Health and safety in engineering workshops

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1 Health ad Safety Health ad safety i egieerig workshops This is a free-to-dowload, web-friedly versio of HSG129 (Secod editio, published 1999). This versio has bee adapted for olie use from HSE s curret prited versio. You ca buy the book at ad most good bookshops. ISBN Price 9.50 Health ad safety i egieerig workshops describes how most serious ad frequet hazards arise, how to assess the risks ivolved, ad how to elimiate or cotrol them. It cotais guidace from over 200 separate HSE publicatios i oe easy to read ad follow guide as well as providig a comprehesive list of refereces ad other sources of help. HSE Books Page 1 of 147

2 Health ad Safety Crow copyright 1999 First published 1995 Secod editio 1999 Reprited with amedmets 2002 Reprited 2004 ISBN All rights reserved. No part of this publicatio may be reproduced, stored i a retrieval system, or trasmitted i ay form or by ay meas (electroic, mechaical, photocopyig, recordig or otherwise) without the prior writte permissio of the copyright ower. Applicatios for reproductio should be made i writig to: The Office of Public Sector Iformatio, Iformatio Policy Team, Kew, Richmod, Surrey TW9 4DU or licesig@opsi.gov.uk This guidace is issued by the Health ad Safety. Followig the guidace is ot compulsory ad you are free to take other actio. But if you do follow the guidace you will ormally be doig eough to comply with the law. Health ad safety ispectors seek to secure compliace with the law ad may refer to this guidace as illustratig good practice Reprit I geeral, the amedmets icluded i this reprit reflect updated publicatios ad regulatios. The overall guidace has ot chaged. HSE gratefully ackowledges the help of Elf Oil Idustrial Lubricats Divisio i the preparatio of the cover illustratio. Page 2 of 147

3 Health ad Safety Cotets Foreword 5 Maagig health ad safety 6 How most accidets ad cases of work-related ill health arise 7 Istat actio checklist 9 How to use this book to start your risk assessmet 10 Five steps to risk assessmet 13 Workig i ad movig aroud the workshop 15 Lightig 17 Geeral vetilatio, temperature ad toilets 19 Liftig equipmet 21 Movig goods safely by had 22 How to lift safely 23 Liftig ad hadlig 24 Ergoomic machie operatio, assembly ad packig 27 Movig vehicles safely 30 Lift trucks 31 Cotrollig hazardous substaces 33 Local exhaust vetilatio 35 Electricity 37 Portable electrical equipmet 38 Commo problems with flexible leads, their plugs ad sockets 40 Pressurised plat ad systems 42 Machiig 43 Computer cotrolled (CNC) machiig 47 Buyig ad sellig machiery 49 Metalworkig fluids 52 Noise 55 Vibratio 61 Millig ad machiig cetre work 62 Drillig (ad reamig) 64 Pressig 66 Turig 69 Gridig 71 Sawig 73 Bedig 74 Guillotiig 75 CNC puch pressig 77 Combiatio metalworkig machies 78 Horizotal borig machies 79 Cleaig ad degreasig 80 Vapour degreasig taks 81 Weldig ad flamecuttig 83 Fume cotrol 85 Safety measures at resistace weldig machies 87 Lasers used for weldig ad cuttig 88 Radiography 89 Health ad safety i egieerig workshops Page 3 of 147

4 Health ad Safety Paitig 91 Spray paitig booths ad eclosures 93 Paits cotaiig isocyaates 95 Powder coatig 96 Persoal protective equipmet (PPE) 98 Offices 100 Orgaisig health ad safety 102 The law 102 Accidets ad emergecies 104 First aid 107 How to obtai publicatios ad further assistace 109 Further readig ad iformatio 111 HSE offices 119 Some useful addresses for selectig a health ad safety cosultacy 120 Appedices 1 Liftig ad hadlig assessmets Metalworkig fluids questioaires Work equipmet risk assessmet Key stadards for egieerig workshops Fire-resistat materials for DIY spray booths Record of examiatio ad test of local exhaust vetilatio (LEV) plat Aswers to frequetly asked questios about work i egieerig workshops 144 Health ad safety i egieerig workshops Page 4 of 147

5 Health ad Safety Foreword This guidace has bee writte for people who ru ad work i small egieerig workshops, ragig from those who make their ow products, to those who maitai ad repair plat ad machiery either idepedetly or as part of larger eterprises. It is iteded to help them maage their ow health ad safety ad work i safer ad healthier ways. As egieerig is a wide ragig activity the booklet does ot deal with every hazard which may arise or every precautio which ca be take. It does, however, outlie the most serious ad frequet hazards ad the best ways of dealig with them. The Further readig sectio: lists HSE ad other publicatios which give more detail o the subjects dealt with; provides iformatio o other sources of help. I this guidace: must deotes a legal obligatio; outlies of the law applyig to egieerig workshops are provided i lied boxes o a blue backgroud just like this paragraph; do ad do t, should ad should ot ad other recommedatios such as use, fit ad prevet represet good practice, which, if adopted, will usually be what is reasoably practicable i the give circumstaces although there may be other legally acceptable ways of achievig the same objective. text i italics (where it is ot a referece, sub-headig or captio) outlies requiremets of Approved Codes of Practice which have bee approved by the Health ad Safety Commissio ad give advice o how to comply with the law. If you are prosecuted for a breach of health ad safety law, ad it is proved that you have ot followed the relevat provisios of the Code, a court will fid you at fault, uless you ca show you have complied with the law i some other way tips o good practice are idicated by phrases such as thik about ad cosider the early sectios deal with how to tackle health ad safety issues commo to most egieerig workshops; later sectios deal with more specific activities which may ot be carried o i all workshops. Health ad safety i egieerig workshops Page 5 of 147

