamps, as at conventional machines, from poor
tables, swarf removal equipment, chucks handling (see page 12), metalworking
and other work handling equipment, during fluids (see page 36), and noise (see
normal operating cycles when clearing page 38), but risks from:
blockages and swarf, loading/unloading, V aerosol mists from metalworking fluids
cleaning and making adjustments. may be higher because of higher operating
pressures and speeds, and
Many accidents also occur during fault V noise, particularly from high-speed cutting
finding, setting, and repair and (and especially from groups of machines
maintenance because safeguarding is operating together) may be higher.
inadequately specified, poorly designed, not
understood by the user, and/or misused.

KEY SAFETY MEASURES

As the degree of computer control may vary from:

complete control of several different machines working together with associated equipment
(such as loading/unloading devices), to
partial control of one aspect of a single machine (such as constant surface speed cutting on
a `microprocessor' enhanced lathe)

provide safeguards appropriate to the risks posed. For example, at a fully programmable
CNC lathe (where many sequences of high-speed, high-power machine movements may be
under computer control) complete enclosure by fixed and interlocking guards or their
equivalents is appropriate.

At a `microprocessor' enhanced mechanical lathe, however, where only constant surface speed
cutting is under computer control, complete enclosure may not be necessary and safeguards more
appropriate to a manually operated lathe may suffice.

Where the speed and power of machine movements under computer control leads to risks of injury:
provide fixed and interlocking guards (or equivalent safeguards) to prevent access to all such
machine movements, not only to metalcutting tools - work zone enclosures may be necessary
arrange interlocking so that power to dangerous machine parts is removed when
interlocking guards are open or movements are limited to safe increments or speeds, which
are automatically prevented from rising to unsafe levels
use enclosing guards to help reduce noise, and control emissions of mists, fume and vapour,
either from metalworking fluids or the material being machined
make sure you understand which safety functions depend on computer control and how to
check and maintain them. If you don't understand, ask your supplier to explain.
check that vision panels intended to contain parts which may be ejected from the machine
are suitably designed and constructed, have sufficient strength and are well maintained.

KEY REFERENCE: Provision and Use of Work Equipment Regulations 1998

ACoP and Guidance on Regulations L22 HSE Books ISBN 0 71.76 1626 6

32
 COMPUTER CONTROLLED (CNC) MACHINING

A range of CNC systems are available that can be fitted to previously manually operated
machine tools, such as milling machines or lathes. Theses systems provide a selection of
features which can significantly improve the productivity of the machine and the quality of
the work produced. When machines are retrofitted, new hazards and the increased risks to
the operator that are associated with CNC machines may be introduced. Automation also
changes the way the operator interacts with the machine and, to some extent, the way the
hazards may be presented to the operator.

Because of the change from manual to automatic operation a retrofitted machine should be
subject to a risk assessment. Fixed and interlocked guards which prevent access to the danger
zone during the automatic cycle should be normally provided. Where it is necessary to have
powered movement of a machine element, with the interlocked guard open, eg for setting
purposes, this should be done under limited speed conditions with hold-to-run controls.

Detailed consideration should be given to the safety-related parts of the machine's control
system. A number of BS EN standards provide specific guidance on this matter and further
information should be available from the control system component supplier.

KEY REFERENCE: Engineering machine tools: Retrofitting CNC

EIS19 HSE Books (free)

33
 BUYING AND SELLING MACHINERY

NEW*
A buyer of `new' machinery should look for For a seller of `new' machinery the `CE' mark
the `CE' mark, which should indicate: among other things should be a claim for
the most commonly used machine tools in
V the supplier's claim to conformity with the engineering that at least:
Supply of Machinery (Safety) Regulations,
which implements the Machinery Directive V hazards, where reasonably practicable,
in the UK have been designed out
V the machinery meets essential health and V mechanical dangers are safeguarded with
safety requirements to eliminate risks of guards and safety devices fitted and
injury from most sources working together with clear instructions
V there should be little if anything further to provided on how risks not safeguarded are
do to make the machinery safe if to be avoided
`Instructions for use' are followed. V the machine is as quiet as is reasonably
practicable with noise reduced at source or
If you buy a machine with a CE mark, assess enclosed (the noise emission level must be
that it is safe and without risks to health stated in `Information for use')
by, for example, checking it against the V steps have been taken to control emissions
standards on any similar machines you of harmful substances when the machine is
may already have; it should at least meet working by, for example, containment or by
current standards. You can use the risk providing for connection to extraction
assessment proforma in Appendix 3 to equipment
help check the machine. V instructions for use are provided to indicate
clearly in English how the machine may be
An outline of what is defined as`machinery' from the safely installed, operated, maintained,
SUPPLY OF MACHINERY (SAFETY) REGULATIONS removed or dismantled; where it is not
immediately clear how safeguards work as
An assembly of linked parts or components, at least one on some computer controlled machinery
of which moves including the appropriate actuators, clear information should be provided on:
control and power circuits, joined together for a specific how they work
application, in particular for the processing, treatment, how they may be checked
moving or packaging of a material how to maintain them, and
An assembly of machines which, in order to achieve what to do in case of faults/failures
the same end, are arranged and controlled so that V information on vibration is provided and
they function as an integral whole vibration minimised for hand-held
Interchangeable equipment modifying the function machines
of a machine which is supplied for the purpose of V metalworking fluids can be cooled where
being assembled with an item of machinery by the necessary, delivered and removed safely
operator himself save for any equipment which is a with risks of contamination minimised,
spare part or tool eg from filter blockages or high working
A `safety component' placed on the market temperatures; information for
separately from machinery to fulfill a safety use should specify how to
function when in use and the failure or malfunction use fluids safely at the
of which endangers safety or health. machine.

*New' means new to the European Union. An old, second-hand machine from the Far East or Eastern Europe, for example, is

regarded as `new' to the European Union for the purposes of the Supply of Machinery (Safety) Regulations 1992. Carrying out

substantial refurbishment, such as fitting a CNC control to a previously manual machine, may also result in a `new' machine subject to these Regulations.

34
 BUYING AND SELLING MACHINERY

SUPPLY OF MACHINERY (SAFETY) SECOND-HAND

REGULATIONS 1992 AND AMENDMENT Sellers of second-hand machinery from
REGULATIONS 1994 outlined outside the European Union must comply
with the law on new machinery.
If you are a responsible person for the supply of
new machinery or, from outside the EU, new or Refurbished machinery from inside the
secondhand machinery for the first time: European Union may also be `new' within
the meaning of the law, and have to
AS A COMPLETE MACHINE (such as a lathe) comply. The degree of refurbishment will
decide whether the machinery is `new' or
AS INTERCHANGEABLE EQUIPMENT TO not. A substantial refurbishment which
MODIFY THE FUNCTION OF ANOTHER gives machinery new functions, such as
MACHINE (such as an internal grinding computer control, which it didn't have
attachment for a centre lathe) before, is likely to make the machinery
make sure it complies with essential health and `new'. A new coat of paint and the straight
safety requirements (of the Machinery Directive, replacement of worn-out items, on the
listed in the Supply of Machinery (Safety) other hand, most likely would not.
Regulations)
keep relevant information on its design, Consult your local HSE inspector where it is
construction and use so that a `technical file' (or not clear.
part of one) may be assembled if an enforcing
authority asks for it Buyers of second-hand machinery should
provide `Instructions for use' in the language of make sure that it complies with the
the country where it will be used requirements of the Provision and Use of
issue a Declaration of Conformity to your Work Equipment Regulations 1998 (see
customer page 30-33). The risk assessment proforma
attach the `CE' mark in Appendix 3 can be used to help check
ensure that it is safe compliance.

AS A SAFETY COMPONENT THE HEALTH AND SAFETY AT WORK ETC

take all the above steps but do not attach the `CE' ACT 1974 SECTION 6, on the supply of machinery,
mark new or old, from whatever source, outlined

AS PART OF ANOTHER MACHINE, which It must be:

cannot function independently, (eg a swarf conveyor so far as is reasonably practicable designed and
intended for incorporation into another machine) constructed so that it is safe and without risks to health
take all the above steps and issue a Declaration of accompanied by adequate information for use.
Incorporation instead of Conformity to your
customer, in which case do not attach the `CE' mark Only a written undertaking from the buyer that
specified steps will be taken to safeguard the
SPECIAL REQUIREMENTS apply to presses and machine he/she is buying relieves the supplier of
other highly dangerous machines and some safety his duties in relation to second-hand machines
components, which must either conform to the BS from within the EU.
EN `C' standard or have EC-type examination.

KEY REFERENCES: Product standards: Machinery DTI (tel: 0870 150 2500)
Supplying new machinery INDG270, Buying new machinery INDG271 HSE Books

35
 JJ

METALWORKING FLUIDS
Correctly managing your metalworking fluids will reduce the risk of ill health, prolong the life of
the fluid, increase tool life, and improve the machining performance.

ILL HEALTH from metalworking fluids, make suitable arrangements to clean

used neat or mixed with water, most contaminated overalls and clothing
commonly arises from: do not use unrefined mineral oils and
mildly refined distilled oils which may

S'.
a) skin contact during cause cancer and for which safer
alternatives are available.
preparation, application and removal of
fluid Cases of oil acne (folliculitis - irritation of the
handling of workpieces hair roots from prolonged and regular
splashing when machining contact with neat oils) and skin cancer
V changing and setting of tools must be reported to HSE (see page 79).
maintainance and cleaning of machines
Where there is significant skin contact or
causing skin irritation and dermatitis, and exposure to fume, mists or aerosols, health
surveillance is likely to be needed.
b) breathing in aerosols, mist and fumes
when machining causing irritation of the Appoint a responsible person to:
eyes, nose and throat and occasionally
breathing difficulties such as bronchitis encourage high standards of personal

4-i
C.'

f3.
and asthma. hygiene
undertake regular skin inspections (about
As most metalworking fluids, either as once a month)
concentrates or when in use, are or contain check that controls are effective
hazardous substances, the strategy for encourage employees to complete
controlling them outlined on page 20 is questionnaires (about once a year) for both
almost always relevant and useful. skin and breathing symptoms
review absence records
In particular: advise those with problems to seek further
medical advice.
maintain them in good condition (see next
page)
operate and maintain processes to Appendix 2 (pages 99-100) gives examples of
minimise mist, fume, vapour and splashing useful questionnaires.

KEY REFERENCE: Working safely with metalworking fluids (pack)

HSE Books ISBN 0 7176 2561 3

36
 U1

SAFE WORKING WITH METALWORKING FLUIDS

MINIMISE RISKS BY

MAINTAINING FLUIDS IN GOOD maintain fluid flow at correct volumes and

CONDITION pressures, as:
insufficient flow will lead to higher
DO: working temperatures and more fume
read and follow supplier's guidance higher pressures may lead to more mist
use fluids compatible with machines, eg those formation
that will not: larger volumes may increase risks of
strip paint from the machine to block filters, or splashing
dissolve metals being worked such as provide local exhaust ventilation at
cobalt, chromium and nickel which may machines to remove fume and mist at
cause health problems later if inhaled or in harmful levels and have the ventilation
contact with skin system examined and tested by a competent
make use of special expertise, and develop in- person every 14 months.
house competence to maintain fluids by, for
example, keeping a weekly record of DON'T:
visual sump inspections for fluid and allow fluids to overheat as this increases
tramp oil leaks risks of biological contamination
concentration and pH measurements, and allow water-mix fluids to stagnate when not
bacteria dip slide measurements in use (for example, use small circulation
top up in accordance with suppliers pumps or pass air gently through the fluid)
instructions use air lines to blow components clean - use
keep machines clean and free from debris a vacuum-type cleaner instead.
clean sumps, pipework and machines before
refilling with fluids which should be recently MAINTAINING HIGH STANDARDS
mixed outside the machine in clean containers OF PERSONAL HYGIENE
adding concentrate to drinking quality water
use a refractometer to check strengths. DO:
use machines, enclosures and extraction
DON'T: equipment properly to minimise splashing
store fluids outside, where strong sunlight or frost and breathing aerosols and mists
may damage water-mix fluids and moisture wash with soap and water regularly to
may lead to the contamination of neat oils remove metalworking fluids
add too much biocide which will increase the use an after-work cream each time after
risks of skin sensitisation and respiratory washing and drying
irritation wear clean overalls and keep oily rags out of
use fluids beyond their normal working life pockets
allow other oils used to lubricate the machine cover cuts and abrasions with waterproof
to contaminate metalworking fluid. dressings.

OPERATING MACHINES SAFELY DON'T:

wear jewellery, rings or watch straps under
DO: which fluids may collect and be difficult to
train and instruct employees in the hazards clean
and safeguards eat, drink or smoke in working areas.
enclose sources of emissions and aerosols

KEY REFERENCE: Working with metalworking fluids INDG365 HSE Books

(single copies free; ISBN 0 7176 2545 1 for priced packs of 10)

37
 -:- 4, J;

NOISE

Too much loud noise damages hearing by MEASURING NOISE

causing: Exposure to noise is measured in decibels -
usually written as dB(A). The noise level
V deafness, or (loudness) is measured as a scale from a
V permanent tinnitus (ringing in the ear). silent zero dB(A) to 140dB(A) for the
noisiest situations. For most jobs risk
If you cannot hear clearly what someone is depends not only on noise levels but how
saying (in a normal voice) 2 m away, the long people are exposed to them. The total
noise level is likely to be 85dB(A) or amount of noise exposure over the whole
higher: working day is called the daily personal
noise exposure (usually shortened to
TYPICAL MINIMUM NOISE LEVELS NEXT LEP,d)
TO OPERATIONS WHERE NO STEPS
HAVE BEEN TAKEN TO REDUCE Many engineering workshops may need to
NOISE: have their noise levels measured. This
dB(A) should be done by people who understand
air exhausting from pneumatic 85-95 and can apply HSE's guidance on how to
equipment measure noise.

grinding on pedestal grinder 90-95

discharging metal objects into 85-95

metal tins/chutes

general noise level in 85-95

fabrication shop

using vibratory bowl feeders 90-100

hammering steel 95-100

guillotining 95-100

multi-spindle automatic turning 95-105

tail

circular sawing - metal 95-105

pressing - blanking 95-110

- punch pressing 110-120

riveting 100-110
Actual noise levels can be higher than those
shown above.

KEY REFERENCE: Reducing noise at work: Guidance on the Noise at Work

Regulations 1989 L108 ISBN 0 7176 1511 1; HSE website: www.hse.gov.uk/noise

38
 NOISE

NOISE AT WORK REGULATIONS 1989 outlined

Action to be taken where LEP,d is likely to be 85dB(A) 90dB(A)

Employers must:
reduce risk of hearing damage to lowest level reasonably practicable
have noise assessed by a competent person
keep records of assessment until a new one is made
reduce exposure to noise as far as is reasonably practicable by means other than
ear protectors
provide information, instruction and training to employees
mark ear protection zones with notices, as far as is reasonably practicable
ensure so far as is practicable that ear protectors are:
provided to all who ask for them *
provided to all exposed
maintained and repaired
used by all exposed
ensure so far as is reasonably practicable that all who go into marked ear protection
zones use ear protectors *
ensure that all equipment issued under the Regulations is used and
maintained. * *

Employees must, so far as is practicable:

use ear protectors
use any other protective equipment *

report any defects.

A new European Directive dealing with noise has been agreed. It is expected that new noise at
work legislation will come into force in 2006, when the above action levels will be reduced.

Regular hearing checks (health surveillance)

THE LAW* ON NOISE ASSESSMENTS outlined may be required under the Management
of Health and Safety at Work Regulations
Noise assessments must: 1992 (see page 1) depending on how noisy
identify persons at risk the workshop is. It is good practice to
enable employers to: carry out hearing checks on all employees
reduce noise where reasonably practicable whose daily personal noise exposure
other than by the provision of ear protection regularly equals or exceeds 90dB(A).
provide the right sort of ear protection
establish the correct protection zones You should take noise risks into account when
give suitable information to employees buying new work equipment. Make sure
be reviewed when circumstances change. that you get proper information about the
levels of noise likely to be produced by the
* Noise at Work Regulations 1989 equipment. Consider a policy of
purchasing only low-noise equipment.

KEY REFERENCE: Noise at Work: Advice for employers

INDG362 HSE Books (single copies free; ISBN 0 7176 2539 7 for priced packs of 10)

39
HOW TO MAKE THE MOST OF NOISE ASSESSMENTS

TASK I TASK 2 TASK 3

Operating a power press Sorting metal components Breaks taken at/near
carrying out a blanking into metal bins, around machines
operation workshop

Sample Leq* dB(A) Sample Leq dB(A) Sample Leq dB(A)

98 for 3 hours 93 for 4 hours 88 for 1 hour
giving fractional exposure giving fractional exposure giving fractional exposure
`f value 2.37 `f value 1.00 `f value 0.08

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

R E D U C E N O I S E

Use protective measures as Line metal bins with noise Provide quiet restibreak
for Task 2 until tools absorbent materials, to room, to give <85 dB(A).
designed to use shear/skew give 90-91 dB(A).
cut and/or feed automated
and/or discharge Mark ear protection zones.
chutes/bins lined with Provide and maintain ear
noise absorbent material protectors and warning
and/or press enclosed, to signs. Make sure
give 85dB(A). protectors are worn.
Provide information,
Maintain noise reduction instruction, training.
measures. Make ear
protection available. Review when
circumstances change.
Provide information,
instruction, training.

