Health and safety in engineering workshops

Transcription

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 [email protected] 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

39 Health ad Safety Activity Work iside metal taks which may be damp or humid (through codesatio, for example) Work o apparatus where water may be preset (o a metalworkig fluid circulatio system o a machie tool) Work i close cotact with metalwork i cool dry coditios Ad hoc maiteace work ad outside work i good weather Preferred equipmet Use peumatic power tools. Lightig, if essetial, should be 25V dc CTE* max ad fixed out of reach. Use equipmet operatig at voltages of 50V ac, 120V dc or less. Highervoltage equipmet should be built to waterproof stadard, eg BS EN 60529: 1992 Specificatio for degrees of protectio provided by eclosures. The supply to earthed equipmet should icorporate back-up protectio which automatically discoects the supply i the evet of a fault, preferably earth moitorig. Use equipmet operatig at voltages of 50v ac, 120v dc or less (110v ac CTE may be used i cojuctio with all-isulated or double/isulated tools). Frequet cleaig of vetilatio louvres is ecesary. Reduced low-voltage equipmet is preferred such as 110 volt CTE. * CTE: cetre tapped to earth. Key referece: Maitaiig portable ad trasportable electrical equipmet HSG107 HSE Books ISBN Health ad safety i egieerig workshops Page 39 of 147

40 Health ad Safety Commo problems with flexible leads, their plugs ad sockets ad how to avoid them May accidets causig bur ad shock ijuries which are sometimes fatal arise from poorly maitaied ad damaged leads, plugs ad sockets. Problem Failure to select the right equipmet for the job/eviromet Precautio Choose the right equipmet. For example i a heavy fabricatio shop, armoured, heat-, oil- ad fire-resistat leads will ofte be ecessary. Select reduced low voltage equipmet (110V AC CTE max) wheever possible. Failure to give adequate support to suspeded cables (such as o pedat cotrol leads for overhead craes) Use a wire or chai to relieve the cable of tesio. Poor joits i cables Replace cables rather tha repair them, particularly those used for a log time, or for short legths whe the cost of repair may be more tha replacemet; for loger legths cut off the damaged part if it is close to a ed or use a proprietary plug/ socket which provides both electrical ad mechaical protectio for cables. (If a coupler is used the socket must be o the supply side ad the plug o the cable coected to the apparatus.) Repairs should be carried out oly by competet persoel; isulatio ad sheath damage ca be repaired by vulcaisig or usig compatible proprietary self-sealig material together with a heat shrikable plastic sleeve to give the fiished joit ecessary isulatig value, stregth ad waterproofig. Isulatig tapes aloe are usatisfactory. Leads trailig too log may prevet circuit protectio from operatig withi desiged limits Provide more coveiet sockets, closer to work. Health ad safety i egieerig workshops Page 40 of 147

41 Health ad Safety Problem Cables ad coductors isufficietly protected ad liable to damage Cables ad coductors too ofte flexed, which may cause damage to the isulatig sheath or coductor Damage to cables ad coductors by portable equipmet such as solderig iros ad portable griders Arcig whe plugs withdraw o load Weight ad leverage of adaptors damagig socket outlets Failure of plug cord grips Precautio Where liable to damage, for example i a busy area, re-route or provide a suitable cover, eg a coduit. Check regularly, especially where the cable is termiated ito the apparatus cocered, ad repair or replace as ecessary. Secure leads as far as possible out of harms way, where risk of damage is miimised. Above 16A provide a switch (iterlocked with plug if possible) to eable currets to be safely broke before withdrawig plug. Do ot use adaptors or other plug-i devices where their weight ad leverage may damage socket outlets. Provide sufficiet socket outlets or, if ecessary, use purpose made, portable multi-socket outlets. Esure that it is the sheath which is beig gripped ot the coductors; do ot remove plugs by pullig leads. Use the correct type of plug (particularly for armoured lead). Cosider heavyduty idustrial plugs. Esure it is termiated as per the maufacturer s istructios. Loss of securig screws for plugs Screeed ad armoured flexible cables icorrectly termiated i smaller portable equipmet Overheated extesio lead drums Check them regularly, ad replace missig oes. Secure the whole cable usig purposemade glads/termiatios fitted by a skilled perso where ecessary. Uwid lead from drum completely before use. Health ad safety i egieerig workshops Page 41 of 147