6 Health ad Safety Maagig health ad safety Successful health ad safety maagemet i small egieerig workshops is about idetifyig the most frequet ad serious risks ad adoptig the right precautios, takig accout of time, moey ad resources. This book idetifies how most serious accidets happe ad how most ill health is caused i egieerig workshops. If you use machies or processes which are ot described i this booklet, see where they are similar to those described ad work out whether they pose the same hazards ad whether the precautios suggested would be right, as well as seekig further advice. The Maagemet of Health ad Safety at Work Regulatios 1999 outlied Employers must: assess risks to the health ad safety of their employees ad o-employees arisig i, or from, the workshop, ad review them whe there is sigificat chage. Records of sigificat fidigs of the assessmet must be kept where there are five or more employees pla, orgaise, cotrol, moitor ad review the prevetative ad protective measures take as a result of the assessmet provide health surveillace where ecessary (see pages 33 34), for example to help cotrol health risks from metalworkig fluids appoit ay competet perso(s) eeded to help them comply with legal obligatios, for example, whe havig liftig equipmet thoroughly examied set out what should be doe i case of serious ad immiet dager i the workshop, such as the spillage of a large amout of degreasig solvet tell employees about the risks ad precautios ivolved i their work trai employees to work safely. You may eed help beyod that give i this book. If you do, trade ad employer associatios, such as EEF The Maufacturers Orgaisatio, the Maufacturig Techologies Associatio (for machie suppliers) or local Chambers of Commerce, offer a rage of advice ad support. These sources of iformatio are give o page 108. HSE ispectors are always willig to help (see page 118 for iformatio o HSE Offices). Employers must also cosult with all their employees (icludig self-employed workers classed as employed persos uder health ad safety law) o health ad safety matters. This will ivolve ot oly givig iformatio but also listeig to ad takig accout of what employees say before ay health ad safety decisios are take. Key referece: Maagemet of health ad safety at work Approved Code of Practice L21 HSE Books 2000 ISBN Health ad safety i egieerig workshops Page 6 of 147

7 Health ad Safety How most accidets ad cases of work-related ill health arise Accidet ad ill-health data for such a wide ad varied sector is available from a umber of sources, icludig published HSE material, research papers, idustry statistics, ad trade associatio ad trade uio publicatios, although it is difficult to see the whole picture. The iterpretatio of the available data i this booklet is based upo the experiece of health ad safety ispectors gaied over may years i dealig with the sector. Accidets ad ill health There are may thousads of accidets ad cases of ill health reported every year i small egieerig workshops. Almost two-thirds of all such accidets reported to HSE arise from the movemet of people, goods ad vehicles ito, aroud ad out of workshops. Of these movemet accidets: about half ivolve liftig ad movig goods, ad about half ivolve slips, trips ad falls ad hittig statioary or movig plat ad equipmet. No-movemet accidets usually arise from the use of machiery; these accout for betwee 10 ad 15% of all accidets. Electrical accidets are ot ucommo ad frequetly have the potetial for more serious ijuries tha those recorded. The most commo occupatioal diseases are dermatitis, deafess, asthma ad vibratio white figer, ad back, had, arm, shoulder ad eck problems. I ay particular workshop risks which are relevat should be assessed. Those likely to be of most cocer iclude: movemet of people, goods ad vehicles aroud the workshop, particularly maual hadlig machiery safeguardig hazardous substaces, particularly metalworkig fluids, degreasig solvets, ad dust or fume from weldig, brazig, solderig, coatig ad paitig oise, ad vibratio. Costs The costs of accidets ad ill health to small egieerig workshops may be disproportioately high. May employees are key workers whose loss through ijury or ill health severely disrupts productio ad lowers profitability. Health ad safety i egieerig workshops Page 7 of 147

8 Health ad Safety Ijuries i egieerig idustries as reported to HSE s Field Operatios Directorate ad local authorities 1998/ /01 No-fatal 98/99 99/00 00/01 (provisioal) Total of which mai cause ivolved: Hadlig ad carryig 5057 (33%) 4955 (33%) 4842 (33%) Beig struck (eg by fallig objects, movig machiery) 2826 (19%) 2872 (19%) 2698 (18%) Slippig ad trippig 2318 (15%) 2386 (16%) 2349 (16%) Machiery 1778 (12%) 1734 (12%) 1641 (11%) Falls from height 935 (6%) 950 (6%) 910 (6%) Workplace trasport 331 (2%) 331 (2%) 360 (2%) Health ad safety i egieerig workshops Page 8 of 147

9 Health ad Safety Istat actio checklist If you wat to start checkig coditios right away use this istat actio checklist Check Istat actio Log-term solutio Are fixed machie guards i positio ad secured? Are iterlockig guards fitted ad workig? Are all work area ad passageway floors i good coditio, kept clear ad free from trippig ad slippig hazards? Is ayoe required to lift or carry heavy or bulky items ad equipmet uaided? Are ay employees sufferig from dermatitis? Do metalworkig fluids smell upleasat, particularly after a break from machiig? Is there a visible fume mist or haze i the workshop? Is there much visible dust from gridig, polishig or blastig? If you ca t hear someoe 2 m away talkig i a ormal voice. Are vibratio levels of had-held tools as low as possible? If all vehicles (icludig fork-lift trucks) ad pedestrias are kept. Replace discarded guards ad secure them by a fixig which eeds a tool to udo it. If ot, restore or repair them. Keep all areas tidy ad clea, ad avoid trailig leads. Repair holes i floors ad clear up spillages. Mark each load with its weight ad trai all employees to lift ad carry safely. Get them to see their GPs ad provide suitable gloves if these wo t add to risks at machiery. Replace with clea fluid, after cleaig the machie ad sump. Check existig cotrols ad vetilatio, remedy ad, if ecessary, improve geeral vetilatio. Make sure oise/machie eclosures are closed ad hearig protectio is beig wor. Check suppliers data o vibratio levels. Keep equipmet maitaied. Esure that all drivers o site are properly traied ad fork-lift truck operators authorised. Eforce speed limits ad reduce the eed for reversig. If fixed guards are beig removed for frequet access (more tha oce per shift) replace with iterlockig guards. Start a programme of prevetative maiteace. Provide o-slip floor surfaces. Mark gagways. Trai ad istruct employees to keep workplace uobstructed. See how the job may be avoided. Provide mechaical aids where possible. Try to remove the cause, eg redesig the work so that hadlig the source of cotamiatio is avoided. Try to fid ad elimiate cause of cotamiatio. Prevet fume, mist, vapour or dust from beig geerated or capture it close to source before it ca be breathed ad remove it from the workshop. Assess, remove, reduce or eclose oise at source. Buy ad use reduced-vibratio tools wherever possible. Review all trasport movemets, icludig delivery ad customer vehicles. Cosider oe-way systems ad clearly mark ad sig traffic routes. Health ad safety i egieerig workshops Page 9 of 147