For most industrial situations LEP,d can be calculated

using Figure 2 from the key reference below.
*(Leq is a continuous equivalent sound level)

KEY REFERENCE: Reducing noise at work: Guidance on the Noise at Work

Regulations 1989 L108 ISBN 0 7176 1511 1; HSE website: www.hse.gov.uk/noise
 HOW TO REDUCE NOISE

Noise may be reduced by: Examples of successful noise reduction

V eliminating the need for the process V increasing precision in castings, more
concerned, all of the time... accurate metal cutting (eg by laser, by
maintaining guillotine blades) may reduce
the need to trim, grind or chip excess
material
... or part
of the time by substituting a V operating an air ejector on a press only for
quieter machine or process the time required to eject the component
V welding instead of riveting
V using quieter riveting machines
V using a mechanical instead of pneumatic
ejector on a press

V by changing the way an operation is : V applying a shear edge to press tools for
carried out, or a machine works blanking
V using only sufficient air pressure to
operate the machine reliably
V avoiding or cushioning impacts between
noisy parts by, for example, using rubber
conveyors or chutes and bins lined with
rubber or plastic
V by providing effective means of vibration
isolation
V damping vibrating surfaces to reduce the
C1.

tendency of metal surfaces to ring by using

surface coatings or plates, as on metal
cutting circular saw blades
V using silencers to reduce noise caused by
turbulence at air exhausts and jets

V by maintaining machinery V using tie bars on C-frame presses where

provided
V lubricating moving parts as appropriate

V by enclosing the machine or process in V fitting noise absorbent panels as for

enclosures... example around cold heading machines,
power and punch presses

... or in separate areas/rooms V fitting noise absorbent room dividers such

as plastic curtains to separate noisy from
quiet operations

V by using noise absorbent material near : V fitting suspended noise absorbers in a

noisy operations. fabrication workshop to lower high
intermittent noise levels.

KEY REFERENCE: Reducing noise at work: Guidance on the Noise at Work

Regulations 1989 L108 ISBN 0 7176 1511 1; HSE website: www.hse.gov.uk/noise

41
 -_e

In many circumstances engineering control may be the most cost effective way of reducing noise.
Expert analysis of noise sources, and identification of the right control measures are necessary.

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

Operation Method Reduction

vibratory feeders, and damping high frequency vibration 95 dB(A) Leq

conveyors without affecting performance to 73 dB(A) Leq

hydraulic power packs for mounting the motor pump unit on a 96 dB(A) Leq
guillotines rigid frame, isolating it and the valve to 79 dB(A) Leq
bank from the machine body

machining of castings reducing the vibration of the casting 104 dB(A) Leq to
by using a pair of damping straps 88 dB(A) Leq

blanking introducing small amounts of 98 dB(A) Leq

stagger and shear into the press tools to 91 dB(A) Leq

blanking isolation of the press frame from its 101 dB(A) Leq to
fabricated legs using 6 mm 92 dB(A) Leq
composite pads

blanking fitting dynamic vibration absorbers 99 dB(A) Leq

to the flywheel from which 'bell-like' to 89 dB(A) Leq
tones radiated

TRAINING SPECIFIC S

Training for those who work in noisy areas should include:

what the risk is to their hearing
how to use any noise enclosure provided
who to report defective enclosures to
how to follow systems of work designed to reduce exposure
when and how to use ear protectors provided, who to report defective ones to, and how
to keep them clean
that hearing problems must be reported to a doctor, with details of the noise involved.

KEY REFERENCE: Sound solutions HSGI38 HSE Books ISBN 0 7176 0791 7
Protect your hearing or lose it INDG362 2002 (single copy free; ISBN 0 7176 2539 7 for priced
packs of 10 copies) HSE Books

42
 VIBRATION

Vibration White Finger (VWF), known as `dead TO MINIMISE HARM

finger' or `dead hand', is widespread in V Identify hazardous jobs
some workshops and is the most obvious
symptom of hand-arm vibration syndrome V Consider changing the process or product
(HAVS); design to eliminate or reduce the use of
vibrating machinery
V Attacks are painful and can result in the loss
of sense of touch and of the ability to grip For example:
properly Mechanise or automate
Use hydraulic rather than pneumatic
V The most common causes are work with: impulsive riveting
Rough machine rather than hand grind
hammers and chisels
powered percussive metalworking tools
including hammers for riveting, clinching V Choose low vibration equipment such as:
and flanging
tagging machines to shape bar material properly balanced grinding wheels, rotary
pedestal and hand-held grinding and rather than impact or impulse action-
polishing machines powered screwdrivers, nut runners and
torque wrenches for assembly work, and
although any regular prolonged use of any low-vibration or recoilless chipping
high-vibration tool or machine which causes hammers or machines incorporating
tingling or numbness after five to ten vibration reducing features such as
minutes is a possible cause. isolating handles

Personal protective equipment will not V Maintain equipment properly by keeping

normally reduce the amount of vibration cutting tools sharp, dressing grinding wheels
reaching the worker's hands. properly, and replacing anti vibration
mounts to maintain their effectiveness

THE LAW ON VIBRATION outlined V Reduce the amount of hand force needed
when grinding, for example, by supporting
Unlike noise there are currently no specific heavy workpieces and using jigs with anti-
regulations dealing with vibration, but where the vibration mounts
hazard exists the Management of Health and Safety
at Work Regulations (see page 1) and Provision and V Carry out health surveillance of exposed
Use of Work Equipment Regulations (see page 30) workers under the general supervision of a
apply. However, a European Directive which deals medical practitioner, and
with hand-arm vibration risks has been agreed and
will result in UK Regulations in 2005. V Have symptoms investigated fin-ther by
someone able to assess them medically

V Ensure that heating is adequate to keep

hands and body warm.
KEY REFERENCES: Hand-arm vibration HSG88 HSE Books ISBN 0 7176 0743 7
Vibration solutions HSG170 HSE Books ISBN 0 7176 0954 5
Power tools: How to reduce vibration health risks INDG338 (single copies free;
ISBN 0 7176 2008 5 for priced packs of 15); HSE website: www.hse.gov.uk/vibration

43
 MILLING AND MACHINING CENTRE WORK

HOW MOST ACCIDENTS HAPPEN Most ILL HEALTH arises from:

V Entanglement and contact with rotating V unsafe handling (see pages 12-17), harmful
cutters when: metalworking fluids (see pages 36-37), and
loading/unloading components too much noise (see pages 38-42), but in
removing swarf particular
measuring
adjusting coolant flow. V handling heavier workpieces at larger
machines which may require mechanical
These cause entanglement injuries such as aids such as hoists
broken bones, and dislocations,
amputations and lacerations V noise (which may be difficult to predict
and reduce at source) from cutters
V not wearing eye protection when operating against workpieces.
machining, cleaning and removing swarf.
KEY SAFETY MEASURES
TRAINING SPECIFIC S
For a manual horizontal milling machine
As well as understanding general rules for used for a variety of workpieces:
the safe operation of machinery (see page Fixed guard adjustable by means of a
30), operators need to know how to: tool
remove swarf False table to help restrict access to
adjust coolant flow cutter.
load and unload components safely.

KEY REFERENCES: BS EN 13128: 2001 Machine tools - Safety - Milling machines (including
boring machines); BS EN 12417: 2001 Machine tools - Safety - Machining centres

44
 L_
MILLING MACHINE AND MACHINING CENTRE WORK

For a vertical milling machine used for

batch production work:
Fixed and interlocking
moveable guards to prevent
access to the cutters and chip
ejection
For a vertical milling machine
used for a variety of one-off
jobs (including toolroom
applications)
Fixed and interlocked
moveable guards, or an
adjustable table guard
Component securely fixed in all cases.

KEY SAFETY MEASURES

For a small machining centre:
Sliding interlocking
guards to prevent
access to
dangerous
movements when
guards are open
If access to
machine
movements is
necessary when
the guards are
9 9
open, safe slow
movements
under hold-to-
run control may
be provided
Guards also help
control
metalworking fluid
and swarf
Exhaust ventilation fitted
or capable of being connected.

45
 DRILLING (AND REAMING)

HOW MOST ACCIDENTS HAPPEN Most ILL HEALTH arises from:

V Hair caught on rotating spindles, chucks or V unsafe handling (see pages 12-17)
tools V harmful metalworking fluids (see
V Entanglement of gloves, clothing, pages 36-37)
bandages and rings, usually at the drill tip V too much noise (see pages 38-42)
V Violent spinning of the workpiece because
of poor clamping - causing scalping but in particular risks from handling and
injuries, broken bones metalworking fluids may be higher at
V Not wearing eye protection causing eye manually operated machines used for
injuries from machine cleaning, swarf batch production because of more frequent
removal and unenclosed machining loading/unloading
V Swarf -causing cuts and contact with
fluids.

fixed guard
feed magazine
discharge slide to
prevent access to
all dangerous
parts

TRAINING SPECIFIC S

In addition to general rules for safe operation (see page 30) users should
be trained:

to wear eye protection, and

NOT
to wear jewellery, loose clothing or long hair not tied back
to wear gloves unless complete enclosure of rotating chucks, spindles and attached rotating
parts is provided
to leave chuck keys in chucks.

KEY REFERENCES: Guidance Note PM83 Drilling machines: Guarding of spindles

and attachments HSE Books ISBN 0 7176 1546 4
BS EN 12717: 2001 Machine tools - Safety - Drilling machines

46
KEY SAFETY MEASURES
For a small CNC drilling machine: --It
Sliding interlocking guards to prevent
dangerous movements when guards are
open __
F Lll -

If access to machine
movements is necessary when
the guards are open, safer,
slower movements under hold-
to-run control may be
p ermitted
Exhaust ventilation fitted or
capable of being connected.

I KEY SAFETY MEASURES

0 For a maually operated radial arm drilling

machine:
Use suitable tripping device and regularly
check its operation
Vertical trip not more than 75 mm from
the tool and positioned within the first 900
of rotation from the operator's position
Clamp workpiece securely to machine
table
Alternatively fixed, adjustable guards may
-7¢

be used.

KEY SAFETY MEASURES

For a small maually operated bench

drilling machine used for a variety of
one-off jobs:
Fixed adjustable guard adjusted so that
spindle and drill tip is guarded to the
greatest extent practicable
Vice clamped securely to table.

47
 PRESSING

HOW MOST ACCIDENTS HAPPEN All other presses, including hydraulic and
V Fingers or hand are amputated or crushed pneumatic, should have similar
between closing tools arrangements to achieve the same
when loading and unloading components objectives - a planned, regular system of
when setting up. inspections and tests by competent and
authorised persons to enable the safety of
Most ILL HEALTH arises from: the press and its safety devices to be
V unsafe handling (see page 12-17) and too regularly signed for by an authorised
much noise (see pages 38-42), but in person on behalf of the company.
particular
V noise from the impact of tools on These inspections may be carried out as
workpieces, air ejection, and described on page 31 under the regulation
V handling of workpieces during highly inspection requirements of PUWER.
repetitive batch production.

PROVISION AND USE OF WORK EQUIPMENT

REGULATIONS 1998 AS APPLIED TO POWER
PRESSES

BY LAW every metalworking press and press brake

with a flywheel and clutch and its guards must be
thoroughly examined by a competent persont: For a mechanical press:
before use on first installation, whether new or Guards as noise enclosures
secondhand Loading/unloading components without
periodically, presses with only fixed guards access between tools
every 12 months; other presses: every 6 months using automatic
feed.
Reports of defects must be notified in writing to
factory occupiers and copied to the enforcing
authority.
SETTERS who prepare presses for use:
must be:
competent
specifically designated in writing
properly trained
must carry out an inspection of safety devices
after any work on the tools which involves any
alteration to or disturbance of any safety device
not later than four hours after the start of each
working day or shift
must sign a certificate, kept near the press, that
safety devices are in efficient working order.

tom an insurance company, for example

KEY REFERENCE: Safe use ofpower presses L112 ISI3N 0 7176 1627 4

48
 PRESSING

KEY SAFETY MEASURES

For a hydraulic press brake using photoelectric

guards:
Ensure that the back and sides of the press
are guarded and that no-one can stand
between the light curtain and machine, or
reach under, around or over the light curtain
or guards to dangerous parts
Ensure that photoelectric light curtain when
interrupted brings downward movement to
a halt before dangerous parts can be reached
Muting (switching the beam off to permit
metal sheets to be inserted and bent through
the light curtain) must only occur when KEY SAFETY MEASURES
there is a safe distance* between the bottom
of the top tool and the top For a pneumatic hand-fed bench press using
surface of the interlocking guards:
component. Chairs used by operators should be
adjusted to the right height and provide
good support for the back. Provide foot
rests
Stillages should be positioned to minimise
twisting and turning when lifting and
.L"

L.'

lowering components
Use two pneumatic circuits to control and
check interlocking functions or an
automatic scotch to prevent tools closing
when guards are open
Ensure overlap of guard and table before
press will operate
Interlock the pneumatic power supply to
the press with the movement of the guard.

KEY REFERENCES: BS EN 692: 1996; BS EN 693: 2001; BS EN 12622: 2001

49
 TURNING

HOW MOST ACCIDENTS HAPPEN Most ILL HEALTH arises from:

V A fatal accident arising from entanglement V unsafe handling (see pages 12-17), harmful
on rotating parts happens every year or so metalworking fluids (see pages 36-37) and too
in the UK much noise (see pages 38-42), but in
V Entanglements on workpieces, chucks, particular
carriers and unguarded stock bars cause
most accidents V noise levels from stock bars rotating in stock
V Many accidents happen using hand-held bar tubes which can be very high,
emery cloth to smooth and polish particularly on multi-spindle machines
components
V Direct contact with moving parts causes V risks from breathing in mists and aerosols
many injuries may be higher at higher speed machines, and
V Eye injuries from machine cleaning, swarf throughout the workshop from groups of
removal and unenclosed machining when machines operating together
eye protection is not worn are frequent
V Chuck keys ejected from rotating chucks. If required surface finish or dimensional
accuracy cannot be achieved by turning
A large proportion of injuries result in techniques, consider using dedicated
amputation of fingers, broken bones and grinding, honing or polishing machines as
torn ligaments. appropriate instead of hand-held emery cloth.

KEY SAFETY MEASURES

For a small CNC turning machine:
Sliding interlocking guards to prevent access to dangerous movements when guards are open
If access to machine movements is necessary when guards are open, safer, slower
movements under hold to run control may be permitted when guards are open
Exhaust extraction fitted or capable of being connected.
A strong properly maintained vision panel, capable of withstanding foreseeable ejections.
 TURNING

For a manually operated turret lathe:

Fixed guard at rear of machine
Chuck guard
Feed and lead screws guarded or
well back from operator
Splashguard for suds and swarf.

Wear eye protection

Don't wear jewellery, loose clothing or
long hair if it's not tied back.

If using emery cloth cannot be avoided, in

addition to general rules for safe
operation (see page 30), users should be
trained about the dangers of using emery
cloth:
Backing board
Never use emery cloth at CNC lathes
If required finish may only be obtained
holding emery cloth against rotating
components,
then use:
a backing board
a tool post
a `nutcracker' Tool post
hand-held abrasive-impregnated wire
brushes.

'Nutcracker'

KEY REFERENCES: BS EN 12415: 2000; 12478: 2001; 12840: 2001; 13788: 2001
Accidents at metalworking lathes using emery cloth EIS2 HSE Books (free)
 JIJ

GRINDING

HOW MOST ACCIDENTS HAPPEN Most ILL HEALTH arises from:

Injuries from contact with rotating unsafe handling (see pages 12-17), harmful
abrasive wheels metalworking fluids (see pages 36-37)
Impact injuries from bursting wheels, vibration from hand fed or hand-held
(sometimes fatal) grinding machines which may cause a
Cutting and crushing injuries from condition called vibration white finger,
trapping between the wheel and workrest which damages hands and arms,
Fires and explosions arise from the poor sometimes permanently (see page 43)
control of grinding dust containing too much noise from the grinding
aluminium magnesium and similar materials operation itself (see pages 38-42) and
Eye injuries from the failure to wear eye inhaling the harmful dust/fume generated.
protection or use protective screens.
THE LAW* ON ABRASIVE WHEELS outlined
TIPS FOR OPERATORS
The specific risks associated with mounting abrasive
As well as general rules for safe operation (see wheels require that such tasks are only done by
page 30), users should be trained: people who have been specifically designated to do
to use the right wheel and machine for so. Adequate training must be provided for people
the job mounting abrasive wheels. Such training should
not to grind on the sides of straight-sided include:
wheels used for off hand grinding hazards arising from the use of abrasive wheels
to keep wheels used for off hand grinding and precautions which should be observed
trued and dressed to reduce out of balance methods of marking abrasive wheels as to type
and enable workrests to be adjusted close to and speed
the wheel methods of storing, handling and transporting
to lubricate spindles regularly abrasive wheels
to run new wheels free for about a minute methods of inspecting and testing abrasive wheels
with persons standing clear to check for damage
to support heavy workpieces and use jigs to the functions of all components used with abrasive
reduce vibration at pedestal and bench wheels, including flanges, blotters, brushes and
grinding machines used frequently for long nuts used in mounting and including knowledge of
periods (see page 43) particularly for tool the correct and incorrect methods of assembling
sharpening all components and correct balancing of abrasive
not to stop wheels by applying pressure to wheels
the wheel periphery or face the proper method of dressing abrasive wheels
not to leave wheels immersed in coolant the adjustment of the rest of an abrasive wheel.
which may lead to out of balance; coolant
should be switched off before wheels are * P,vvirion and Use of Work Equipment Regulations 1998, Regulation 7
stopped to enable them to dry
to take care not to insert oversize
components into centreless grinders to
minimise risks of ejection and whee
breakage
to use wheel dressers which minimise risks
of vibration white finger.

KEY REFERENCES: Safety in the use of abrasive wheels HSG17 2000 HSE Books
ISBN 0 7176 1739 4; BS EN 13218: 2001 Machine tools - Safety - Stationary grinding machines

52
 GRINDING

At a manually operated pedestal

grinding machine used occasionally for
tool sharpening:
Opening in guard restricted to that
needed to enable work to be done
Guard of sufficient strength to
contain
fragments of bursting wheels
Well-adjusted workrest
rpm of spindle clearly marked
Easily accessible and operated onloff
switch
Clear floor area.

KEY SAFETY MEASURES

For a manually operated surface grinding

machine:
As for machine above, plus:
Provide extraction, maintain and
inspect and test it every
14 months, recording the results
Secure workpiece firmly.
 SAWING
USING MANUALLY-FED PIVOTING-HEAD
METAL-CUTTING CIRCULAR SAWS

HOW MOST ACCIDENTS HAPPEN Most ILL HEALTH arises from:

V Contact with the running saw blade when: V unsafe handling (see pages 12-17)

feeding, adjusting or removing worpieces V harmful metalworking fluids (see pages

36-37) and
cleaning the machine or removing swarf.
V too much noise (see pages 38-42) from the
action of the blade against the workpiece

KEY SAFETY MEASURES

NOISE Fixed adjustable guards
Noise high enough to damage hearing is Linkage operated moving guard to prevent
common at many saws, especially high- contact with the blade in the raised
speed saws for non-ferrous (eg position
aluminium) cutting. exposure of the blade during cutting
Gravity operated guards may only be
Reduce at source by, for example: used with hold to run controls
clamping workpieces securely Where fixed guards only are used,
using noise/vibration absorbing workpieces should be fed and removed
materials on feed tables through openings small enough to
avoiding the use of `damaged' saw prevent access to blades
blades Ensure the head spring balance (if fitted)
enclosing the cutting head in noise is properly adjusted.
absorbing materials
using `damped' saw blades Training in good sawing technique may help
minimise handling problems and noise.
KEY REFERENCES: Safety at manually fed pivoting-head metal-cutting circular saws
EIS12 HSE Books (free)
BS EN 13898: 2003 Machine tools - Safety - Sawing machines for cold metal

54
 N

BENDING USING 3 ROLL BENDING MACHINES

HOW MOST ACCIDENTS HAPPEN Most ILL HEALTH arises from:

V Hands are frequently drawn into counter- V unsafe feeding/unloading of workpieces
rotating rollers, particularly during initial which are too heavy/sharp/awkward (see
feeding of the workpiece pages 12-17)

V Hands are often trapped between a TRAINING SPECIFIC S

workpiece and a roller
In addition to general rules for safe
V Wearing gloves increases the risks of trapping operation (see page 30), users should be
trained to:
V Many injuries are serious; amputations are not wear gloves during the initial feeding
not uncommon of workpieces
avoid gripping workpieces close to the
KEY SAFETY MEASURES rolls; feed tables and rollers can help
avoid slips and trips around the machine
Hold to run controls should by keeping the area clear
automatically return to stop on release clear rolls and maintain only when the
Braking may be required to achieve a safe machine is switched off and isolated.
stopping time
Position trip devices to be easily
activated by any person drawn towards
cud

them at both sides of the

machine to bring
it to a stop before
serious injury
Emergency stop
buttons requiring
manual reset
after use
Use feed tables
.-.

and rollers to help

avoid gripping
workpieces close
to the rolls.

KEY REFERENCE: Safeguarding 3 roll bending machines EIS7(revl) HSE Books (free)

55
 COMBINATION METALWORKING MACHINES

HOW MOST ACCIDENTS HAPPEN

V Working small workpieces at a workstation,
resulting in amputations of fingers.

KEY SAFETY MEASURES

Guards should: The take off side should also be guarded
prevent access to closing tools, punches to allow only workpieces to pass through
or blades from all sides Do not take off pieces by hand:
provide a view of the operation where use a chute which discharges into a box
needed for smaller pieces
Workpieces should be properly supported and a table or roller track for larger
by guides and stops ones.

When bending, either restrict the gap

between the tools to a safe distance (see
pages 49 and 108) or provide photo-electric
4

or other safeguards as for press brakes (see

page 49).
P4

Special attention should be paid to the safety of

young people (under the age of 18) using combination
metalworking machines. The law* requires that
employers assess risks to young people before they
start work, taking into account their inexperience
and their immaturity. You should take account of the
risk assessment in determining whether the young
person should use the equipment. Proper training
and supervision will be essential.

Most ILL HEALTH arises from

V unsafe handling (see pages 12-17)
and too much noise (see pages 38-42),
but particularly from:
V handling large and/or sharp edged
workpieces
V noise from tool impacts.

KEY REFERENCE: Safeguarding of combination metalworking machines EIS13(rev)

HSE Books (free)

58
 HORIZONTAL BORING MACHINES

HOW MOST ACCIDENTS HAPPEN Most ILL HEALTH arises from

V Most injuries occur during activities such
as setting/adjustment, swarf removal, or 'V unsafe handling (see pages 12-17)
observation for the purpose of process 'V harmful metalworking fluids (see pages
control. 36-37)
The largest single cause of injury is
entanglement at revolving tools.
V Crushing and trapping hazards at tools and
the moving worktable are also very
significant causes of injury.
V Injuries are often very severe and include
limb and skull fractures and amputations.
The potential for fatal injury at these
machines should not be underestimated.

KEY SAFETY MEASURES

Prevent access to the work zone by fixed and/or interlocked guards.
Trip probes with breaking devices may be used in some circumstances, but these will only
provide limited protection , stopping the machine quickly in the event
of contact with revolving tools. They do not provide
protection against crushing and trapping hazards.
Where access to the work zone is needed for setting purposes,
dangerous machine movements should be controlled using a
hold-to-run control arrangement or enabling device.
Guard other hazardous parts such as transmission elements
including shafts, gears, pulleys etc using fixed guards.
Follow safe systems of work for cleaning, maintenance,
setting and adjustment, loading of workpieces etc. Activities
such as swarf removal should normally be
carried out with the spindle stopped.
A

KEY REFERENCE: Safeguarding at horizontal boring machines EIS28

HSE Books (free); BS EN 13128: 2001

59
 CLEANING AND DEGREASING

Many cleaning and degreasing substances WHEN USING LIQUIDS TO CLEAN

used are hamful if not used properly, by dipping, wiping or spraying:
either through direct skin or eye contact
or through breathing in mist or vapour V avoid halogenated solvents such as
given off, commonly causing dermatitis trichloroethylene ('trike'). perchloro
and narcotic effects. Some cleaners give ethylene ('perk') methylene chloride and
off vapour which is easily ignited. n-propyl bromide (nPB) unless they are
enclosed and extraction ventilation and
TO MINIMISE HAZARDS: other necessary protective equipment is
V reduce the need to clean by, for example, provided; other solvents may also need
avoiding contamination in the first place similar controls

V compare safety data sheets from suppliers V use the least flammable (with flashpoints
to find the least harmful cleaner and the ideally above 45°C) hydrocarbon solvents
cleaner which is non-flammable or the such as petroleum distillates, terpenes
least flammable (with a higher flashpoint) and alcohols
(different hazards posed by solvents may
need to be balanced to ensure that V adopt precautions necessary to minimise
overall, hazards to health and safety are risks from contact with alkaline or acid
minimised) water-based solutions or inhalation of
fume or dust arising from them
V avoid spills and evaporation by keeping
lids on containers and transferring liquids V avoid work in confined spaces (inside
between containers by pipework or pump metal fabrications for example) unless
absolutely necessary in which case make a
V mark stores and their contents clearly separate special assessment of the
hazards posed by the cleaning liquid and
V provide appropriate personal protective system of work proposed. (Special
equipment such as gloves, overalls, eye precautions, including compressed airline
and foot protection, to prevent contact breathing apparatus, a safety harness and
where necessary a second person standing by, may be
necessary, see page 62.)
V you may need to draw up an emergency
plan (see page 78) to cope with gross
spillages of some cleaning and degreasing
substances.

KEY REFERENCE: Safe use of solvent degreasing plant EIS40

HSE Books (free); Maintenance and cleaning of solvent degreasing plant EIS20(revl)
 VAPOUR DEGREASING TANKS

USING THEM badly may expose MAINTENANCE minimises risks to

operators and others to harmful levels of operators and others:
vapour which if inhaled can cause drowsiness
and in extreme cases unconsciousness or even V from escaping vapour
death. Direct contact with the vapour or liquid
can cause irritation and dermatitis, and from the build up of oil and grease which
should never be frequent or prolonged. can catch fire

Solvent degreasing should be carried out in an V and can prevent the need to enter in order
enclosed system where reasonably practicable. to remove baked-on residues. Getting into
Otherwise, the process should be enclosed as vapour degreasing tanks causes a sizeable
far as possible. proportion of all fatal accidents in small
engineering workshops.
To minimise exposure:
DO: Always:
position tank in an area free from draughts set thermostats correctly and balance
stack components inside the degreaser so heating and cooling systems
they drain properly check and maintain the effectiveness of
allow them to dry in the freeboard zone extraction systems
before removing them pump in fluid below the existing liquid level
use covers when not using the tank repair leaks
use a mechanical hoist when treat pits in which degreasing tanks are set
loading/unloading components. as extensions of the tank itself
maintain the correct solvent level
DON'T: check the solvent condition
move, load or remove components too ensure adequate freeboard height
quickly, pushing or dragging vapour out ensure the bath has a bottom drain for
run hoists at more than three metres per removing solvent.
minute vertically
spray above the vapour layer.

KEY REFERENCE: Surface cleaning and preparation: Choosing the best option GG354
Available free from Envirowise on Environment and Energy Helpline Tel: 0800 585794;
Website: www.envirowise.gov.uk
 VAPOUR DEGREASING TANKS

TO AVOID ENTRY: IF ENTRY CANNOT BE AVOIDED

V Fix a sign on or near the degreaser V Establish a safe system of work in writing using
prohibiting entry without authorisation a formal permit-to-work system for entry
and breathing equipment authorised by a responsible person

V Regularly monitor contamination by V Remove as much solvent and sludge as possible

measuring the temperature of boiling before entering
solvent; distil off solvent into a storage
drum; drain mobile residues into a V Use suitable self-contained breathing apparatus
suitable container, and or air line compressed air equipment, and
a safety harness or belt and rope held or
V Use a long-handled scraper to remove secured outside the degreaser to pull the
remaining sludge, or person out if necessary
a second person standing by to raise the
V Pump dirty solvent directly into a alarm and start the rescue (it is unlikely that
container for recovery. one person could pull someone out single-
handedly - have a rescue plan ready)

V Provide additional breathing apparatus and

other suitable protective equipment capable of
being used for rescue

V Make oxygen resuscitation equipment

immediately available

V Wear protective clothing resistant to the solvent

involved

V Check and maintain breathing apparatus and

air line compressed air equipment, harnesses
and lifelines at least once a month, and keep
records

THE LAW* ON ENTRY INTO DEGREASERS V Fully train all who may become involved.

No person shall enter a degreasing tank for any If, while all the above precautions are being taken:
purpose (such as to clean it), unless it is not V the tank is thoroughly cleaned, tested and
reasonably practicable to achieve that purpose certified as safe for entry, and
without such entry. If a degreasing tank is entered,
this must be done in accordance with a safe system of V an adequate supply of breathable air is
work that allows it to be done safely and without risks maintained
to health.
breathing apparatus may not be needed for further
*Confined Spaces Regulations 1997 work (but see page 60, final paragraph, and
pages 63-65, Welding).

KEY REFERENCE: Maintenance and cleaning of solvent degreasing plant

EIS20(revl) HSE Books (free)

62
 WELDING AND FLAMECUTTING

Common causes of ILL HEALTH are: COMMON CAUSES OF ACCIDENTS

V inhalation of harmful welding fume ARE:
V unsafe handling of workpieces and welding As a result of
equipment, particularly gas cylinders V falling gas cylinders
V noise, particularly from plasma arc cutting, V particles entering unprotected eyes during
gouging operations and weld preparation chipping after welding
V burn from ultra violet radiation, including V electric shocks from arc welding equipment
`arc eye' V fires started by flames, sparks and hot
V vibration during grinding for weld material from welding and cutting
preparation processes
V discomfort from heat and uncomfortable V fingers being crushed between the
postures. electrodes of fixed resistance welding
machines
KEY SAFETY MEASURES
TRAINING SPECIFIC S
for arc welding:
for arc welders:
Extraction equipment Know how to use extraction equipment
Provide appropriate protective clothing Do not wear metallic jewellery, rings, or
and ensure it is worn, eg overalls, watch straps
protective apron, gloves, safety boots, Know how to change electrodes safely
respiratory protection (if necessary) Use an insulated box or hook to rest the
Use welding screens and eye protection
electrode holder NOT the face shield,
(to BS 679) to prevent arc eye
clothing or rags.
Local isolation switch
Welding set transformer
Workpiece earth when required
Insulated electrode holder
Insulated box for electrode holder
Proper cable connections
Suitable fire extinguisher easily
accessible
Welding leads should be insulated,
robustly constructed and big enough
carry the current safely
Residual current devices may
enhance safety
Work in confined spaces and on
large structures supported on
manipulating devices needs special
precautions (see Further reading,
page 87).

KEY REFERENCE:
Electrical safety in arc welding HSG118 HSE Books ISBN 0 7176 0704 6

63
 WELDING AND FLAMECUTTING

Maintain welding ventilation and Store and use welding gas

protective equipment cylinders safely
V Have local exhaust ventilation examined V Store full and empty cylinders in a safe,
and tested by a competent person every 14 well-ventilated place preferably outside
months (see page 21) buildings
V Examine respiratory protective equipment V Never keep cylinders below ground level
thoroughly every month (testing air fed next to drains, basements and other low-
equipment at the same intervals, checking lying places - heavy gases will not disperse
the volume and quality of breathing air easily
supplied) V Do not leave charged hoses where
V Examine flexible gas and oxygen hoses ventilation is poor for extended periods in
regularly and replace damaged ones; never case of leaking gases or oxygen
repair them with tape V Some gas cylinders, for example acetylene,
V Check and maintain other safeguards as contain liquid - store them with their
appropriate. valves uppermost
V Protect cylinders from damage, for
NEVER APPLY heat to containers, tanks example by chaining unstable cylinders in
or drums which may contain flammable racks or on trolleys
residues. Either use cold, non-sparking V Provide suitable trolleys with restraining
methods or clean and make them gas free chains for moving oxy-acetylene sets and
first. other cylinders
V Minimise damage by using the correct
hoses, clamps, couples and regulators for
the particular gas and appliance being
used
V Never apply grease oil or other lubricants
to oxygen fittings
V Prevent damage to hoses. Do not run
them unprotected, for example, across
traffic routes
V Turn off cylinder valves at the end of each
day's work
V Change cylinders away from sources of
ignition in a well-ventilated place
V Minimise welding flame 'flash-back' into
hoses or cylinders by training operators in
correct lighting up and working procedures
and by fitting effective non-return valves
and flame arresters
V Use soap or detergent and water solutions
to test for leaks - NEVER A FLAME
V Do not use oxygen as a substitute for
compressed air to power pneumatic tools.

KEY REFERENCE: The safe use of compressed gases in welding, flame cutting and allied
processes HSG139 HSE Books ISBN 0 7176 0680 5

64
 JJ
CONTROL OF FUME AND GASES AT WELDING,
FLAMECUTTING
AND SIMILAR PROCESSES SUCH AS BRAZING AND SOLDERING

Fume from welding, flamecutting, brazing and MINIMISE RISKS by:

soldering varies greatly in composition and V avoiding welding and flamecutting, using
concentration. Different jobs lead to other bonding and cutting techniques where
different levels of exposure to different reasonably practicable
susbtances. Fume from welding and flame V using safer filler materials, such as cadmium
cutting may cause: free silver solder
V dryness of the throat, tickling, coughing, V controlling exhaust fume by providing local
tightness of the chest and difficulty in exhaust ventilation unless a detailed and
breathing thorough risk assessment shows that
V an acute flu-like illness (metal fume fever) harmful fume is not being generated or that
V long-term changes in the lung. it may be controlled by general ventilation
V providing respiratory protective equipment,
Welding or cutting processes releasing the but only if control measures are unable to
greatest quantities of harmful fame include: reduce fumes to safe levels
V work on metallic coatings such as cadmium V ensuring workshops have enough low-level
or zinc plating and chromium, manganese, inlets and high-level outlets for air changes
cobalt and/or nickel hard surfaces V not welding near (10 in for most welding;
V work on painted surfaces which contain lead, 20 m for aluminium) cleaning processes
zinc, chromium or cadmium pigments using chlorinated solvents; the heat and arc
V mechanised flame cutting from welding may break down the solvents
V flame gouging into more harmful substances.
V frequent and regular manual Flexible arm
metal arc welding
V flux cored electrode welding
V higher current metal inert gas
shielded welding particularly
on stainless steel, and
aluminium, copper, nickel
and their alloys
V oxygen arc cutting
Face velocity of at
and least 0.5 ms-`
gouging
V using cadmium-
containing solder. Flanged head: keep the
distance between the head
opening and the weld less
than the smallest
dimension of the opening

MOBILE EXTRACTION
Consider on-gun extraction particularly WELDING BENCH/BOOTH
with semi- automatic Mig welding guns Extracted air may be filtered electro-
and flux cored wires without gas shielding. statically, for example, and returned to
the workshop to prevent heat losses.