10 Health ad Safety How to use this book to start your risk assessmet Here are some questios for fidig out how dagerous or uhealthy your workshop might be, ad what to do about it. Geerally Thik about the times whe people have bee off work recetly: Could their abseces be put dow to coditios at work? Is there a patter to ay of them? Have the lessos of ay recet accidets, ear misses or cases of work-related ill-health bee missed? Are there health or safety aspects of ay processes/operatios you feel ueasy about? If the aswer is yes Ivestigate the possible causes further. The most likely oes are outlied i this booklet. The workshop itself Are there ay parts which are: dirty dark obstructed poorly vetilated uecessarily wet, or otherwise dagerous or uhealthy to move aroud or work i? See pages for details of the stadards required. Health ad safety i egieerig workshops Page 10 of 147

11 Health ad Safety Movig ad workig with articles by had; loadig/ uloadig machies; assembly ad packig Has ayoe complaied about or bee off work with a bad back, or persistet had, arm, shoulder or eck problems which could be put dow to work? What about the loads beig moved? Are they too: If the aswer is yes Complete the more detailed questioaire o pages (for liftig) ad pages (for hadlig). If you have problems, the solutios suggested o pages may help. heavy sharp large awkward hot or cold? Does the job ivolve a lot of frequet, forceful or awkward movemets? Vehicles (icludig fork-lift trucks) Is there ay damage to the workshop or plat ad machiery from vehicles? Do vehicles operate close to pedestrias? This may idicate too fast/careless drivig or a poorly laid out workplace ad also potetial for ijuries. Ivestigate further. Are vehicles required to reverse? Does ayoe use vehicles without beig properly selected ad traied? Are the coditios i which they operate too dark, obstructed, wet or otherwise dagerous? See pages for advice o the selectio ad traiig of drivers. See pages for the miimum stadards required for workshops. Health ad safety i egieerig workshops Page 11 of 147

12 Health ad Safety Metalworkig machiig ad weldig Is it difficult to hear someoe talkig (i a ormal voice) 2 m away at ay poit i the workshop? Is it possible to reach (DON T TRY!) ay pressig, shearig, rotatig, cuttig or sawig tools especially whe: loadig/ uloadig compoets; removig swarf; or makig adjustmets? Is there ay visible fume, dust, mist or spray, or ca it be smelt? Do some operators frequetly have to maipulate or load/uload compoets which are too heavy, hot, awkward or sharp? Do you machie, weld or work with compoets cotaiig cadmium, lead, chrome or similarly hazardous substaces? Do employees complai about umb or tiglig figers, dead hads o cold days or figer blachig. If the aswer is yes Carry out a oise assessmet pages tell you how to do this ad make the most of it ad how to reduce ad cotrol excessive oise. See the idividual machiig sectios of this booklet, pages 62 77, for advice o how to guard machiery. Viewig ay suspected source with a strog light (eg a Tydall beam or video light) behid it will show where the fume is. See pages o how to avoid or cotrol harmful fume, dust, mist ad spray. See pages for guidace o checkig the health of people workig with metal cuttig fluids. See pages for advice o liftig ad hadlig. See pages for advice o how to cotrol exposures to hazardous substaces. See page 61 for advice o how to deal with had-arm vibratio. Cleaig ad fiishig If the aswer is yes Do you use: a vapour degreaser? other meas of degreasig? See pages for how to maitai it ad prevet the eed to get i ad clea it. See page 79 for how to avoid ad cotrol exposures to harmful cleaers. Do you pait compoets, or use coatig powders? See pages for how to avoid ad cotrol exposures to harmful substaces i paits ad coatig powders. Health ad safety i egieerig workshops Page 12 of 147

13 Health ad Safety Five steps to risk assessmet For a loger look, take five steps to your risk assessmet The Five Steps Look for the hazards Decide who might be harmed ad how Evaluate the risks ad decide whether precautios are adequate or more should be doe Record your fidigs Review you assessmet from time to time ad revise it if ecessary Key referece: 5 Steps to risk assessmet INDG163(rev1) (sigle copy free or priced packs of 10 ISBN ) Health ad safety i egieerig workshops Page 13 of 147

14 Usig the iformatio o the precedig pages ad the rest of this booklet, idetify: Possible hazards (chage ad/or isert your ow as ecessary) Who might be harmed Whether existig measures are adequate Hadlig Trasport ad vehicle movemets Metalworkig fluids Cleaig ad degreasig solvets Machiery (icludig settig ad maiteace) Weldig processes ad materials Noise Vibratio Health ad safety i egieerig workshops Page 14 of 153 What more eeds to be doe Date of the ext review Health ad Safety

15 Health ad Safety Workig i ad movig aroud the workshop About two thirds of all accidets i small egieerig workshops happe durig the movemet of vehicles, people ad goods. A safe, well-lit, clea workplace ca help prevet may of these. Workplace (Health ad Safety ad Welfare) Regulatios 1992 ad Approved Code of Practice outlied A safe place of work You must have: buildigs i good repair precautios such as feces or rails to stop people or materials fallig from ope edges* space for safe movemet ad access, eg to machiery safe glazig where ecessary, marked to make it easy to see floors, corridors ad stairs free of obstructio good draiage at wet processes such as washig ad cleaig widows that ca be opeed (if opeable) ad cleaed safely. They should be desiged to stop people fallig out or bumpig ito them whe ope. You may eed to fit achor poits if widow cleaers have to use haresses outdoor routes kept safe durig icy coditios, eg salted/saded ad swept. Safe movemet You must have: safe passage for pedestrias ad vehicles you may eed separate routes level, eve surfaces without holes or broke boards hadrails o stairs ad ramps where ecessary safe doors, eg visio paels i swig doors surfaces which are ot slippery well lit outside areas. Work statios Work statios ad seatig must fit the worker ad the work. Make sure that: back rests support the small of the back ad foot rests are provided where ecessary work surfaces are at a sesible height there is easy access to cotrols. * Particularly o the flat roofs of offices provided i small idustrial uits, which are ofte used for storage; proper stairs should be provided for frequet access to these areas. Health ad safety i egieerig workshops Page 15 of 147

16 Health ad Safety Clealiess You must: provide clea floors ad stairs, which are draied where ecessary ad ot slippery provide clea premises, furiture ad fittigs provide cotaiers for waste materials remove dust, refuse ad trade-waste regularly clear up spillages promptly keep iteral walls/ceiligs clea. They may eed paitig to help easy cleaig. Maiteace Maitaiig the workshop ad the equipmet i it may pose differet hazards from those ecoutered i the ormal ru of productio work. Cotractors as well as your ow employees may be at icreased risk, particularly durig the repair ad cleaig of plat cotaiig toxic, flammable or hazardous materials, machiery ad durig work at heights or i cofied spaces. Key referece: Workplace health, safety ad welfare Approved Code of Practice ad Guidace o Regulatios HSE Books 2000 ISBN Health ad safety i egieerig workshops Page 16 of 147

17 Health ad Safety Lightig Poor lightig is ofte a factor i accidets ad ca also icrease visual fatigue. The law* o lightig outlied You must provide: good light use atural light where possible but try to avoid glare a good level of local lightig at work statios where ecessary suitable forms of lightig (fluorescet tubes operatig at mais frequecy may be dagerous with rotatig machiery whe the rotatig part ca appear to have stopped) special fittigs for flammable ad explosive atmospheres, eg i spray booths, to reduce risks of igitio ad explosio. * Workplace Health, Safety ad Welfare Regulatio Problems Typical activity Average illumiace lux (lx) i work areas Miimum measured illumiace (lx) at ay poit or a suitable place Geeral hazards from the movemet of people, machies ad vehicles i ad aroud the workshop ad visual fatigue from work requirig limited perceptio of detail Visual fatigue from work requirig perceptio of detail Visual fatigue from work requirig perceptio of fie detail Geeral work i the workshop, assembly of large compoets Sheet metal work, geeral machiig, office work Drawig office work, assembly of electroic ad other fie compoets Health ad safety i egieerig workshops Page 17 of 147

18 Health ad Safety Avoid: large differeces i the lightig of adjacet areas glare from direct sulight by providig blids, for example, ad from directly visible lamps by excludig them sufficietly from lies of sight whe ecessary strobe effects by: supplyig adjacet rus of light fittigs from differet phases providig a high frequecy supply washig out the effect with local tugste filamet lightig if high itesity tugste haloge or mercury lamps are used to provide local lightig, maufacturers filters should always be kept i place. For the electrical safety of lightig systems see pages Key referece: Lightig at work HSG38 HSE Books ISBN Health ad safety i egieerig workshops Page 18 of 147

19 Health ad Safety Geeral vetilatio, temperature ad toilets Fas ad/or additioal air ilets (at low level) ad outlets (at high level) may be eeded i workshops where there are o meas of vetilatio other tha air leakig i ad out (particularly i uits o some factory estates) ad where: work geerates hazardous airbore pollutats workshops have bee sealed to coserve eergy. Provide at least five litres/secod per occupat (eight is recommeded for comfort) ad air movemet i the workshop of at least 0.1 to 0.15 metres/secod. Measure velocities, usig specialist help if eeded, at ilet ducts (to calculate air flows iwards) ad iside the workshop (to calculate air movemets). The law o temperature outlied You must provide: a reasoable temperature ad a thermometer iside workshops. The temperature should be at least 16 C uless work ivolves severe physical effort, i which case the miimum should be 13 C. The law o toilets ad washig facilities outlied You must provide: suitable ad sufficiet (ad adequately vetilated ad lit) saitary coveieces ad (earby) washig facilities kept clea ad orderly, i the miimum umbers outlied below separate rooms for me ad wome, except where they are for the use of oe perso ad are capable of beig secured from the iside hot ad cold, or warm water with meas of cleaig ad dryig. No of people i workshop No of WCs ad wash statios Health ad safety i egieerig workshops Page 19 of 147

20 Health ad Safety Alteratively, for saitary accommodatio used oly by me, the followig umbers are recommeded: No of me No of WCs No of urials Make separate calculatios where groups such as office workers have separate accommodatio. Key referece: Workplace Health, Safety ad Welfare Regulatios 1992 Approved Code of Practice ad Guidace o Regulatios L24 HSE Books ISBN Health ad safety i egieerig workshops Page 20 of 147