65
 RADIOGRAPHY

X-rays, gamma rays and other forms of TO MINIMISE RISKS:

radiation used for non-destructive testing always carry out routine radiography of
(NDT) may injure by causing burns, readily moveable articles inside a
dermatitis, cancer, cell damage, blood permanent shielded enclosure, sufficient to
changes or cataracts. limit dose rates outside the enclosure to
less than 7.5 microsieverts an hour
THE IONISING RADIATION REGULATIONS make sure there are no people near open-
1999 outlined topped enclosures (in offices, or overhead
crane cabs, for example) who may be
If radiography is carried out in your workshop you affected
(or, if a contractor is doing the work, they) must: if you change your generator or source you
notify HSE before starting work may have to upgrade the enclosure
consult a suitable radiation protection adviser have to hand an emergency plan and the
carry out a prior risk assessment equipment necessary to put the plan into
arrange for medical examinations/reviews and effect (for radioactive sources to include
routine dose assessments of employees whom you bags of lead shot, a shielded pot and long-
designate as "classified persons" handled tools) and rehearse the plan
appoint one or more of your employees to V wear your dosemeter when required and
supervise radiation work make sure it is not damaged or exposed to
provide local rules and training radiation when not being worn
make arrangements to deal with stuck use a maintained and tested radiation dose
radioactive sources, x-ray exposures failing to rate meter to check radiation levels around
terminate, etc and rehearse them. the controlled area and always use the
Get authorisation for the use, storage and safe monitor when approaching the source
disposal of radioactive substances from the container to check the that the sealed
Environment Agency/SEPA, as appropriate. source has fully retracted or x-ray
generator is no longer producing x-rays
OTHER NON-DESTRUCTIVE TESTING V maintain radiography controls, for
TECHNIQUES, such as magnetic particle example windouts and guide tubes for
and dye penetrant techniques may involve sealed source equipment, and warning
the spraying of harmful solvents. Exposure devices.
to harmful levels of such solvents needs to
be assessed in line with COSHH (see page IF YOU CAN'T DO THE WORK IN A
20) and prevented or controlled. SHIELDED ENCLOSURE, YOU MUST:
notify HSE at least seven days in advance
of each occasion on which you propose to
work
plan the work to ensure radiation exposures
are suitably restricted by use of collimation
and localised shielding, barriers, warning
signals, lighting and other means to
demarcate the controlled area.

KEY REFERENCE: Industrial radiography: Managing radiation risks IRIS1(revl)

available from HSE Books (free)

68
 PAINTING

THE HAZARDS OF USING PAINTS, THE LAW ON THE MAIN HAZARDS

THINNERS OR SOLVENTS INCLUDE: ASSOCIATED WITH PAINTING outlined
breathing in vapour
direct skin or eye contact Hazardous substances in paints must be controlled in
swallowing causing irritation and diseases of line with the Control of Substances Hazardous to
the skin, eyes and lungs, and Health Regulations (see page 20).
fires from the ignition of flammable
vapours. The Highly Flammable Liquids and Liquefied
Petroleum Gases Regulations 1972 specify steps which
The risks of harm actually occurring are highest must be taken to minimise the risks of igniting vapours
when: from paints and solvents which are classified as highly
using paints containing large proportions of flammable liquids (flash point less than 32°C).
toxic materials such as lead or isocyanates
painting in confined spaces Don't forget to obtain a licence for the storage of
spraying in unventilated open workshops. petroleum products from your local petroleum
officer who works for your Fire Brigade or
TO REDUCE RISKS local Tradings Standards Department.
Use the least hazardous materials for the
job (water based paints for example and Storing and mixing paints
alternatives to lead for rust prevention are In order to minimise the flammable (and to some
widely available) extent other) risks from vapours given off by
Follow the rules for work in confined many paints and solvents:
spaces (see pages 60 and 62) and keep only small quantities (not more than
Always control spray by using ventilated 50 litres) on their own in a metal cupboard or
booths, enclosures or separate workspaces. bin for immediate use at the workplace and
larger stocks in a fire-resisting store with
Take care with paints by: spillage retention and good ventilation
using protective clothing and eye keep lids on cans and containers closed to
protection stop vapour escaping. Contain spillages by
using any pre-work barrier or protective decanting paint over a tray. Have absorbent
conditioning cream provided material readily available to soak up spillages.
removing rings or watches which can trap Keep contaminated material in a lidded
paint against the skin metal bin and dispose of its contents safely
taking care with solvents when cleaning exclude sources of ignition and use suitable
brushes, spray guns etc electrical equipment. Do not smoke where
never eating, drinking or smoking while paints are stored or used
painting ensure adequate ventilation where paints are
keeping overalls and respirator in a clean mixed. Breathing protection may be needed
state by regular washing treat containers emptied of liquid the same
washing hands before eating, and as full ones; they will often be full of vapour.
showering or bathing at the end of the day
leaving protective clothing at work to
reduce the risk of harmful substances
being taken home.

KEY REFERENCES: EIS 32 Chromate primer paints HSE Books (free)

69
 JJ

SPRAY PAINTING
BOOTHS AND ENCLOSURES

If you make your own spray booth To maximise the efficiency of any booth or
or enclosure: enclosure:

V use fire-resistant materials (see list in V provide means to indicate when dry filters
Appendix 5) need replacement. The air speed in the
immediate vicinity of the sprayer in a dry
V keep unprotected electrical equipment filter spray booth or enclosure may be the
outside (for example by installing lights lowest in the booth because of the
outside booths and shining them through accumulation of spray deposits on the
fixed and sealed fire resisting wired glass filter. Hence the air speed tends to be
panels) slowest where it is most needed

V get advice from a competent ventilation V keep unnecessary equipment out of booths.
engineer and: Large drums of paint for example can
extract to a safe place in the open air disturb the air flow pattern and cause
away from people, sources of ignition recirculation of contaminated air into the
and nearby buildings and equipment sprayer's breathing zone

use a centrifugal or bifurcated fan (with V provide sufficient and suitably protected
the motor outside the ducting in a lighting in the booth to remove the
vapour free area driving the fan through temptation to spray outside it
a gas tight shaft seal). Use flexible
armoured cable for electrical wiring to V give training in the techniques of spray
withstand fan vibration rather than painting to teach how to spray with the
mineral insulated metal sheathed cable minimum amount of overspray and
bounceback, to obtain the correct balance
use filters to prevent deposits of paint on between air and liquid flow rates, and to
motor casings, fan blades and inside ensure that the minimum pressure for
ducts; deposits may cause fans to vibrate good atomisation is always used
and run out of balance and direct
deposits may also cause motors to V consider the efficiency of the spraying
.t'',

overheat and ignite equipment used. Some equipment

generates lower levels of solvent vapour
provide access points for inspection and and overspray than others.
cleaning inside ducting.

KEY REFERENCE: Introduction to local exhaust ventilation HSG37

HSE Books ISBN 0 7176 1001 2
 SPRAY PAINTING
Booths and enclosures

MAINTAINING BOOTHS AND SPRAYING LARGE ARTICLES

ENCLOSURES: Where articles too large to enclose are sprayed
V Check booths and enclosures regularly for use a separate room after:
leaks, have them thoroughly examined and
tested every 14 months by a competent V ensuring adequate half-hour fire resistant
person (eg an insurance company separation from adjoining rooms
engineering surveyor or representative of V removing all sources of ignition such as
the supplier) and keep the reports directly fired heaters or domestic-type
V Maintain a minimum average air velocity electric and gas fires and turning off and
of 0.7 m/s at the front of open-fronted isolating electrical equipment which is not
booths and enclosures explosion protected
V Where a sprayer works inside a side V providing ventilation to a safe place while
draught booth or enclosure the average air spraying, and
velocity where the sprayer stands should V ensuring adequate personal protection is
be not less than 0.5 m/s with a minimum worn and that no-one else unprotected in
measured value of 0.4 m/s the workroom or nearby will be exposed to
V The sprayer should never stand between the spray or vapour.
the article being sprayed and the point of
extraction; a turntable to rotate articles as
necessary should be used
V Where a sprayer works inside a down
draught booth or enclosure, air
velocity (measured to points around
a typical article sprayed) should
average 0.4 m/s with a minimum
measured value of 0.3 m/s
V Ensure that airflow or air
pressure differential switches are
working to warn if designed
exhaust ventilation flow rates
are not maintained
V Maintain any interlocks fitted
between spray guns and
exhausts ventilation
V Repair damaged spray booth
and enclosure panels to
maintain the fire resistance of
the unit
V Keep escape routes and access
to rescue equipment clear
V Ensure that air intakes are not
obstructed and that discharge
vents are correctly sited and in
good repair.

KEY REFERENCE: The maintenance, examination and testing of local exhaust

HSG54 HSE Books ISBN 0 7176 1485 9
 PAINTS CONTAINING ISOCYANATES

HEALTH HAZARDS HOW CAN HEALTH BE

PROTECTED?
Two-pack spray paints containing isocyanates V Consider non-isocyanate two-pack paints
are often used to achieve hard, durable, which are available
easy to clean finishes. In these paints, V Assess the hazards and risks and prevent
isocyanate hardeners or activators are or control exposure in line with the
added to liquid resin and pigments to COSHH Regulations (see page 20)
produce a polyurethane film. V Identify isocyanate-containing two-pack
paints from their labels or suppliers' data
Vapours and spray mists containing sheets
isocyanates are highly irritant to the eyes V If you suffer from chronic respiratory
and respiratory tract and are known to disease such as chronic asthma do not
cause asthma. Isocyanates are respiratory work with two-pack paints containing
sensitisers. This means they can cause an isocyanates
allergic reaction called sensitisation. Once V Consult an occupational health
a person is sensitised to isocyanates, professional before working with
further exposure, even to the tiniest trace isocyanate-containing two-pack paints for
will cause symptoms, eg: advice on a suitable health surveillance
programme
sore eyes V Spray only in mechanically ventilated
running nose booths or separate workrooms adequately
sore throat ventilated
coughing V Use only mechanically ventilated ovens for
wheezing, tight chest accelerating curing. Run them under
fever and breathlessness. negative pressure
V Ventilate vapour and spray, after filtration,
At first these complaints may clear up at to a safe place in the open air where they
weekends or during holidays, but are likely will not be drawn back into the workroom
to return when back at work. or into nearby premises
V When mixing and spraying wear protective
Exposure to isocyanate containing glues clothing including gloves and eye
during assembly may cause similar protection; wear air fed or compressed
problems and require similar avoidance, airline breathing apparatus (depending on
control and/or protective measures. the outcome of your risk assessment) even
for small spraying jobs
V If a full facepiece canister respirator is
worn for mixing or similar jobs change the
canister before its recommended life (often
as little as 15 minutes) is exceeded. Gauze
facemasks do not provide protection
V Maintain and keep respiratory protective
equipment clean.

KEY REFERENCES: Safety in motor vehicle repair: Working with 2-pack isocyanate paints
INDG388 HSE Books (single copies free ISBN 0 7176 2756 X for priced packs of 10)
Preventing asthma at work: How to control respiratory sensitisers
L55 HSE Books 1994 ISBN 0 7176 0661 9

72
 1

POWDER COATING

HEALTH HAZARDS V If using conveyorised spray booths stand

outside the booth to spray; do not lean inside
Powder coating is an alternative finishing V Never spray towards another operator
process to spray painting. The hazards of V The amount of powder sprayed should be kept
using coating powders include: to the level that minimises its usage and
direct skin contact with the powders achieves the desired finish, by controlling gun
breathing in powders in the air settings
swallowing powders. V Provide suitable personal protective equipment
and make sure it is worn properly
Some curing or hardening agents used in V Train your employees in safe powder coating
powders, especially TGIC (triglycidl techniques to minimise exposure
isocyanurate) and TMA (tri-mellitic V Practise good housekeeping by keeping work
anhydride) can cause direct irritation of areas around the spray booths clean. Use an
the skin, eyes and lungs or allergic skin industrial vacuum cleaner rather than
reactions. There is concern that some sweeping up with a broom
curing agents may cause asthma. V Follow safe systems of work for cleaning and
maintenance activities; in particular, the use
The risks of harm occurring are highest when: of compressed air for cleaning should be kept
V using powders containing curing agents to a minimum and operators should avoid
such as TGIC or TMA standing inside the booth to clean it by using
V spraying powder in poorly ventilated long-handled rubber scrapers (not brushes)
powder-coating booths and compressed air lances
V following poor systems of work, such as V Ensure good standards of personal hygiene by
leaning into the coating booth when spraying keeping overalls clean by regular washing, and
V carrying out powder transfer, maintenance by washing hands before eating and drinking.
and cleaning work. THE LAW ON THE MAIN HAZARDS
ASSOCIATED WITH POWDER COATING outlined
TO REDUCE RISKS
V Ensure that you have chosen a powder
Hazardous substances in coating powders must be
coating that presents the lowest risk to your
controlled in line with the Control of Substances
workers' health and safety, and to the
Hazardous to Health Regulations (see page 20).
environment. Talk to your supplier or trade
association for advice. For example, you
should only use TGIC-based coating powders Other precautions to take include:
when these are needed for technical reasons.
Ask your supplier whether you need to use V minimise the risk of a fire or explosion by
them. Take care when selecting an alternative regular cleaning to prevent build up of
powder coating as some also contain other dust and exclude sources of ignition, such
hazardous substances such as isocyanates. as naked flames, cigarettes, etc from
V Minimise the amount of manual spraying powder coating work areas
carried out - many coating-booths are V minimise the risk of electric shock by ensuring
automatically operated good earthing of work equipment and regular
V Ensure that your spray booth is working at its maintenance of electrical equipment
optimum so that the air entering the system is V maintain compressed air systems associated
at least 0.5 metres per second with powder coating equipment (see page 28)

KEY REFERENCES: Controlling exposure to coating powders

HSG203 2000 HSE Books ISBN 0 7176 1761 0
Working safely with coating powders
INDG319 HSE Books 2000 (single copy free or priced packs of 10 ISBN 0 7176 1776 9)

73
 PERSONAL PROTECTIVE EQUIPMENT (PPE)

If you are thinking of using personal protective equipment (PPE) to control employees' exposure
to substances hazardous to health remember that COSHH (see page 20) limits its use to
situations where it is not reasonably practicable to use other measures.

THE PERSONAL PROTECTIVE EQUIPMENT AT WORK REGULATIONS 1992 outlined

Employers must:
provide suitable PPE free of charge to protect employees against risks which have not been
controlled by other means
take all reasonable steps to ensure it is properly used
before providing PPE, assess risks to health and safety which have not been avoided by other
means and define the characteristics which PPE must have against those risks; then
compare those characteristics against PPE available
maintain PPE provided in clean and efficient working order with appropriate
accommodation for it when not in use
give information, instruction and training.

Employees must:
use PPE provided
report any loss or obvious defect to the employer.

RESPIRATORY PROTECTIVE EQUIPMENT (RPE)

Choosing
When choosing breathing protection consider in detail the job to be done. For example, are the insides or
undersides of large articles to be sprayed?

It is likely that the ventilation will be less effective in these areas. Different types of RPE offer
different levels of protection and the correct type has to be matched to the job and the wearer.
For most spray jobs with the sprayer inside the booth, compressed airline breathing apparatus
with a full facepiece or air fed equipment may be most suitable. Before choosing, assess the work
carefully and consult your suppliers of paint and protective equipment.

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

Ensure that breathing air supplied to equipment is satisfactory; proprietary equipment to do this
is widely available.

KEY REFERENCES: Personal Protective Equipment at Work Regulations -

Guidance on Regulations L25 HSE Books ISBN 0 7176 0415 2; The selection, use and
maintenance of respiratory protective equipment HSG53 HSE Books ISBN 0 7176 1537 5

74
 PERSONAL PROTECTIVE EQUIPMENT (PPE)

EAR PROTECTION
Protectors should:
V be suitable for conditions in which they are to be used
V Provide sufficient attenuation to reduce the noise exposure level to below 90dB(A) and
preferably to below 85dB(A)
V only be issued on a personal basis
V never be removed in a noisy environment
V be compatible with other forms of necessary personal protective equipment.

In relation to ear protection, THE NOISE AT WORK REGULATIONS 1989 require in outline

ear protection to be made available on request if the daily noise exposure exceeds 85dB(A)
ear protection to be worn if the daily noise exposure exceeds 90dB(A)

EYE PROTECTION
Will have to be provided and used (sometimes throughout the whole workshop) where work
which puts eyes at risk is carried out, eg:
V machining (particularly grinding) and the use of hand tools which leads to the uncontrolled
ejection of metallic particles, and
V the use of harmful substances, such as metalworking fluids, paints or solvents which may
splash into the eye.

The provision and use of FOOT PROTECTION will also have to be considered in most
engineering workshops where there are risks of injury to the feet, for example from heavy
components being moved.

Where any PPE is needed to help control a risk to health or safety of an employee, it must be
provided and maintained (including cleaning of overalls) free of charge to the employee.