21 Health ad Safety Liftig equipmet Although liftig, supportig ad hadlig equipmet ca lighte the load of maual hadlig whe properly used, may accidets happe whe loads are dropped from liftig equipmet, either because of poor sligig, or equipmet failure or overloadig. Always: maitai all liftig equipmet, icludig that used oly occasioally, such as attachmets to fork lift trucks trai all users, particularly i the use of sligs where ecessary pla lifts i advace esure that the weight ad the distributio of ay load is ot beyod the capacity of the equipmet beig used provide safe places of work from which to maitai hoists ad lifts, particularly at heights; do ot allow overhead travellig craes to work withi 6 m of persos o crae tracks check the coditio, type ad size of ay eyebolts used ad esure that the thread type matches the hole ito which it is to be screwed. The law* o liftig equipmet outlied The same regulatios ow apply to all liftig equipmet, which icludes ay equipmet used at work for liftig or lowerig loads, ad liftig accessories such as chais, sligs, eyebolts etc. You should esure that: liftig equipmet is sufficietly strog, stable ad suitable for the proposed use, ad marked to idicate its safe workig load; liftig equipmet is positioed or istalled to miimise the risk of ijury, eg from the equipmet or the load fallig or strikig people; every part of a load (icludig, for example, pallets ad stillages) ad aythig attached to the load ad used i liftig (icludig for example the liftig poits o skips) is of adequate stregth; liftig operatios are plaed, supervised ad carried out i a safe maer by people who are competet; liftig equipmet (icludig accessories) is thoroughly examied for ay defect before it is put ito service for the first time (uless it is ew ad is covered by a EC declaratio of coformity which is less tha 12 moths old). Where the safety of liftig equipmet depeds o istallatio coditios, it must be thoroughly examied after istallatio ad before beig put ito use for the first time. Periodic thorough examiatios are also required at six-mothly itervals for accessories ad equipmet used for liftig people, ad at least aually for all other equipmet; or at itervals laid dow i a examiatio scheme draw up by a competet perso. * Liftig Operatios ad Liftig Equipmet Regulatios Key referece: Safe use of liftig equipmet: Liftig Operatios ad Liftig Equipmet Regulatios 1998 L113 HSE Books ISBN Health ad safety i egieerig workshops Page 21 of 147

22 Health ad Safety Movig goods safely by had The usafe movemet of goods by had, either by liftig or hadlig causes more accidets ad ill health i small egieerig workshops tha ay other sigle activity, especially to those most at risk, icludig the youger more iexperieced employees, the older ad/or less physically fit, ad those who may make a existig ijury worse. Back ijuries are very commo as are had, arm, shoulder ad eck ijuries, particularly from usafe, highly repetitive work. Cuts ad abrasios from sharp edges are also very umerous. Maual Hadlig Operatios Regulatios 1992 outlied Employers must: avoid the eed for hazardous maual liftig ad hadlig if reasoably practicable assess the risk of ijury from ay hazardous maual liftig ad hadlig which caot be avoided; ad reduce the risk of ijury accordigly. Employees must: follow safe systems of work laid dow by their employers use mechaical aids provided by their employers properly remember to use the traiig provided o liftig. Sharp edges These cause as may as a third of all accidets i some egieerig workshops, resultig i cuts, abrasios, ifected wouds, dermatitis, amputatios ad occasioally fractures. Those workig with sheet metal, either flat or coiled, heavy sharp items, such as tools ad cutters, ad scrap metal ad swarf are most at risk. Cosider how to avoid hadlig sharp edges, ad if this is ot reasoably practicable, reduce exposure to them. Reducig the risks Key referece: Maual Hadlig Operatios Regulatios 1992 Guidace o Regulatios L HSE Books ISBN Ask your supplier to remove or protect sharp edges, eg by machiig out sharp edges or fittig plastic covers or paddig. Remove sharp edges or protect them before hadlig. Avoid hadlig by usig, for example, trays, jigs, holders or baskets. Miimise hadlig by automatig processes by usig, for example, coveyors, feed ad discharge chutes. Store articles correctly so that they are retrieved easily. Use persoal protective equipmet such as gloves, gautlets ad apros, but oly where these do ot add to other risks from machiery, such as etaglemet. See Appedix 1 for checklists. Health ad safety i egieerig workshops Page 22 of 147

23 Health ad Safety How to lift safely Here are some importat poits, usig a basic liftig operatio as a example. Pla the lift. Where is the load to be placed? Use appropriate hadlig aids if possible. Do you eed help with the load? Remove obstructios such as discarded wrappig materials. For a log lift, such as floor-to-shoulder height, cosider restig the load mid-way o a table or bech i order to chage grip. (a) Pla the lift (b) Determie the best liftig techique Positio the feet Feet apart, givig a balaced ad stable base for liftig (tight skirts ad usuitable footwear make this difficult). Leadig leg as far forward as is comfortable. Adopt a good posture Whe liftig from a low level, bed the kees. But do ot keel or overflex the kees. Keep the back straight (tuckig i the chi helps). Lea forward a little over the load if ecessary to get a good grip. Keep the shoulders level ad facig i the same directio as the hips. (c) Get a secure grip Try to keep the arms withi the boudary formed by the legs. The best positio ad type of grip depeds o the circumstaces ad idividual preferece; but it must be secure. A hook grip is less tirig tha keepig the figers straight. If you eed to vary the grip as the lift progresses, do it as smoothly as possible. Keep close to the load Keep the load close to the truk for as log as possible. Keep the heaviest side of the load ext to the truk. If a close approach to the load is ot possible, slide it towards you before tryig to lift. Lift smoothly, keepig cotrol of the load. Do t twist the truk whe turig to the side. If precise positioig of the load is ecessary, put it dow first, the slide it ito the desired positio. Traiig for liftig ad hadlig This should cover: how to recogise harmful maual hadlig appropriate systems of work use of mechaical aids good hadlig techique. (d) Pull the load i close to your body Health ad safety i egieerig workshops Page 23 of 147

24 Health ad Safety Liftig ad hadlig Assessig risks Assessmet Some of the importat questios to ask Job: Load: Work area: Idividual: Too high to lift/lower? Too rushed? Too far to carry? Too repetitive? Too much twistig ivolved? Too heavy? Too large? Too ustable? Too hot/cold? Too sharp? Too difficult to grasp? Too dark? Too slippery? Too obstructed? Too may steps? Fit for the job? I eed of special cosideratio or traiig? Health ad safety i egieerig workshops Page 24 of 147

25 Assessig risks Takig actio Health ad Safety Job Short-term actio Log-term actio Loadig/uloadig lorries/vas by had Provide help for heavy loads. Use the right perso for the job Palletise load(s). Use fork lift trucks Movig materials to/from machies Break dow loads ito easily hadled uits/cotaiers Use coveyors/hoists /fork lift trucks Sortig/coutig compoets Use appropriate traied, fit, persoel Ask suppliers to pre-sort before delivery. Weigh istead of cout. Automate sortig Health ad safety i egieerig workshops Page 25 of 153

26 Assessig risks Takig actio Health ad Safety Job Short-term actio Log-term actio Loadig/uloadig machies Raise stillages/bis to right height/positio/ Automate load/uload operatios. Use hoists ad/or mechaical aids Assemblig ad packig Use appropriate fit, traied, persoel at the right place. Rotate the work to prevet too much repetitio Provide good workig eviromet, well lit ad appropriate mechaical aids ad tools to do the work without udue strai. Desig out the eed for maual assembly ad packig Preparig, maitaiig, movig ad repairig machiery Use appropriate fit, traied persoel Provide uobstructed access ad mechaical aids as ecessary Health ad safety i egieerig workshops Page 26 of 153

27 Health ad Safety Ergoomic machie operatio, assembly ad packig To miimise risks avoid applyig too much force for too log or too frequetly usig a awkward posture of the had, wrist or arm. Cosider Reducig the force ivolved by, for example: keepig cuttig tools sharp providig a larger grippig area supportig tools by meas of balacers or tesioers (which may also help miimise vibratio). A modified hadle desig ca lead to a more comfortable had positio Reducig highly repetitive movemets by, for example: restructurig jobs so they cotai more varied work automatio. Reducig the eed for awkward postures by, for example: chagig the orietatio of the part beig worked upo to eable the wrist to be straight movig the operator so work is more comfortable. Traiig is vital, particularly: to prevet the repetitio of old, bad ways of workig to protect ewer employees from workig too quickly too soo. Health ad safety i egieerig workshops Page 27 of 147

28 Health ad Safety Most ill health arises from: prologed forceful or repetitive grippig, twistig, reachig or other movemet without eough rest or recovery. This causes pai, a restrictio of joit movemet ad soft tissue swellig, leadig sometimes to permaet disability, mostly i the hads, arms ad shoulders liftig ad hadlig goods usafely by had. Cosider workstatios where both stadig ad sittig is possible. I geeral it is less physically stressful to sit, provided there are opportuities for movig aroud. Key referece: Upper limb disorders i the workplace HSG60 HSE Books ISBN Health ad safety i egieerig workshops Page 28 of 147

29 Health ad Safety Ergoomic aspects to cosider For operatig machiery Sit-stad seat make frequetly operated had cotrols easy to reach ad work if seats are provided leave sufficiet room for kees ad legs avoid bedig ad twistig to load/uload machies by havig material/bis o racks which ca be raised ad lowered to keep them at waist height cosider lea-o or sit-stad, wheeled, slidig, suspeded or fixed seats see pages for ormal chairs. For process or assembly work Tiltig seat arrage the work i a semi-circle provide a swivel chair brig the work to the worker cosider chairs with forward-tiltig seats ad backrests to help workers reach further without loss of support, ad cosider work surfaces ad compoet trays which slope towards the worker racks for material ad fiished items should be adjustable so that work is comfortable to reach ad put away. For precisio work To avoid tese postures, a forward tiltig seat ad a work surface which slopes to the worker may be particularly helpful. Foldaway seat Zoe of coveiet reach Normal workig area Horizotal reach distaces i millimetres Key referece: Seatig at work HSG HSE Books ISBN Health ad safety i egieerig workshops Page 29 of 147

30 Health ad Safety Movig vehicles safely Lorries, vas, cars ad other vehicles ad mobile plat are ivolved i may accidets, whe reversig ad maoeuvrig i or aroud small workshops. These accidets cause ijuries ad occasioally deaths whe victims are ru over or crushed. To reduce risks: Idetify ad clearly mark safe routes ad locatios for deliveries ad despatches which are: away from pedestrias as much as possible i good coditio well lit at all times whe beig used away from vulerable plat marked clearly with suitably low speed limits. Provide loadig bays with a exit from low level or a refuge to prevet crushig Do ot allow utraied drivers to drive vehicles Avoid reversig (eg by suitable traffic routig for example) or provide help for reversig drivers if possible (eg a guide) Use speed bumps to limit traffic speeds where ecessary ad make sure there are gaps for ay lift trucks which have to cross them Select ad trai your ow drivers with care. Loadig ad uloadig vehicles Accidets frequetly happe whe people fall from vehicles. Avoid the eed to climb o loads (by usig curtais o the sides of vehicles or mechaical or proprietary sheetig systems), or provide safe access ad safe systems of work. If it is ecessary to walk o the top of high loads, safety lies ad haresses should be provided ad wor. Key referece: Workplace trasport safety HSG136 HSE Books ISBN Maagig vehicle safety at the workplace INDG199 HSE Books (sigle copies free) Health ad safety i egieerig workshops Page 30 of 147