KEY REFERENCE: Protect your hearing or lose it INDG363 1999 HSE Books
(single copy free or priced packs of 25 ISBN 0 7176 2540 0)
 1i

OFFICES

ACCIDENTS and cases of ILL HEALTH : Electricity in offices can cause the most
are generally less frequent and severe in serious accidents from electric shock and
offices. To minimise risks: fire; defective plugs, sockets and leads
cause more accidents than appliances
DO themselves.
clear up spillages
replace/repair torn floor covering DO
also see the general advice on the provide enough socket outlets; avoid or
workplace (see pages 8-10) minimise the use of adaptors
follow legal requirements (see Key test any residual current devices fitted
References below) for continuous or visually inspect plugs and leads and get
extensive use of VDUs, ensure adequate them repaired by someone competent if
breaks and provide workstations which are necessary
reasonably adjustable for comfort (see consider whether more detailed tests are
pages 12-17 on how to avoid upper limb needed (for example, is the equipment
disorders). faulty or only working intermittently?)
switch off and unplug before cleaning.
DON'T
allow trailing leads to create tripping DON'T
hazards. use taped joints in electrical cables (see
pages 26-27).

90°-11 0°

100-200
_J-

Recommended adjustability u

Recommended dimensions
CHAIRS All dimensions in millimetres

KEY REFERENCE:
The law on VDUs: An easy guide HSG90 HSE Books ISBN 0 7176 2602 4

76
 1L1

ORGANISING HEALTH AND SAFETY

WHAT THE LAW REQUIRES BASIC LEGAL REQUIREMENTS outlined

Under the HSW Act, you have to ensure the health You must:
and safety of yourself and others who may be affected have a written, up-to-date health and safety policy
by what you do or fail to do. This includes people if you employ five or more people
who: work for you, including casual workers, part- carry out a risk assessment (and if you employ five
timers, trainees and sub-contractors; use workplaces or more people, record the main findings and
you provide; are allowed to use your equipment; visit your arrangements for health and safety)
your premises; may be affected by your work, eg your notify occupation of premises to your local inspector
neighbours or the public; use products you make, if you are a commercial or industrial business
supply or import; or use your professional services, display a current certificate as required by the
'peg if you also design as well as make machinery, Employers' Liability (Compulsory Insurance) Act
1969 if you employ anyone
The Act applies to all work activities and premises, display the Health and Safety Law poster for
and everyone at work has responsibilities under it, employees or give out the leaflet
including the self-employed. notify certain types of injuries, occupational
diseases and events
consult your employees, either directly or via
appointed union safety representatives on certain
issues, such as any changes which might affect
health and safety and any information and
training which has to be provided

You must not

employ children of under school leaving age, apart
from on authorised work experience schemes, if
you are an industrial undertaking.

ENFORCING THE LAW

Health and safety laws relating to your firm will usually be enforced by a health and safety inspector from the HSE,
but where the workshop is part of a larger enterprise, such as a large department store where health and safety law
is enforced by the local authority, by a local authority inspector.

Inspectors may visit workplaces without notice but you are entitled to see their identification before they come in.
They may want to investigate an accident or complaint, or inspect safety, health and welfare in the workshop. They
have the right to talk to employees and safety representatives, take photographs and samples, and even in certain
cases to impound dangerous equipment. They are entitled to co-operation and answers to questions.

Inspectors will be aware of the main risks in engineering workshops and will give you help and advice on how to
comply with the law. If there is a problem they may issue a formal notice requiring improvements or, where
serious danger exists, one which prohibits the use of a process or equipment.

Inspectors have powers to prosecute a firm (or an individual) for breaking health and safety law.

KEY REFERENCE: Essentials of health and safety at work HSE Books ISBN 0 7176 0716 X
 ACCIDENTS AND EMERGENCIES

Before the event Points to include in emergency procedures:

In any workshop, things sometimes go wrong. You V Consider what might happen and how the
need to be ready to deal with these unplanned alarm will be raised. Don't forget night and
events. Look at incidents which have caused shift working, week-ends and (possibly) times
injuries and ill health or other damage - what when the premises are closed, eg holidays
can you learn? Think about emergencies - V Plan what to do, including how to call the
plan for the worst that can happen. You must emergency services. Assist the emergency
have the right first-aid arrangements. Some services by clearly marking your premises
events need to be reported - this chapter tells from the road. Consider drawing up a simple
you how to do this. plan marked with the location of hazardous
items
THE LAW ON ACCIDENTS AND V If you have at least 25 tonnes of certain
EMERGENCIES outlined dangerous substances you must notify the fire
authority and put up warning signs
The Management of Health and Safety at Work V Decide where to go to reach a place of safety
Regulations 1992 cover emergencies. or to get rescue equipment. Provide
The requirements for first aid are in the Health and emergency lighting if necessary
Safety (First Aid) Regulations 1981, and for reporting V You must make sure there are enough
incidents in the Reporting of Injuries, Diseases and emergency exits for everyone to escape
Dangerous Occurrences Regulations 1995 quickly, and keep emergency doors and escape
(RIDDOR). routes unobstructed and clearly marked
The Dangerous Substances (Notification and Marking V Nominate competent persons to take control
of Sites) Regulations 1990 cover sites where at least V Decide who the other key people are such as
25 tonnes of certain dangerous substances are held. first aiders
V Plan essential actions such as emergency plant
shut-down or making processes safe;
Emergency procedures clearly label important items like shut-off
When things go wrong, people may be exposed to valves and electrical isolators for plant and
serious and immediate danger. Special machinery
procedures are necessary in engineering V You must train everyone in emergency
workshops for emergencies such as serious procedures
injuries, explosion, poisoning, electrocution, V Don't forget the needs of people with
fire, release of radioactivity and chemical spills. disabilities.
Write an emergency plan if a major incident at
your workplace could involve risks to the
public, rescuing employees or the co-
ordination of emergency services.

Think about
V The worst that can happen if things go wrong
V How the person in charge and others will deal
with the problems. You should look at any
particular responsibilities and training needs
V Is everyone adequately prepared and could
emergency services get to the site?

78
 ACCIDENTS AND EMERGENCIES

Investigating events THE LAW ON REPORTING INJURIES AND

When an accident happens: OTHER EVENTS outlined
take any action required to deal with the
immediate risks, eg first-aid, put out the fire, The Reporting of Injuries, Diseases and Dangerous
isolate any danger, fence off the area Occurrences Regulations 1995 (RIDDOR) apply to all
assess the amount and kind of investigation employers and the self-employed and cover everyone at
needed - if you have to disturb the site, take work.

x00
photographs and measurements first
investigate - find out what happened and why The main points are that you must:
take steps to stop something similar notify your inspector immediately, normally by
happening again telephone, if anybody dies, receives a major injury or
also look at near misses and property is seriously affected by, for example an electric shock
damage. Often it is only by chance that or poisoning.
someone wasn't injured. notify your inspector immediately if there is a
dangerous occurrence, eg a fire or explosion, which
Checklist stops work for more than 24 hours, or an overturned
To help with your investigations, find out the crane
following: confirm in writing within seven days on F2508
Details of injured personnel report within seven days (on form F2508) injuries
Details of injury, damage or loss which keep an employee off work or unable to do
What was the worst that could have their normal job for more than three days
happened? Could it happen again? report certain diseases suffered by workers who do
What happened? Where? When? What was specified types of work as soon as possible on
the direct cause? learning about the illness. Use form F2508A. Cases of
Were there standards in place for the occupational
premises, plant, substances, procedures asthma (from isocyanate paints, for example)
involved? oil acne
Were they adequate? Were they followed? vibration white finger
V Were the people up to the job? Were they dermatitis
competent, trained and instructed? may arise in some engineering workshops.
What was the underlying cause? Was there keep details of the incidents reported.
more than one?
What was meant to happen and what were Incident Contact Centre (ICC)
the plans? How were the people organised? In addition to the above procedures, new arrangements
Would inspection have picked up the problem were introduced for reporting incidents which occurred
earlier? on or after April 2001. Incidents can now be reported to
Had it happened before? If so, why weren't the ICC by telephone, fax, post or via the Internet
the lessons learnt? (www.riddor.gov.uk or www.hse.gov.uk)

Most accidents have more than one cause so

don't be too quick to blame individuals - try
to deal with the root causes.

KEY REFERENCE:
Guide to the Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1995 L73
HSE Books ISBN 0 7176 2431 5

79
 FIRST AID

A first-aid box should contain a sufficient quantity of suitable first-aid materials and nothing else
no lotions, medicines or treatments (including paracetamol).

The box of a typical small workshop with no additional or special hazards may include:

Item Quantity
Guidance Card IND(G) 4 (P) Rev 1

Individually wrapped sterile adhesive dressings (assorted size) 20

Sterile eye pads, with attachment 2
Individually wrapped triangular bandages 6
Safety pins 6
Medium sized individually wrapped sterile unmedicated wound dressings 6
(approx 10 cm x 8 cm)
Large sterile and individually wrapped unmedicated wound dressings 2
(approx 13 cm x 9 cm)
Extra large sterile individually wrapped unmedicated wound dressings 3
(approx 28 cm x 17.5 cm)

If work in confined spaces, such as large metal fabrications or vapour degreasing tanks is carried
out, resuscitating equipment should be provided and maintained, and persons trained in its use.

If cyanide or other especially hazardous substances are used, appropriate antidotes, equipment
and training should also be provided, and the suppliers of the substances concerned, or
EMAS, consulted in the first instance.

HEALTH AND SAFETY (FIRST AID) As your company grows, look again at your
REGULATIONS 1981 outlined need for qualified first aiders. They must
ono

be properly trained and have a valid first

You must have: aid at work certificate. These certificates
someone who can take charge in an emergency. are issued for three years but can be
cow

(The minimum requirement is for an appointed renewed following refresher training and
person to be available whenever people are at work re-examination. Training organisations
- and is the lowest grade of first aid cover) are registered with the Employment
a first-aid box Medical Advisory Service - ask your
notices telling people where the first-aid box is and Employment Nursing Adviser at the local
who the appointed person is HSE office.
a qualified first aider where the situation demands,
eg if your work gives rise to special hazards, such as
those from toxic materials or dangerous machinery
a first-aid room if you are a long way from
emergency medical services.

KEY REFERENCES: Basic advice on first aid at work INDG347

(single copy free or priced packs of 20 ISBN 0 7176 2261 4)
First aid at work. Approved Code of Practice and Guidance
L74 HSE Books ISBN 0 7176 1050 0
 HOW TO OBTAIN PUBLICATIONS
AND FURTHER ASSISTANCE

HSE Publications Surface Engineering Association

HSE priced and free publications are available by Confederation House
mail order from HSE Books, PO Box 1999, 10 Vyse St
Sudbury, Suffolk COlO 2WA Tel: 01787 881165 Birmingham B18 6LT
Fax: 01787 313995 Website: www.hsebooks.co.uk Tel: 0121 236 2657 Fax: 0121 237 1124
(HSE priced publications are also available from
bookshops.) EEF. The Manufacturers' Organisation
Broadway House, Tothill Street
For information about health and safety ring HSE's London SW1H 9NQ
InfoLine Tel: 08701 545500 Fax: 02920 859260 Tel: 020 7222 7777 Fax: 020 7222 2782
e-mail: hseinformationservices@natbrit.com or Website: www.eef.org.uk
write to HSE Information Services, Caerphilly
Business Park, Caerphilly CF83 3GG. You can also AMICUS AEU
visit HSE's website: www.hse.gov.uk Engineering Section
Terry Duffy House, Thomas Street
Engineering sector pages: Holloway Circus, Queensway
www.open.gov.uk/hse/fod/engship.htm. West Bromwich B70 6NT
Tel: 0121 643 1042 Fax: 0121 569 8910
HSC Newsletter is available on subscription
from: Envirowise
Harwell
HSE Books Oxfordshire OX 11 ORA
Subscriptions Department Tel: 0800 585794 Fax: 0870 1906713
PO Box 1999, Sudbury, Suffolk CO10 2WA
Tel: 01787 881165 Fax: 01787 313995 Other publications
Stationery Office publications are available
Other sources of information from:
British Safety Council
National Safety Centre, 70 Chancellors Road The Publications Centre
London W6 9RS PO Box 276, London SW8 5DT
Tel: 020 8741 1231 Fax: 020 8741 4555 Tel: 0870 600 5522 Fax: 0870 600 5533
Website: www.tso.co.uk (They are also
Royal Society for the Prevention of Accidents available from bookshops.)
Edgbaston Park, 353 Bristol Road
Birmingham B5 7ST British Standards are available from:
Tel: 0121 248 2000 Fax: 0121 248 2001
BSI Customer Services
The Manufacturing Technologies Association 389 Chiswick High Road London W4 4AL
62 Bayswater Road, London W2 3PS Tel: 020 8996 9001 Fax: 020 8996 7001
Tel: 020 7298 6400 Fax: 020 7298 6430 Website: www.bsi-global.com
Website: www.mta.org.uk
HSE videos are available from HSE Books

81
 FURTHER READING AND INFORMATION
Unless otherwise indicated, the following titles are available from HSE Books.

Managing health and safety

HSG65 Successful health and safety management rev 1997 ISBN 0 7176 1276 7
HSG96 The costs of accidents at work rev 1997 ISBN 0 7176 1343 7
L21 Management of health and safety at work. Management of Health and Safety
at Work Regulations 1999. Approved Code of Practice and guidance (Second
edition) HSE Books 2000 ISBN 0 7176 2488 9
INDG324 Starting your business. Guidance on preparing a health and safety policy
document for small firms (single copy free; ISBN 0 7176 1799 8 for priced pack
of 5 copies)
HSC13(revl) Health and safety regulation: a short guide 2003 (free)
HSE40 Employers' Liability (Compulsory Insurance) Act 1969 2002 (free)
HSE34 HSE and you 2000 (free)
HSE38 HSE: Working with employers 2000 (free)
INDG275 Management of health and safety. Five steps to success 1998 (single copy free;
ISBN 0 7176 2170 7 for priced packs of 10 copies)
5 steps to risk assessment 1998 (single copies free; ISBN 0 7176 1565 0 for
priced packs of 10 copies)
Safety representatives and safety committees (Third edition) HSE Books 1996
ISBN 0 7176 1220 1
Health risk management 1995 ISBN 0 7176 0905 7
Essentials of health and safety at work 1994 ISBN 0 7176 0716 X
SCB 014 Be safe: A guide to health and safety in training available from Department for
Education and Skills, tel 0845 6022260
INDG355 Reduce risks - cut costs: The real cost of accidents and ill health at work 2002
(single copy free; ISBN 0 7176 2337 8 for priced packs of 15 copies)
INDG322 Need help on health and safety? 2000 (single copy free; ISBN 0 7176 1790 4 for
priced packs of 10 copies)
HSC14 What to expect when a health and safety inspector calls 1998 (free)
INDG232 Consulting employees on health and safety: A guide to the Law (single copies
free; ISBN 0 7176 1615 0 for priced packs of 15 copies)
INDG218 Guide to risk assessment requirements: Common provisions in health and
COD

safety law (single copies free; ISBN 0 7176 1211 2 for priced packs of 5 copies)
HSG165 Young people at work: A guide for employers (Second edition) 2000
x11

ISBN 0 7176 1889 7

A guide to the Working Time Regulations DTI tel 08701 502 500
HSG218 Tackling work-related stress: A manager's guide 2001 ISBN 0 7176 2050 6
HSG183 Five steps to risk assessment: Case studies 1998 ISBN 0 7176 1580 4
L95 A guide to the Health and Safety (Consultation with Employees) Regulations
1996 1996 ISBN 0 7176 1234 1
Improving maintenance: A guide to reducing human error 2000
ISBN 0 7176 1818 8

82
Workshops
HSG194 Thermal comfort in the workplace: Guidance for employers 1999 ISBN 0 7176 2468 4
L64 Safety signs and signals. The Health and Safety (Safety Signs and Signals)
Regulations 1996. Guidance on Regulations 1996 ISBN 0 7176 0870 0
L24 Workplace health, safety and welfare. Workplace (Health Safety and Welfare)
Regulations 1992. Approved Code of Practice and Guidance 1992 ISBN 0 7176 0413 6
INDG244 Workplace health, safety and welfare: A short guide 1997 (single copies free;
ISBN 0 7176 1328 3 for priced packs of 10 copies)
HSG38 Lighting at work 1998 ISBN 0 7176 1232 5
INDG63(rev) Passive smoking at work: Workplace air pollution 1992 (single copies free;
ISBN 0 7176 0882 4 for priced packs of 10 copies)
INDG225 Preventing slips, trips and falls (single copies free; ISBN 0 7176 1183 3 for
priced packs of 15 copies)
IND G3 6 (rev2 ) Working with VDUs (single copies free; ISBN 0 7176 2222 3 for priced packs of
10 copies)
HSG165 Young people at work: A guide for employers (Second edition) 2000
ISBN 0 7176 1889 7
HSG122 New and expectant mothers at work: A guide for employers (Second edition) 2002
ISBN 0 7176 2583 4
HSG155 Slip and trips. Guidance for employers on identifying hazards and controlling
risks 1996 ISBN 0 7176 1145 0
Lifting equipment
L113 Safe use of lifting equipment. Lifting Operations and Lifting Equipment Regulations.
Approved Code of Practice and guidance 1998 ISBN 0 7176 1628 2
PM55 Safe working with overhead travelling cranes 1985 ISBN 0 11 883524 6