31 Health ad Safety Lift trucks How most accidets happe Lift trucks, (powered ad o-powered, pedestria ad rider-operated,) are ivolved i may accidets i small egieerig workshops. These are frequetly caused by reversig usafely, speedig, overloadig, carryig passegers or liftig persoel the truck was ot desiged for, or drivers ot beig traied, ad result i may serious ijuries ad some deaths every year whe victims are ru over or crushed. Most ill health arises from: usig diesel trucks i eclosed cofied workig areas, leadig to breathig problems poor seatig ad cotrols leadig to back ad upper limb disorders poor roadways which may cause vibratio leadig to back problems. The law* o mobile work equipmet outlied mobile work equipmet icludes fork lift trucks ad ay other work equipmet which carries out work while it is travellig or which travels betwee differet locatios where it is used to carry out work. where mobile work equipmet is used for carryig people, it must be suitable for this purpose. Measures must be take to reduce the risks to the safety of people beig carried, the operator, ad ayoe else. These iclude measures to reduce the risks from equipmet rollig over (most couter-balaced, seated cetre-cotrol fork lift trucks have a vertical mast which prevets them rollig more tha 90 ). Measures, such as fittig restraiig systems, eg seat belts, must also be take to reduce the risk of ayoe beig crushed betwee ay part of the equipmet ad the groud if it rolls over or overturs. you must esure that self-propelled work equipmet (ie work equipmet which is propelled by its ow motor mechaism) has appropriate facilities to esure the safety of people i the workplace, icludig facilities for prevetig its beig started by a uauthorised perso. * Provisio ad Use of Work Equipmet Regulatios Approved Code of Practice o rider operated lift trucks operator traiig outlied Employers to provide basic traiig by recogised istructors Traiees to pass a test of their competece Records to be kept of traiig. Health ad safety i egieerig workshops Page 31 of 147

32 Health ad Safety Safe lift truck operatio Get the right truck for the job Maitai all lift trucks regularly i accordace with the maufacturer s istructios, esure seats are maitaied to miimise uhealthy postures ad vibratio Select oly suitable persoel for traiig as operators/drivers, authorise operators/drivers i writig Avoid routes ear vulerable plat, eg flammable liquid stores, or protect such plat Segregate busy lift truck areas/routes from pedestria ad workig areas as much as possible, pay particular attetio to barriers, layout, visibility, lightig ad warigs where lift trucks ad people work alogside each other; eforce rules for low speed ad safe reversig Esure operatig surfaces are strog eough, well maitaied ad gradiets are ot too steep Trai all employees o lift truck movemets, if the lift truck is used o the road (to load ad uload, for example) provide a secod perso to help with traffic, as ecessary Rider operated lift trucks used regularly o the road for log periods, ad their drivers, must be licesed by the Departmet of Trasport Keep keys secure whe trucks ot beig used Do ot use forks, pallets or bis to lift persos to work at heights uless these are suitably modified; use properly desiged mobile work platforms if possible. Key refereces: Rider operated lift trucks operator traiig L117 HSE Books ISBN ; Safety i workig with lift trucks HSE Books 2000 ISBN Health ad safety i egieerig workshops Page 32 of 147

33 Health ad Safety Cotrollig hazardous substaces Exposure to hazardous substaces most frequetly occurs whe: machiig (see pages for geeral cotrol of hazardous substaces ad pages for the cotrol of metalworkig fluids) weldig (see page 82) paitig (see pages 90 91) ad cleaig ad degreasig (see page 79). The cotrol of dust, fume, spray ad vapour ad the prevetio of ski cotact by adequate persoal protectio will miimise risks of adverse health effects, but pay particular attetio to precautios whe machiig, weldig, polishig or gridig: ickel-copper ad ickel-chrome alloys (foud i cois, magets, chemical ad food process equipmet ad i the aerospace idustry) stailess steel ad ickel alloys; stailess steel ad chromium alloys lead ad lead alloys copper alloys cotaiig beryllium (commoly foud i the electrical idustry ad i high defiitio tools ad dies used, for example, i plastic ijectio mouldig machies) cadmium-plated articles. The Health ad Safety at Work etc Act 1974, sectio 6 i relatio to the supply of substaces for use at work outlied Suppliers must: esure so far as is reasoably practicable that the substace will be safe ad without risks to health provide adequate iformatio about ay risks to health or safety to which the iheret properties of the substace may give rise. Labels ad safety data sheets supplied with hazardous chemicals cotai importat iformatio about hazards (see CHIP referece page 112) to help you use them safely. The most commo health effects from hazardous substaces are: ski diseases such as dermatitis from metalworkig fluids ad oils lug problems, such as asthma, from isocyaate paits ad glues poisoigs, such as lead poisoig, ad very rarely cacer, such as ski cacer from certai mieral oils. Health ad safety i egieerig workshops Page 33 of 147

34 Health ad Safety The Cotrol of Substaces Hazardous to Health Regulatios outlied You must: assess risks to health prevet exposure, for example by usig a less hazardous substace a differet process where prevetio is ot reasoably practicable, cotrol exposure by, for example, isolatig or eclosig the process or, if this is ot reasoably practicable, local exhaust vetilatio, ad where prevetio or cotrol is isufficiet o its ow, provide persoal protective equipmet iform, istruct ad trai employees carry out air moitorig ad health surveillace where ecessary. A hazard may be defied as somethig that ca cause harm such as the chemicals i a ti of pait while a risk may be see as the chace of harm actually beig doe which ca vary with how the pait is actually used; sprayig i a ucotrolled eviromet without persoal protectio could pose high levels of risk. Key referece: Cotrol of Substaces Hazardous to Health Regulatios Approved Code of Practice ad guidace L5 (Fourth editio) HSE Books 2002 ISBN Health ad safety i egieerig workshops Page 34 of 147