Manual handling
L23 Manual handling. Manual Handling Operations Regulations 1992. Guidance
on Regulations (Second edition) 1998 ISBN 0 7176 2415 3
INDG90(rev2) Understanding ergonomics at work: Reduce accidents and ill health and
increase productivity by fitting the task to the worker 2003 (single copies free;
ISBN 0 7176 2599 0 for priced packs of 15 copies)
INDG143(revl) Getting to grips with manual handling: A short guide for employers 2000
(single copies free); ISBN 0 7176 1754 8 for priced packs of 15 copies
INDG171 Aching arms (or RSI) in small businesses: Is ill health due to upper limb
disorders a problem in your workplace? 2003 (single copies free;
ISBN 0 7176 2600 8 for priced packs of 15 copies)
HSG60 Upper limb disorders: A guide to prevention (rev) 2002 ISBN 0 7176 1978 8
HSG57 Seating at work 1998 ISBN 0 7176 1231 7
HSG115 Manual handling: Solutions you can handle 1994 ISBN 0 7176 0693 7
HSG121 A pain in your workplace? Ergonomic problems and solutions 1994
ISBN 0 7176 0668 6
EIS16 Preventing injuries from the manual handling of sharp edges in the
engineering industry (free)
INDG390 Choosing a welding set? Make sure you can handle it 2003 (single copy free;
ISBN 0 7176 2773 X for priced packs of 10 copies)

83
Transport (and storage)
L117 Rider operated lift trucks - operator training. Approved Code of Practice and
guidance 1999 ISBN 0 7176 2455 2
HSG6 Safety in working with lift trucks 2000 ISBN 0 7176 1781 5
INDG148 Reversing vehicles 1993 (single copies free; ISBN 0 7176 1063 2 for priced packs
of 15 copies)
HSG76 Health and safety in retail and wholesale warehouses 1992 ISBN 0 7176 0445 4
HSG136 Workplace transport safety 1995 ISBN 0 7176 0935 9
INDG199 Managing vehicle safety at the workplace 1995 (single copies free;
ISBN 0 7176 0982 0 for priced packs of 10 copies)
INDG313 Safe unloading of steel stock 2000 (single copies free or priced packs of 15
ISBN 0 7176 1765 3)
Hazardous substances
L132 Control of lead at work. Control of Lead at Work Regulations 2002. Approved
Code of Practice and guidance (Third edition) HSE Books 2002
ISBN 0 7176 2565 6
EH40/2002 Occupational exposure limits ISBN 0 7176 2083 2
Supplement 2003 ISBN 0 7176 2172 3
1-4

HSG37 An introduction to local exhaust ventilation 1993 ISBN 0 7176 1001 2

HSG54 The maintenance, examination and testing of local exhaust ventilation
1998 ISBN 0 7176 1485 9
INDG174 A short guide to the Personal Protective Equipment at Work Regulations 1992
(single copies free; ISBN 0 7176 0889 1 for priced packs of 10 copies)
INDG233 Preventing dermatitis at work (single copies free; ISBN 0 7176 1553 7 for priced
packs of 15 copies)
INDG95(rev2) Respiratory sensitisers and COSHH (single copies free; ISBN 0 7176 0914 6 for
priced packs of 15 copies)
INDG188 Asbestos alert for building maintenance, repair and refurbishment workers
(pocket card) 1995 (single copies free; ISBN 0 7176 1209 0 for priced packs of 25
copies)
INDG223(revl) Managing asbestos in workplace buildings 1996 (single copies free;
fin

ISBN 0 7176 1179 5 for priced packs of 10 copies)

INDG136(rev2) COSHH. A brief guide to the Regulations (single copies free;
ISBN 0 7176 2677 6 for priced packs of 10 copies)
HSG126 CHIP for everyone 2002 ISBN 0 7176 2370 X
L5 Control of substances hazardous to health. The Control of Substances
Hazardous to Health Regulations 2002. Approved Code of Practice and guidance
(Fourth edition) HSE Books 2002 ISBN 0 7176 2534 6
L8 Legionnaires' disease. The control of legionella bacteria in water systems.
Approved Code of Practice and guidance (Second edition) HSE Books 2002
ISBN 0 7176 1772 6
INDG181 The idiot's guide to CHIP 3 2002 (single copies free; ISBN 0 7176 2333 5 for priced
packs of 5 copies)
HSG53 The selection, use and maintenance of respiratory protective equipment:
A practical guide rev 1998 ISBN 0 7176 1537 5
L25 Personal protective equipment at work. Personal Protective Equipment at
Work Regulations 1992. Guidance on Regulations HSE Books 1992
ISBN 0 7176 0415 2

84
MS25 Medical aspects of occupational asthma rev 1998 ISBN 0 7176 1547 2
L55 Preventing asthma at work: How to control respiratory sensitisers
HSE Books 1994 ISBN 0 7176 0661 9
HSG61 Surveillance of people exposed to health risks at work 1999 ISBN 0 7176 1705 X
EH1 Cadmium: health and safety precautions 1995 ISBN 0 7176 0825 5
EH13 Beryllium: health and safety precautions 1995 ISBN 0 7176 0824 7
EH60 Nickel and its inorganic compounds: Health and safety precautions 1997
ISBN 0 7176 1341 0
HSG193 COSHH essentials: Easy steps to control chemicals. Control of Substances
Hazardous to Health Regulations (Second edition) 2003 ISBN 0 7176 2737 3 It
can also be freely accessed at www.coshh-essentials.org.uk
HSG188 Health risk management: A guide to working with solvents 1999
ISBN 0 7176 1664 9
HSG110 Seven steps to successful substitution of hazardous substances 1994
.-4

ISBN 0 7176 0695 3

HSG173 Monitoring strategies for toxic substances 1997 ISBN 0 7176 1411 5
HSG203 Controlling exposure to coating powders HSG203 2000 ISBN 0 7176 1761 0
INDG319 Working safely with coating powders 2000 (single copy free or priced packs of
'-1

10 ISBN 0 7176 1776 9)

Electricity
HSR25 Memorandum of guidance on The Electricity at Work Regulations 1989,
1989 ISBN 0 7176 1602 9
HSG85 Electricity at work: Safe working practices 2003 ISBN 0 7176 2164 2
V'1

HSG107 Maintaining portable and transportable electrical equipment 1994

ISBN 0 7176 0715 1
BS 7671:2001 Requirements for electrical installations. IEE Wiring Regulations
ISBN 0 85296 9880
GS38 Electrical test equipment for use by electricians 1995 ISBN 0 7176 0845 X
INDG231 Electrical safety and you (single copies free; ISBN 0 7176 1207 4 for priced
packs of 15 copies)
PM29 Electrical hazards from steam/water pressure cleaners 1995 ISBN 0 7176 0813 1
INDG68 Do you use a steam/water pressure cleaner? You could be in for a shock 1997 (free)
11VDG354 Safety in electrical testing at work: General guidance 2002 (single copy free or
priced packs of 5 ISBN 0 7176 2296 7)
Pressurised plant and systems
L122 Safety of pressure systems. Pressure Systems Safety Regulations 2000. Approved
Code of Practice. HSE Books 2000 ISBN 0 7176 1767 X
GS 4 Safety in pressure testing 1998 ISBN 0 7176 1629 0
PM60 Steam boiler blowdown systems rev 1998 ISBN 0 7176 1533 2
HSG39 Compressed air safety rev 1998 ISBN 0 7176 1531 6

Machinery safeguarding
- Product standards: Machinery - guidance notes on UK regulations Ref 95650 (free)
Department ofTrade and Industry, tel: 0870 1502500
SI 1992/3073 Supply of Machinery (Safety) Regulations 1992 (as amended by SI 1994/2063)

85
 JJ

L22 Safe use of work equipment. Provision and Use of Work Equipment Regulations
1998 Approved Code of Practice and guidance 1998 ISBN 0 7176 1626 6

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

f.'
f/1

EIS7 Safeguarding 3 roll bending machines 1998 (free)

(/1

EIS13 Safeguarding of combination metalworking machines 2000 (free)

(/)

EIS33 CNC turning machines: Controlling risks from ejected parts 2001 (free)
t-4

EIS2 Accidents at metalworking lathes using emery cloth 1993 (free)

PM83 Drilling machines: guarding of spindles and attachments 1998 ISBN 0 7176 1546 4
L112 Safe use of power presses. Provision and Use of Work Equipment Regulations
1998 as applied to power presses. Approved Code of Practice and guidance 1998
ISBN 0 7176 1627 4
HSG17 Safety in the use of abrasive wheels 2000 ISBN 0 7176 1739 4
HSG42 Safety in the use of metal cutting guillotines and shears 1988 ISBN 0 11 885455 0
HSG43 Industrial robot safety: Your guide to the safeguarding of industrial robots 2000
ISBN 0 7176 1310 0
BS EN 60825 Safety of laser products. Part 1: 1994 Equipment classification, requirements
and user's guide
IEC 60825-1:1993 Safety of laser products (including 1997 and 2001 amendments)
p.'
EIS19 Engineering machine tools: retrofitting CNC 1997 (free)
EIS28 Safeguarding at horizontal boring machines 1998 (free)
HSG236 Power presses: Maintenance and thorough examination 2003 ISBN 0 7176 2171 5
HSG180 Application of electro-sensitive protective equipment using light curtains and light
fir"

'LT

beam devices in machinery 1999 ISBN 0 7176 1550 2

Power presses Parts 1 and 2 1992 ISBN 0 7176 1994 X
H.'

Video

Metalworking fluids
INDG365 Working safely with metalworking fluids 2003 (single copy free;
ISBN 0 7176 2545 1 for priced packs of 10 copies)
Exposure to hard metals in metalworking fluids during machining operations
British Lubricants Federation 1994, available from BLF, tel: 01442 230589
Video package Metalworking fluids: Effective coolant care and the control of risks to health
1994 ISBN 0 7176 0875 1
Pack Working safely with metalworking fluids 2002 ISBN 0 7176 2561 3

Noise
'"p

L108 Reducing noise at work. Guidance on the Noise at Work Regulations 1989 1998
ISBN 0 7176 1511 1
INDG362 Noise at work: Advice for employers (single copy free; ISBN 0 7176 2539 7 for
priced packs of 10 copies)
INDG363 Protect your hearing or lose it. 2002 (single copy free; ISBN 0 7176 2540 0 for
priced packs of 25 copies)

86
HSG138 Sound solutions: Techniques to reduce noise at work 1995 ISBN 0 7176 0791 7
INDG201 Protect your hearing or lose it (single copies free; ISBN 0 7176 2540 5 for priced
packs of 25 copies)
PM56 Noise from pneumatic systems 1985 ISBN 0 11 883529 7
INDG362 (rev) Noise at work. Advice for employers 1995 (single copies free; ISBN 0 7176 2539 7
for priced packs of 10 copies)
EIS26 Noise in engineering 1998 (free)
EIS29 Control of noise at power presses 1998 (free)

Vibration
INDG126(revl) Health risks from hand-arm vibration: Advice for employees and the self-employed 1998
(single copies free; ISBN 0 7176 1554 5 for priced packs of 15 copies)
INDG175 Health risks from hand-arm vibration: Advice for employers rev 1998 (single
copies free; ISBN 0 7176 1553 7 for priced packs of 10 copies).
HSG88 Hand-arm vibration 1994 ISBN 0 7176 0743 7
HSG170 Vibration solutions 1997 ISBN 0 7176 0954 5
INDG338 Power tools: How to reduce health risks. Guide for employers (single copy free
or priced packs of 15 ISBN 0 7176 2008 5)

Cleaning and degreasing

INDG98 Permit-to-work systems 1991 (single copies free; ISBN 0 7176 1331 3 for priced
packs of 15 copies)
L101 Safe work in confined spaces. Confined Spaces Regulations 1997. Approved
Code of Practice, Regulations and guidance ISBN 0 7176 1405 0
EIS20(revl) Maintenance and cleaning of solvent degreasing tanks 1998 (free)
EIS21 Immersion and cold cleaning of engineering components (free)
GG354 Surface cleaning and preparation: Choosing the best option Envirowise (see
page 61)
EIS40 Safe use of solvent degreasing plant 2003 (free)
F--1

EIS34 Surface cleaning: Solvent update including the reclassification of

trichloroethylene 2002 (free)

Flamecutting and welding

HSG118 Electrical safety in arc welding 1994 ISBN 0 7176 0704 6
HSE8 Oxygen: Fire and explosion hazards in the use and misuse of oxygen 1992 (free)
CS15 Cleaning and gas freeing of tanks containing flammable residues 1985
ISBN 0 7176 1365 8
Health and safety in welding and allied processes (4th Ed) N.Balchin,
Welding Institute 2002 ISBN 0 85573 538 5 (available from Woodhead
Publishing, tel: 01223 891358)
Welding fume: A welder's guide 1985 Welding Institute (available from
Woodhead Publishing, Tel: 01223 891358)
BS EN ISO Health and safety in welding and allied processes. Sampling of airborne
10882-1: 2001 particles and gases in the operator's breathing zone British Standards
Institution
BS EN 169: 2002 Personal eyeprotection. Filters for welding and related techniques British
Standards Institution
BS EN 166: 2002 Personal eye-protection. Specifications British Standards Institution

87
BS EN 175: 1997 Personal protection. Equipment for eye and face protection during welding and
allied processes British Standards Institution
HSG139 The safe use of compressed gases in welding, flame cutting and allied processes
1997 ISBN 0 7176 0680 5
HSG204 Health and safety in arc welding 2000 ISBN 0 7176 1813 7
INDG327 Take care with acetylene 2000 (single copy free or priced packs of 10
ISBN 0 7176 1817 X)

Radiography
L121 Work with ionising radiation. Ionising Radiations Regulations 1999. Approved
Code of Practice and guidance. HSE Books 2000 ISBN 0 7176 1746 7
IRIS1(revl) Industrial radiography: Managing radiation risks 2000 (free)
IRIS2(revl) Radiation doses: Assessment and recording 2000 (free)
- Radiation safety for site radiography Engineering Construction Industry
Association tel: 0171 799 2000 ISBN 0 903393 867 (o/p; updated version due 2004)

Painting
HSG51 Storage offlammable liquids in containers (rev 1998) ISBN 0 7176 1471 9
HSG140 Safe use and handling of flammable liquids 1996 ISBN 0 7176 0967 7
EH16 Isocyanates: Health hazards and precautionary measures 1999
ISBN 0 7176 1701 7
- Code of safe practice: Application of thermosetting coating powders by
electrostatic spraying 1997 available from the British Coating Federation,
tel: 01372 360660
SI 2002/2776 The Dangerous Substances and Explosive Atmospheres Regulations 2002 The
Stationery Office ISBN 0 11 042957 5
INDG227 Safe working with flammable substances (single copies free; ISBN 0 7176 1154 X
for priced packs of 15 copies)
EIS15 Control of exposure to triglycidyl isocyanurate (TGIC) in powder coatings 1998
(free)
HSG178 The spraying of flammable liquids 1998 ISBN 0 7176 1483 2

88
Offices
INDG236 Maintaining portable electrical equipment in offices and other low risk
environments (single copies free; ISBN 0 7176 1272 4 for priced packs of 10 copies)
INDG36(revl) Working with VDUs 1998 (single copies free; ISBN 0 7176 1504 9 for priced packs
of 10 copies)
L26 Work with display screen equipment. Health and Safety (Display Screen
Equipment) Regulations 1992 as amended by the Health and Safety
(Miscellaneous Amendments) Regulations 2002. Guidance on Regulations
(Second edition) HSE Books 2003 ISBN 0 7176 2582 6
INDG173 Officewise 1994 (single copies free; ISBN 0 7176 0773 9 for priced packs of 10 copies)
HSG90 The law on VDUs: An easy guide. Make sure your office complies with the
Health and Safety (Display Screen Equipment) Regulations 1992 (as amended
2002) 2003 ISBN 0 7176 2602 4

Accidents and emergencies

L74 First aid at work. Health and Safety (First Aid) Regulations 1981. Approved
Code of Practice and guidance 1997 ISBN 0 7176 1050 0
Form F2508/ Report of an injury or dangerous occurrence or case of disease 1996
FormF2508A ISBN 0 7176 1078 0
L73 Guide to the Reporting of Injuries, Diseases and Dangerous Occurrences
Regulations 1999 1999 ISBN 0 7176 2431 5
HSE31(revl) RIDDOR explained 1999 (single copies free; ISBN 0 7176 2441 2 for priced packs
of 10 copies)
INDG214 First aid at work - your questions answered 1997 (single copies free;
ISBN 0 7176 1074 8 for priced packs of 15 copies)
INDG215 Basic advice on first aid at work 2002 (single copies free; ISBN 0 7176 2261 4 for
priced packs of 20 copies)

While every effort has been made to ensure the accuracy of the references listed in this publication,
their future availability cannot be guaranteed.

89
 HSE OFFICES

South West Marches

Inter City House The Marches House, Midway
Mitchell Lane, Victoria Street Newcastle under Lyme, Staffs ST5 1DT
Bristol BS1 6AN Tel: 0117 988 6000 Tel: 01782 602300

South North Midlands

Priestley House, Priestley Road The Pearson Building, 55 Upper
Basingstoke RG24 9NW Parliament Street,
...