35 Health ad Safety Local exhaust vetilatio (LEV) Selectio ad use LEV is a frequetly used way of cotrollig exposure to hazardous substaces by drawig them away from the breathig zoes of workers ito a hood ad ductwork coected to a extract fa. I may circumstaces LEV may be cheaper ad more effective tha dilutio vetilatio. (Dilutio vetilatio works by itroducig fresh air ito the workplace to lower the geeral level of the hazardous substaces i the air.) Heat losses from LEV may be miimised by heat recovery systems or recirculatio of filtered air, but the latter oly after specialist advice to prevet the recirculatio of hazardous materials i harmful quatities. The law* o maiteace, examiatio ad testig of LEV outlied I most small egieerig workshops, employers must esure that thorough examiatios ad tests are carried out: every 14 moths for most processes every six moths where metal articles are abraded or polished for more tha 12 hours a week. Employers must also keep appropriate records for at least five years. See Appedix 6 for details which should be recorded. * Cotrol of Substaces Hazardous to Health Regulatios, regulatio 9. Someoe with sufficiet traiig, kowledge, skills ad experiece is required for the maiteace, examiatio ad testig of LEV, ad isurace compaies frequetly have the competece required. To make the most of LEV LEV used to help draw weldig fume from the breathig zoe of a welder Get a expert to desig ad istall the most appropriate system, with the right hoods/eclosures, ductwork, air velocities ad cleaig ad filtratio systems Keep the hood as close to the source of cotamiatio as possible Make sure the fa draws air away from the operator Make sure partial eclosures are large eough to cotai the work ad that sprayers do ot stad betwee the workpiece ad poit of extractio; cosider a turtable for heavy items Check ad maitai the system, regularly particularly flexible ductwork Provide sufficiet lightig (suitably protected) withi the eclosure to ecourage work to be doe withi the extracted area. Health ad safety i egieerig workshops Page 35 of 147

36 Health ad Safety Commo causes of LEV failure, which you ca check easily ad frequetly yourself to keep it workig properly iclude: physical damage to ad poor positioig of hoods ad booths damaged ad/or blocked ductwork blocked, damaged, usuitable or icorrectly istalled filters too high/low water levels i wet collectors wear or corrosio of fa blades leadig to build up of cotamiat o blades slippig drive belts to fas poor lubricatio of fa bearigs. It helps to keep a record of these checks. Sprayig i the directio of exhaust vetilatio air movemet; a turtable ca help a sprayer avoid stadig betwee the item beig sprayed ad the poit of air extractio from the booth Key referece: Itroductio to local exhaust vetilatio HSG37 HSE Books ISBN Health ad safety i egieerig workshops Page 36 of 147

37 Health ad Safety Electricity How most accidets happe Most accidets arise from cotact with live coductors or equipmet made live by faulty wirig ad coectios. Equipmet usig 240v AC may be as dagerous as that usig 415v AC, depedig o circumstaces. Each year, the use of electricity causes fatal ad other ijuries (eg burs) from electric shock ad fire. The law* o live electrical work outlied No electrical work should be carried out live where there is a possibility of cotact with a potetially dagerous live coductor uless: it is ureasoable i all the circumstaces for the equipmet to be dead; ad it is reasoable i all the circumstaces for the work to be carried out o or ear it while it is live; ad suitable precautios (icludig, where ecessary, suitable protective equipmet) have bee take to prevet ijury, such as proper work plaig ad the use of adequately traied ad supervised staff. * See Key refereces. Precautios ecessary to prevet accidets require everyoe i the workshop (icludig the self-employed) to use equipmet safely ad co-operate with the employer where ecessary. Employers i particular eed to: develop a suitable system of maiteace for both fixed istallatios ad portable equipmet advice from a competet perso may be required esure that electrical cotractors are competet for the work they are expected to do; for example, are they registered with such orgaisatios as the Natioal Ispectio Coucil for Electrical Istallatio Cotractig or equivalet? select equipmet which is suitable for the job (usig reduced low-voltage equipmet lowers the risk of serious ijury) check that wirig ad equipmet is soud ad properly istalled, especially so that protectio equipmet such as fuse ad switchgear will operate adequately i the case of faults. Uiversally accepted stadards are described i BS 7671 Requiremets for electrical istallatios esure ay electricias workig for you are competet. Levels of qualificatio established by the Electrical Joit Idustries Board may be of help here, but check that qualificatios are relevat; a fully qualified TV techicia may ot be competet to re-wire a buildig. Key refereces: Memoradum of guidace o the Electricity at Work Regulatios 1989 HSR25 HSE Books ISBN ; Electrical safety ad you INDG231 (sigle copies free) Health ad safety i egieerig workshops Page 37 of 147

38 Health ad Safety Portable electrical equipmet Use this list to check whether you are maagig the risks from portable electrical equipmet. Have you: prepared ad implemeted a system of maiteace for portable (ad trasportable) electrical equipmet made sure that all items of portable electrical equipmet are icluded i the maiteace system decided how to deal with uauthorised equipmet brought i by employees, eg portable, mais-operated radios collected iformatio o where ad how equipmet is used. This iformatio will help you decide what sort of checks/ispectios/tests are required ad at what frequecies provided straightforward traiig ad iformatio for all users (icludig yourself) to help them carry out user checks whe equipmet is used made sure that all equipmet receives a formal visual ispectio at appropriate itervals, carried out by someoe who has bee traied i what to look for cosidered preparig brief writte guidace relatig to visual ispectio, what to look for, ad procedures to follow whe faults are foud (ad whe uauthorised equipmet is foud) idetified equipmet which will eed periodic combied ispectio ad testig established how ofte combied ispectio ad testig is appropriate (based o the type of equipmet, how it is used, where it is used ad the results of ay previous checks/ispectios/tests) appoited someoe with the appropriate kowledge, traiig ad experiece to carry out the ispectio ad testig reviewed the results of checks/ispectios/tests to idetify ay commo treds ad to cofirm that the chose ispectio/test frequecies are appropriate made sure that the arragemets which you have made are beig put ito practice ad that follow-up actio is beig take? Remember that choosig the right equipmet ad carryig out visual ispectios are perhaps the most importat ways to miimise the risks. Health ad safety i egieerig workshops Page 38 of 147

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