Tel: 01256 404000 Nottingham NG1 6AU Tel: 01159 712800

South East South Yorkshire & Humberside

Phoenix House Edgar Allen House,
23-25 Cantelupe Road, East Grinstead 241 Glossop Road,
West Sussex RH19 3BE Sheffield S10 2GW Tel: 0114 291 2300
Tel: 01342 334200
West & North Yorkshire
East Anglia Marshall's Mill, Marshall Street,
Wren House Leeds LS11 9YJ
f''
Hedgerows Business Park, Tel: 0113 283 4200
Colchester Road, Springfield, Chelmsford,
Essex CM2 5PF Tel: 01245 706200 Greater Manchester
Grove House, Skerton Road,
Northern Home Counties Manchester M16 ORB Tel: 0161 952 8200
z-.

14 Cardiff Road, Luton, Beds LU1 1PP

Tel: 01582 444200 North West
Marshall House, Ringway
East Midlands Preston PR1 2HS Tel: 0161 952 8200
5th Floor, Belgrave House, 1 Greyfriars
Northampton NN1 2BS Tel: 01604 738300 North East
Arden House, Regent Centre
West Midlands Gosforth, Newcastle upon Tyne NE3 3JN
1 Hagley Road, Edgbaston Tel: 0191 202 6200
Birmingham B16 8HS
Tel: 0121 607 6200 Scotland East
`NN

Belford House, 59 Belford Road

Wales Edinburgh EH4 3UE Tel: 0131 247 2000
Government Buildings
Phase 1, Ty Glas Scotland West
Llanishen 375 West George Street, Glasgow G2 4LW
Cardiff CF14 5SH Tel: 0141 275 3000
Tel: 029 2026 3000
(See www.hse.gov.uk/contact/local.htm for up-
to-date list of HSE local offices)
 SOME USEFUL ADDRESSES FOR SELECTING A
HEALTH AND SAFETY CONSULTANCY

Association of Consulting Engineers British Institute of Non-Destructive Testing

Alliance House, 12 Caxton Street 1 Spencer Parade, Northampton NN1 5AA

London SW1H OQL

The Institution of Mechanical Engineers
Association of Noise Consultants 1 Birdcage Walk, London SW1 9JJ

6 Trap Road, Guiden Morden, Herts SG8 OJE

The Institute of Occupational Hygienists
British Occupational Hygiene Society Georgian House, Great Northern Road
Georgian House, Great Northern Road Derby DE1 1LT
Derby DE1 1LT
The Institute of Occupational Safety & Health
British Safety Council The Grange, Highfield Drive
Chancellors Road, London W6 9RS Wigston, Leics LE18 INN

Chartered Institute of Building Services Engineers The Institute of Radiation Protection

Delta House, 222 Balham High Road 64 Dalkeith Road, Harpenden, Herts AL5 5PW
London SW12 9BS
The Royal College of Nursing
Council of Independent Inspecting Authorities Society of Occupational Health Nursing
14 St Mary's Parsonage, Manchester M60 9AP RCN North Western Area, 18 Fox Street
Preston, Lancs PR1 2AB
EEF. The Manufacturers' Organisation
Broadway House, Tothill Street The Royal Environmental Health
London SW1H 9NQ Institute of Scotland
3 Manor Place, Edinburgh EH3 7DH
The Engineering Society
Devonshire House, Devonshire Square The Royal Society of Chemistry
Loughborough, Leics LE11 3DW Burlington House, Piccadilly, London W1V OBN

Independent Safety Consultants Association The Royal Society for the Prevention
c/o Hinton and Higgs, The Firs of Accidents
Marcham Road, Abingdon, Oxon OX14 IAA Edgbaston Park, 353 Bristol Road, The Priory,
Queensway, Birmingham B5 7ST
The Institute of Acoustics
PO Box 320, St Albans, Herts AL1 19Z The Society of Occupational Medicine
6 St Andrew's Place, Regents Park
The Institute of Chemical Engineers London NW1 4LB
165-171 Railway Terrace, Rugby,
Warwicks CV21 3HQ The Society for Radiological Protection
148 Buckingham Palace Road
The Institution of Electrical Engineers London SW1W 9TR
Savoy Place, London WC2R OBL
National Certification Scheme for
The Institute of Environmental Health Officers In-Service Inspection Bodies (NCSIIB)
Chadwick House, Rushworth Street 1 Birdcage Walk, Westminster

London SE1 OQT London SW1H 9JJ

KEY REFERENCE: Need help on health and safety? INDG322 HSE Books (single copies free;
ISBN 0 7176 1790 4 for priced packs of 15)

91
 APPENDIX I
LIFTING CHECKLIST - SECTION A
SUMMARY OF ASSESSMENT

Operations covered by this assessment: Overall priority for remedial action: NiULow/MedlHigh
Remedial action to be taken:

Locations:
Personnel involved: Date by which action is to be taken:
Date for reassessment:
Assessor's name:
Date of assessment: Signature:

Section A - Preliminary:
Ql Do the operations involve a significant risk of injury? Yes / No

z
If `Yes' go to Q2. If `No' the assessment need go no further.
If in doubt answer `Yes'

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

If `No' go to Q3. If `Yes' proceed and then check that the result is satisfactory.

Q3*Are the operations clearly within the numerical guidelines for assessment contained in the
guidance on the Manual Handling Regulations (pages 42-45)? Yes / No
If `No' go to Section B. If `Yes' you may go straight to Section C if you wish.

*This question can only be answered by using pages 42-45 of the publication referenced below:

Section C - Overall assessment ofrisk:

Q What is your overall assessment of the risk of injury? Insignificant/Low/Med/High
If not `Insignificant' go to Section D.
If `Insignificant' the assessment need go no further.

Section D - Remedial action:

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

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

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

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

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

And finally:
complete the SUMMARY above
V compare it with your other manual handling assessments
V decide your priorities for action
V TAKE ACTION ...............AND CHECK THAT IT HAS THE DESIRED EFFECT

KEY REFERENCE: Manual Handling Operations Regulations 1992. Guidance on Regulations

L23 (Second edition) HSE Books ISBN 0 7176 2415 3

92
 LIFTING CHECKLIST - SECTION B
Section B - More detailed assessment, where necessary:

Questions to consider: Level of ris k: Possible remedial action:

(If the answer to a question is `Yes' (Tick as app ropriate) (Make rough notes in this column
place a tick against it and then in preparation for completing
consider the level of risk) Yes Low Med High Section D)

The tasks - do they involve:

V holding loads away from the trunk?
V twisting?
V stooping?
V reaching upwards?
V large vertical movement?
V long carrying distances?
V strenuous pushing or pulling?
V unpredictable movement of loads?
V repetitive handling?
V insufficient rest or recovery?
V a work-rate imposed by a process?

The loads - are they:

V heavy?
V bulky/unwieldy?
V difficult to grasp?

unstable/unpredictable?
V intrinsically harmful (eg sharp/hot)?
'ti

The working environment - are there:

V constraints on posture?
V poor floors?
V variations in levels?
V hot/cold/humid conditions?
V strong air movements?
V poor lighting conditions?

Individual capability - does the job:

V require unusual capability?
V pose a risk to those with a health problem?
V pose a risk to those who are pregnant?
V call for special information/training?

Other factors
Is movement or posture hindered by
clothing or personal protective
equipment?

Deciding the level of risk will inevitably call for judgement.

When you have completed Section B go to Section C.
 CHECKING WHETHER HANDLING PROBLEMS
ARE CAUSING UPPER LIMB DISORDERS
Company/Department:

Workstation: Completed by:

Task:

Worker: Date:

Risk factor Tick your answer Action required

NO . YES
Does your job involve a lot of.

FREQUENT gripping (a tool or workpiece)? If you have no ticks in the

`YES' column on this
or squeezing (eg tool handles)? page, you are unlikely to
have any handling
FORCEFUL twisting? problems caused by work.
You need not go on to
or reaching? the following questions.

AWKWARD moving things (pushing, pulling, lifting)? However, if you have any
ticks in the `YES' column
finger/hand movement (eg keyboard work)? on this page, there may
be a risk in your
workplace. You should
go on to do the full risk
Are there any warning signs of hand/shoulder/ neck assessment.
problems? For example:

V Actual cases in this or similar work?

V Complaints by workers, eg aches and pains in hands,

wrists, arms, shoulders etc? Ask your employees if they
have any of these symptoms.

V Home-made, improvised changes to work-stations or tools

(eg handles cushioned or made longer)?

94
 CHECKING WHETHER HANDLING PROBLEMS
ARE CAUSING UPPER LIMB DISORDERS
RISK FACTOR Is risk present?

FULL RISK ASSESSMENT

Are there any factors in the job that make ULDs likely, such as:

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

V strong force at the same time as awkward movements or posture, eg bent wrists,
work with arms raised or fully extended?

V forceful use of hand/forearm muscles?

V trying to make do with ill-fitting components by forcing them into place?

i..

V tools not ideal for repetitive or frequent use - particularly if squeezing, twisting, or
hammering actions are required?

V using equipment designed for a larger or stronger person (eg women using tools
designed for men)?

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

7G'

V machine pacing, eg to keep up with conveyor?

frequent repetition of the same small number of movements?

awkward movements such as twisting or rotation of wrist, movement of wrist from side to
Sri

side, very bent fingers and wrist, or hand or arm movements beyond a comfortable range?

V pressures on employees to work fast, eg from piecework or bonus systems?

`w°

95
 Tick
when
action
taken

Redesign workstations, eg:

R.'

Reposition supply of components to reduce

reaching required.
V Move controls to more convenient position.

Redesign job, workstation, and/or tools to avoid

P.'

over-use of the hand or forearm.

Maintain tools, eg keep them sharp and lubricated, for
°v°

ease of use.

Improve quality of components, or provide suitable

tools for fitting them.

Replace domestic or DIY hand tools with tools

J."

designed for repetitive industrial use. Redesign tool

handles to achieve even distribution of force across
hand (power grip preferable to pinch grip) and straight
rather than bent wrists. Consider replacing hand tools
with power tools. Reduce squeezing forces by using
R.'

weaker springs to triggers etc.

Redesign equipment or tool (eg counter-balancing to

°C°

reduce force required). Provide powered version.

,°°,

Self pacing is preferable.

Replan work, eg to break up pause/repetition cycles or

spread movement across both hands. Consider adding
extra activities to job, to give variety. Consider scope for
automation or use of power tools.

Redesign workstation, controls or shape of tool handles.

Consider need for such systems (but employees may

resist change). Better training in risks may help.

96
 RISK FACTOR Is risk present?

Awkward or static posture - Does the job involve:

iv.
iii

V cramped body position, and/or not enough space to change posture?

la'

V arms stretched or overhead for long periods?

work at awkwardly high or low height (crouching, stooping, or reaching up)?

Work for long periods without breaks or changes of activity - Does the job involve:
b00

V no changes to work routine or variation of tasks?

V no breaks or infrequent breaks?

V worker not able to have short pauses when desired?

No special arrangements for new employees

i01

(or those returning to work after a long break) - Does the job involve:

V people having to work at full pace as soon as they start (or resume) the job?

V no training in risks and ways employees can reduce risks?

Poor environmental conditions - Is work carried out:

V in dim light, shadow or flickering light?

.-:

V in cold or otherwise adverse conditions?

V with tools that vibrate?

.C.

97
 RECOMMENDATION FOR ACTION
when
action
taken

Improve space available to worker. Provide adjustable

workstation (especially chair) for workers who are
above or below average height or shape.

Move materials or controls to more convenient position.

Move materials or controls to more convenient position.

0

If possible, vary tasks to provide changes in activity.

If not, check there are adequate rest breaks.

Check that breaks are taken, especially if work

involves continuous effort such as holding tools, or
rapidly repeated movements (eg typing).

Redesign work to make short pauses possible.

Allow recruits to build up their work rate sensibly

'L3

as they gain experience.

Provide training in skills, posture, and warning

symptoms for all those at risk.

Provide better lighting so that workers do not have

to adopt awkward postures to see properly.

Cold (eg in handling frozen foods) may increase the

risk. If it is not possible to warm the working
environment, check that protective clothing is well
designed and does not affect posture or grip.

Consider whether the job can be done another way to

avoid need for high-vibration tools. Or provide
vibration-absorbing grip and minimise vibration by
proper maintenance.

98
 APPENDIX 2
METALWORKING FLUIDS QUESTIONNAIRES
QUESTIONNAIRE FOR DETECTION
OF SKIN ABNORMALITIES

To be completed by the employee

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

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

DATE OF BIRTH: ................................................................................................................................................................

JOB TITLE: ............................................................................................................................................................................

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

1. Since your last review or in the last 12 months have you had any of the following symptoms?

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

zzzzzz
0
(b) cracking of skin on fingers or hands; Yes No

0
(c) blisters on fingers or hands; Yes No ELI
(d) flaking or scaling of skin on fingers or hands; Yes No CII
(e) itching offingers or hands with skin cracks or splits; Yes No C1
(f) spots, redness, swelling of any other part; Yes No El
2. Did these problems last for more than three weeks? Yes No
z
3. Did these problems occur more than once? Yes " No

4. Does your skin get better with periods off work? Yes " No I

5. Have you lost time from work with skin problems since your last assessment? Yes No
z

6. Do you think you know what causes the problems? Yes

7. Name the substance/material/contact you think is responsible:

To be completed by the responsible person:

8. Problems confirmed by the responsible person? Yes IEL No
z

9. Action taken:

Name of responsible person:

Date:

Footnote: Any abnormalities found should be referred to the works occupational health physician or nurse if there is one. If not,
employees should be advised to consult their general practitioner. In either case, referral to a consultant dermatologist may be
appropriate. A copy of this completed questionnaire should be supplied to the employee's general practitioner.

99
 JJJ

QUESTIONNAIRE FOR DETECTION

OF LUNG PROBLEMS

To be completed by the employee

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

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

DATE OF BIRTH: ................................................................................................................................................................

JOB TITLE: ............................................................................................................................................................................

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

Since your last review or in the last 12 months:

1. Have you had any episodes of wheezes or chest tightness? Yes I-1 No

z
If `yes', at what time(s) of day?

2. Have you taken any treatment for your chest? Yes " No

z
0
0
3. Have you woken at night with cough or chestiness? Yes No

z
4. Have you had any episodes of breathlessness? Yes No

z
If `yes', at what time(s) of day?

Have you had any time off work with chest disease? Yes L-I No
z
5.

Have you developed chest tightness or breathlessness after exercise? Yes II No

z

6.
0
0

Have you developed difficulty with breathing? Yes L-1 No

z

7.
0

If `yes', at what time(s) of day?

To be completed by the responsible person:

8. Problems confirmed by the responsible person? Yes No
z
0

9. Action taken:
0

Name of responsible person:

Date:

Footnote: If the answer is yes to any of these questions, the employee should be referred to the works occupational health
physician or nurse if there is one. If not, employees should be advised to consult their general practitioner. In either case, referral
to a consultant chest physician may be appropriate. A copy of this completed questionnaire should be supplied to the employee's
general practitioner.
 APPENDIX 3
WORK EQUIPMENT RISK ASSESSMENT

You may wish to use the proforma below to assess aspects of machinery safety as part of your risk
assessment. Where further action is indicated, you should record what is done as a result.
Don't forget to make sure that you also consider fully any risks to health that may arise as a
consequence of using the equipment being assessed. For mobile work equipment, additional
requirements will apply (see page 19)

General equipment description

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

LOCATION: .................................................................................................. PLANT/REF No:.......................................

NAME OF ASSESSOR: ............................................................................ DATE OF ASSESSMENT:.......................

General description of work equipment, including details of ancillary equipment where relevant:

Intended function of work equipment:

Assessment of suitability for intended function:

 Work equipment risk assessment

I Guarding of dangerous parts.

Is access possible to any part of machinery that could cause injury?

Machine part Location Part of body at risk Estimated injury

For the parts identified above, what method of safeguarding is necessary to minimise the risk?

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

Where guards are currently provided, do they satisfy the following criteria? (Y/N)

Adequate
Of good Easily by-passed distance from Adequate view Access only for
.V.

Guardldevice Suitable? construction or disabled? danger? (if needed)? maintenance?

2 Maintenance
What maintenance is needed for guards and protection devices?

Guards/protection device Maintenance required Frequency

3 Inspection
Is inspection of the work equipment necessary?

Inspection required (YIN) Details of inspection Frequency

4 Information, instruction and training

What information, instruction and training must be provided for the following groups?

Operators Maintenance staff Managers/supervisors

5 Other hazards
What action is needed in respect of the following possible additional hazards?
NOTE: The list in the table below is not exhaustive and is intended as a GUIDE ONLY

Hazard Occurring? (YIN) Action required to minimise risk

Any article or substance falling or

being ejected from the machine

A rupture or disintegration

Overheating or fire
roc

Unintentional or premature
discharge of dust, gas, liquid,
vapour or other substance
Any part of the machine at a
high or low temperature likely
'-'

to cause injury
Any other hazards?

6 Emergency stop controls

Is a suitable design of emergency stop control located at appropriate control and operating points?

Identified control/operating points Type of emergency stop control

7 Isolation
How is the machine isolated or locked off from the following energy sources (where relevant)?

Energy source Method of isolation

Electricity

Compressed air or gas

Hydraulic

Steam

Other (eg gravity fall)

P'.
 8 Controls
Yes/No If no, what action is required?
Are controls clearly visible, identifiable
and clearly marked where necessary?

Are controls located to ensure that

operators are not exposed to risk?

Can the operator see any other person

who may be exposed to risk when the
controls are operated?
Are there systems of work to ensure
that no one is likely to be at risk
when the machine starts?
Are there suitable audible, visible or
other warnings (if needed)?

9 Workplace environment
Yes/No If no, action required?
Is there adequate natural
s:.

and artificial light?

'L3

Is lighting of controls
satisfactory, without glare?

Is lighting of parts of the machine

`rte

that have to be viewed adequate?

Is the workplace temperature in

a range of comfort for operators?

Is suitable seating required?

°"'

Is there adequate space around

the machine to allow safe
and easy access?
Is storage for machine parts
and special tools needed?

Are fire extinguishers needed close

to the machine - if so, what type?
1 0 Personal protective equipment (PPE)
Yes/No If no, action required?
Is PPE necessary?

If yes, what type?

Are operators aware that

PPE is required?

Do operators know how

PPE should be worn?

Is local storage necessary

and provided?
'C1

Is PPE subject to
routine maintenance?

II Safety signs and warnings

Are adequate signs fitted to the machine as follows?

Yes/No If no, action required?

Hazardous surfaces

Hazardous materials

Hazardous parts or their movement

Prohibited actions

Correct operation

Personal protective
equipment (PPE)

Emergency action
.^.
 - J.f

APPENDIX 4
KEY STANDARDS FOR ENGINEERING WORKSHOPS

To help designers and manufacturers of new machines meet essential health and safety
requirements (see page 34), a range of Transposed Harmonised Standards (BS ENs) has
been developed to offer four levels of guidance:

`A' standards on basic safety concepts and design principles common to all machinery

`B1' standards on basic safety aspects such as safety distances and noise

`B2' standards on safety related devices such as guards and interlocking devices, and

`C' standards which interpret `A' and `B' standards and give safety requirements for a
particular type or group of machines

`pr EN' standards are BS ENs under development, available from BSI (see page 81)

For machines used in engineering workshops `C' standards are planned for the commonest
metalworking machines including mechanical, hydraulic and pneumatic presses and press
brakes; grinding machines of all kinds; horizontal and vertical turning machines, both CNC
and manually operated; machining centres, drilling, milling and boring machines of all
types; and metalcutting saws and electro-discharge machines.

These standards will also be relevant to users of existing machinery to help them assess risks
and decide whether safeguards are adequate.

Standard and title Key contents and requirements

BS EN 292: Part 1 : 1991 1. Describes machinery hazards, defines safety terms, requires
Safety of machinery. designers to assess risks, remove or control them.
Basic concepts, general 2. All hazards from mechanical, electrical, thermal, noise, vibration,
principles for design radiation, materials or ergonomic sources including any
combination, have to be considered over the lifetime of the
machine.

BS EN 292: Part 2: 1991 1. Describes methods to reduce risks by design.

Safety of machinery. 2. Advises on selection, design and construction of safeguards for
Technicalprinciples and hazards which cannot be eliminated by design.
specifications 3. Describes information for use to be provided for users by suppliers.

BS EN 1050: 1997 1. Advises on the identification of hazards and provides criteria for
Safety of machinery. assessing risks and selecting safety measures consistent with
Risk assessment technical and economic restraints.
2. Outlines qualitative and quantitative risk assessment
techniques and risk reduction measures.
BS EN 60204-1 1. Applies to low voltage equipment (1000vAC and 1500vDC, not
Safety of machinery. Electrical exceeding 200Mz) from the point of supply to its use at the
equipment of machines - machine.
Part 1: General requirement 2. Covers protection against electric shock, measures to protect
equipment against overcurrent, overspeed, overload and from the
environment, restarting a hazardous operation from loss of power,
general requirements, electrical controls, the accessibility, layout
and identification of controls, ergonomic requirements for
electrical controls, requirements for cabling, wiring, accessories,
lighting, documentation and testing.

BS EN 953: 1998 1. Contains definitions of different types of guard.

Safety of machinery. Guards 2. Sets requirements for when to use a particular type of guard and
(fixed, movable) how to design guards to minimise hazards.

BS EN 1088: 1996 1. Defines basic concepts and general principles for interlocking
Safety of machinery. devices controlling any power source.
Interlocking devices with and 2. Specifies requirements for electrical interlocking devices, and parts
without guard locking of guards which activate interlocking devices.

BS EN 294: 1992 1. Two values are given for reaching up to danger zones and two
Safety of machinery. Safety tables for reaching over protective structures.
distances to prevent danger 2. Designer must decide what is to be used depending on whether
zones being reached by upper situations are high or low risk.
limbs 3. Standard is not concerned with preventing climbing over barriers;
1800 mm may be sufficiently high for this.

BS EN 349: 1993 1. Describes factors to be taken into account in the assessment to

Safety of machinery. Minimum prevent crushing only.
distances to avoid crushing 2. Minimum gaps for whole body, leg, head, foot, toes, arm, hand,
parts of the human body and finger are given in an illustrated table.
3. Annex A (Informative) illustrates three typical crushing zones at a
milling machine table.

BS EN 626-1: 1995 1. Contains information on the types of hazards to be considered,

Safety of machinery. Reduction with examples.
of risks from hazardous 2. Annex A (Informative) provides examples of how exposure to
substances emitted by machinery hazardous substances may be reduced by eliminating or reducing
- Part 1: Principles and risks.
specifications for machine
manufacturers

BS 5304:1988 A non-harmonised standard containing many useful principles and

Safety of machinery examples of safeguarding for machinery which is being progressively
replaced by harmonised standards.
 USEFUL DEFINITIONS FROM BS EN 292:
PART 1: 1991
Safety of a machine Guard
The ability of a machine to perform its Part of a machine specifically used to
function, to be transplanted, installed, provide protection by means of a
adjusted, maintained, dismantled and physical barrier.
disposed of, under conditions of intended
use, without causing injury or damage to Fixed guard
health. Guard kept in place (ie closed) either
permanently (eg by welding) or by means
Hazard of fasteners (screws, nuts etc) making
A source of possible injury or damage to health. removal/opening impossible without using
tools.
Risk
A combination of the probability and degree of Movable guard
the possible injury or damage to health in a Guard generally connected to the machine by
hazardous situation. mechanical means (eg hinges or slides)
which can be opened without tools.
Risk assessment
A comprehensive estimation of the probability Adjustable guard
of possible injury or damage to health in a Fixed or movable guard which is adjustable as
hazardous situation in order to select a whole or which incorporates adjustable
appropriate safety measures. part(s). The adjustment remains fixed
during a particular operation.
Danger zone
Any zone within and/or around machinery in Interlocking guard
which a person is exposed to risk of injury Guard associated with an interlocking device
or damage to health. so that:

Safety device V the hazardous machine function `covered'

Device (other than a guard) which eliminates by the guard cannot operate until the
or reduces risk, alone or with a guard. guard is closed
V if the guard is opened while hazardous
Interlocking device machine functions are operating, a stop
Mechanical, electrical or other type of device, instruction is given
the purpose of which is to prevent the V when the guard is closed, the hazardous
operation of machine elements under machine functions `covered' by the guard
specified conditions (generally as long as can operate, but the closure of the guard
guard is not closed). itself does not initiate their operation. (To
achieve this would require a control
Hold-to-run control device guard.)
Control device which initiates and maintains
operation of machine elements only as the Guard locking with interlocking
manual control (actuator) is actuated. The Prevents the opening of an interlocking guard
actuator returns automatically to the stop until hazardous motions are stopped, and
position when released. their restart until the guard is locked.
 'J ''J'J

Safeguard Enabling (control) device

A guard or safety device. Additional manually operated control device
used in conjunction with a start control
Two-hand control device and which, when continuously actuated,
Hold-to-run control device which requires at allows a machine to function.
least the simultaneous operation of two
manual controls (actuation) in order to Trip device
trigger and maintain operation of the Device which causes a machine or machine
machine or machine elements, thus elements to stop (or ensures an otherwise
affording a measure of protection for the safe machine condition) when a person or
person operating the actuators. a part of a body goes beyond a safe limit.

Defining hazards Trip devices may be:

Hazards at machinery may arise from: mechanically actuated, eg trip wires,
telescopic probes, pressure sensitive
mechanical movements, such as shearing devices etc

electricity non-mechanically actuated, eg photo-

electric devices, devices using capacitive,
ultra-sonic etc means to achieve detection.

vibration

V radiation

substances being used

neglecting ergonomic principles in design

combinations of hazards

failures of energy supply

missing safety measures, and

V being trapped inside.

 J 1J 113

APPENDIX 5
FIRE-RESISTANT MATERIALS
FOR DIY SPRAY BOOTHS
Effective segregation, ventilation and prevention Where existing walls or partitions are not fire-
of ignition can be achieved in home-made resisting constructions, the standard can be
spray booths, but with professional and achieved by adding 12.5 mm plasterboard;
competent advice. ensure that the joints between the overlap
are formed over the supporting framework
Segregation or otherwise suitably constructed.
The separation or isolation should be fire
resistant. Some examples of floor, wall and Doors
door construction that will provide a Fit: The door should be reasonably straight and
standard of half-hour fire resistance are: true and lie flush against the stop when
closed; the gap between the door edge and
Floors the frame should not exceed 3 mm.
Plain edge boarding on timber joists not less than
38 nun wide with a ceiling of 12.5 mm Door frame: Should have a rebate or stop not
plasterboard and 12.5 mm gypsum plaster. less than 25 mm deep; existing planted stops
may be replaced or additional material
Tongued and grooved boarding not less than screwed or pinned and glued on.
16 mm thick on timber joists and not less
than 38 mm wide with a ceiling of 12.5 mm Door furniture: One pair of metal hinges, all
minimum of plasterboard and a skim coat of parts of which are non-combustible and have

goo
gypsum plaster. a melting point not less than 800°.

Plain edge boarding on timber joists not less than Glazing: Any plain glazing should be replaced by,
38 mm wide with a ceiling of timber lath and or backed with, 6 mm wire reinforced glass
plaster, the plaster at least 16 mm thick, not exceeding 1.2m2 in area and fitted with
covered on the underside with a 12.5 mm solid wood beading not less than 13 mm in
thickness of plasterboard. cross section.

Walls Flush doors**- 6 mm wallboard cover to both

100 mm brick (unplastered). sides of the door; fixing to be 32 mm screws
at approximately 300 mm centres, or
50 mm woodwool slabs plastered at least annular nails at approximately 200 mm
'CI

12.5 mm thick on both sides, framed centres, driven into solid timber.
construction (non load-bearing).
Panel, framed, ledged and braced doors *:
Steel or timber studding with 12.5 mm portland Protection as for flush doors to both faces of
cement plaster, portland cement/lime plaster the door; or, if protection against fire is
or gypsum plaster on metal or timber lathing needed from one side only, then 9 mm
(non load-bearing conditions only). insulating board fixed to room-risk side of
the door, as above, with the panels first made
Steel or timber studding with 9.5 mm thick up with tightly fitting cutouts of plasterboard
plasterboard on each side with the exposed or solid wood.
facing of the boarding plastered with 5 mm
thick neat gypsum plaster (non load-bearing * The importance offixing cannot be over-
conditions only). emphasised Additional material must be so

ii1
 fixed to the existing door that, under
condition offire where thermal movement is
likely to take place between the door and
protective material, the screws or nails are
not stressed so that they are pulled out

Electrics
Unprotected electrical equipment must be kept
outside spray booths.

Install lights outside booths and shine them

through fixed and sealed fire-resisting wired
glass panels.

Use only explosion protected electrical

equipment inside the booth.
 .1
J

APPENDIX 6
RECORD OF EXAMINATION AND TEST OF

a4,
LOCAL EXHAUST VENTILATION (LEV) PLANT
A suitable record containing at least the following particulars should be kept in respect of each
thorough examination and test of LEV plant:

(a) Name and address of employer responsible for the plant

(b) Identification and location of the LEV plant, process, and hazardous substance concerned

(c) Date of last thorough examination and test

(d) Conditions at time of test; normal production or special conditions (eg maximum use, stood
down)

(e) Information about the LEV plant which shows:

(i) its intended operating performance for controlling the hazardous substance

(ii) whether the plant now still achieves the same performance

(iii) if not, the repairs required to achieve that performance

(f) Methods used to make judgement at (e)(ii) and (e)(iii) above (eg visual, pressure
measurements, air flow measurements, dust lamp, air sampling, filter integrity tests)

(g) Date of examination and test

(h) Name, designation and employer of person carrying out examination and test

(i) Signature or unique authentication of person carrying out examination and test

(j) Details of repairs carried out.

 APPENDIX 7

20-4
ANSWERS TO FREQUENTLY ASKED QUESTIONS
ABOUT WORK IN ENGINEERING WORKSHOPS
QUESTION ANSWER

Is it all right to work alone in the workshop? It would not generally be reasonable for
employers to permit employees to work
alone, because there is usually some
dangerous machinery about. (Fatal
accidents have occurred following
entanglements on centre lathes which may
have been prevented had there been
another person to switch off the machine
and help the trapped worker.) However, if
just low-risk work such as assembly or
some cleaning is being planned, then
provided other risks are minimised and a
system of checking or line of
communication established, it would be
reasonable for an employee to work alone.
See page 1 on how to manage safety.

What are the rules on smoking? Smoking should not be permitted where
flammable liquids are used, or anywhere
near degreasing operations. Also, smoking
may make any dust, fume, mist or vapour
more harmful if inhaled. There is also a
slight general health risk to non-smokers
from tobacco smoke in the workshop and
offices. Employers should develop a policy
to minimise this risk. Rest room
ono

arrangements must protect non-smokers

from discomfort caused by tobacco smoke.

Do I need to keep an accident book? No, but you need to record details of accidents
and occurrences which must be reported
(see page 79).

You may use the DSS B1510 Accident Book,

0.1
o0.1

another book or a computer to record the

following details:
V date and time of accident or occurrence
V full name and address of the person
involved and the injury or condition
suffered
V where the accident or occurrence
happened
V a brief description of the circumstances

114
 QUESTION ANSWER

V in the case of a reportable disease the date

of diagnosis, the occupation of the person
concerned and the name or nature of the
disease.

Keep the above information for at least three

years.

What can young people do in the workshop? Employment of children under 13 is

forbidden, and children under this age
should not normally be allowed in an
engineering workshop. Children over 13
but under minimum school leaving age
may only work under an official work
experience scheme.

Young people under 18 are often exposed to

risks to their health and safety when using
work equipment as a consequence of their
immaturity, lack of experience, and
absence of awareness of existing or
potential risks. Training and proper
supervision of young people is therefore of
particular importance.

If you employ a young person, the management

regulations require you to assess risks to
them before they start work, taking the
above factors into account. You must use
the risk assessment to determine whether
the young person should be prohibited from
certain work activities, except where
necessary for their training. Young people
should not for example be allowed to use
high-risk lifting machinery unless they have
the necessary maturity and competence and
have successfully completed appropriate
training. Your risk assessment may indicate
that similar prohibitions are appropriate for
high-risk machines such as presses,
guillotines and milling machines

KEY REFERENCES: Young people at work: A guide for employers HSG165 HSE Books
ISBN 0 7176 1889 7; New and expectant mothers at work: A guide for employers (Second
edition) HSG122 HSE Books ISBN 0 7176 2583 4
 QUESTION ANSWER

Sufficient training and adequate supervision

should, of course, be provided for all work
for all employees.

Do women have to be treated differently in the : In general no, but where work with lead or
workshop? ionising radiations is concerned, their
work needs careful assessment so that it
can be managed properly to prevent
undue risks to unborn children.

What notices do I have to put up? : V The only notice now required to be displayed
is the Health and Safety Law poster (or an
approved leaflet containing the same
information can be given to each employee)

V Electric shock and first-aid at work

placards are no longer required to be
displayed by law but contain advice for use
in emergencies.

V The above posters may be obtained from

HSE Books in an encapsulated format.

What breaks are workers entitled to, and A worker is entitled to an uninterrupted break
what hours of work are required? of 20 minutes when daily working time is
more than six hours. Additionally, a worker
is entitled to a rest period of 11 consecutive
hours between each working day and to an
uninterrupted rest period of not less than
24 hours within each 7-day period.

The weekly working time for a worker must not

exceed 48 hours per week, averaged over a
17-week period. Workers may individually
or collectively sign an agreement with their
employer to work over this limit. The
normal hours of night workers must not
exceed an average of 8 hours for each 24
hours over a 17-week period.

KEY REFERENCE: A guide to Working Time Regulations (free)

DTI: 08701 502 500

116
 QUESTION ANSWER

Are eye tests required for users of VDUs? Users, and those to become users, can request
an eye and eyesight test that you have to
pay for, if they are your employees. If the
test shows they need glasses specifically for
their VDU work, you have to pay for a
basic pair of frames and lenses.

Users are entitled to further tests at regular

intervals after the first test, and in between
if they are having visual difficulties which
may reasonably be considered to be
caused by their VDU work.
If users' normal glasses for other work are
suitable for VDU work you don't need to
pay for them. You don't have to pay for
fancy frames, or lenses. Eye and eyesight
testing is not an entitlement for the self-
employed.

When setting up a system for providing users

with eye and eyesight tests, these points
might help:
V contact a number of opticians and ask
what they charge for tests and basic
glasses
V ask if they will come to the firm to test the
users
V ask for standard information about each
user they test, if they need glasses for VDU
work and when they should be re-tested
V tell users what arrangements you have
made
V make sure users understand what you will
and won't pay for (eg tinted lenses, glasses
for non-VDU purposes are not your
responsibility).

KEY REFERENCE: Working with VDUs INDG36(revl) HSE Books (single copy free;
ISBN 0 7176 1504 9 for priced packs of 10)
 02/04
O
NO
O

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ki)
U

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 Meath and safety in engineering workshops describes how most
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