42 Health ad Safety Pressurised plat ad systems The law* o pressurised plat ad systems outlied All plat ad systems must be desiged, costructed ad istalled to prevet dager Systems must be properly maitaied Modificatios or repairs must ot cause dager There must be a writte scheme for examiatio of certai pressure vessels, such as air receivers, steam boilers, fittigs ad pipework, draw up by a competet perso Examiatios as set out i the writte scheme must be carried out by a competet perso Records must be kept i most cases. Pressure testig Accidets, some fatal, occur durig pressure testig whe the eergy cotaied i the vessel uder test is released with explosive force Wherever practicable, avoid usig compressed air, steam or gas (which cotais more tha 200 times the eergy of water of the same volume) Use hydraulic (liquid) pressure with suitable precautios ad always, if possible, before leak testig (usig air, steam or iert gas) compoets ot iteded as pressure vessels, eg vehicle fuel taks, radiators, small castigs, storage taks ad oil drums. Ijectio ijuries Ijuries, occasioally fatal, may be caused by accidetal or deliberate ijectio of material ad/or compressed air either through the ski or ito a body orifice Ordiary workig clothes do ot sigificatly resist the peetratio of compressed air ito the body High-pressure fluid gus may iject material at psi ad cause serious ijuries. Care should be take to avoid accidetal ijectios Horseplay should be strictly forbidde Because the degree of ijury may ot always be immediately apparet, medical advice should always be sought after compressed air peetratio occurs or is suspected. Key referece: *Safety of pressure systems. Pressure Systems Safety Regulatios Approved Code of Practice HSE Books ISBN X Compressed air safety HSG39 HSE Books ISBN Health ad safety i egieerig workshops Page 42 of 147

43 Health ad Safety Machiig How most accidets happe Most accidets at all types of machie, icludig automatic ad CNC machies, happe to operators durig ormal operatio whe: loadig/uloadig compoets removig swarf takig measuremets ad makig adjustmets (to the coolat supply i particular). O maually operated machies, the most dagerous machie movemets are the rotatig, cuttig, shearig, sawig or pressig movemets of tools, particularly o: presses drillig machies millig machies lathes metal cuttig saws guilloties ad gridig machies. Hads are most frequetly ijured, the most umerous ijuries beig cuts ad abrasios, may of which are severe. Broke boes ad dislocatios are umerous. Amputatios of figers ad hads are ot ifrequet ad there are some fatalities, ofte arisig from etaglemets, every year. Eye ijuries are also commo. O automatic ad computer cotrolled machiery, a larger proportio of accidets happes at automatically ad computer cotrolled clamps, axes, tables, swarf removal equipmet, chucks ad other work hadlig equipmet. At all types of machiery a large umber of accidets happe to setters, electricias ad maiteace persoel durig set-up, ispectio, fault-fidig, maiteace ad repair. Most ill health arises from: usafe loadig/uloadig ad hadlig of compoets, i particular whe highly repetitive, which may cause back ijuries ad upper limb disorders ski cotact with metalworkig fluids, for example whe preparig fluids or hadlig compoets, which may cause ski irritatio ad dermatitis breathig i aerosols, oil mists ad fumes from metalworkig fluids durig machiig which may cause irritatio of the eyes, ose ad throat, ad occasioally breathig difficulties such as brochitis ad asthma sharp edges ad swarf which may cause cuts which exacerbate dermatitis high oise levels which may cause deafess most frequetly at machies which geerate impacts whe operatig, higher speed machies or groups of machies ruig together vibratio, particularly whe gridig. Health ad safety i egieerig workshops Page 43 of 147

44 Health ad Safety Safety measures To prevet access to dagerous movemets durig batch productio at maually operated machies use fixed guards with: jigs ad fixtures (such as slidig trays) to load ad uload compoets away from the tools safe meas of removig swarf (such as a hook or rake which may be iserted through small opeigs i fixed guards) ad adjustig coolat (such as taps outside fixed guards). Use fixed ad iterlockig guards or safety devices providig equivalet protectio at automatic ad CNC machies to esure all dagerous movemets, ot oly tools, are guarded (see pages ad idividual machies for further guidace o guardig CNC machies). Cotrol oise by egieerig meas at source or adapt ad exted guards to serve as oise eclosures (eg by liig them with oise absorbet materials). (See pages ) Use guards to help eclose ad cotrol hazardous substaces with LEV where appropriate. Maually operated machies used ifrequetly for oe-off operatios such as those ofte foud i toolrooms may require costat adjustmet ad close observatio; guards may also eed to be readily adjustable ad allow close observatio. Traiig essetials Operators should kow: what the mai dagers are, how the mai safeguards work ad who should be otified of defective oes how to start, operate ad stop the machie safely what to wear (eg protective equipmet) ad what ot to wear (eg loose clothig at some machies) how to load ad uload compoets remove swarf, ad adjust coolat flow safely ot to clea machies usig compressed air to blow material away idustrial vacuum cleaers or brushes should be used how to work safely with ay metalworkig fluids used. Health ad safety i egieerig workshops Page 44 of 147

45 Health ad Safety Maiteace ad settig persoel should kow: that before ispectio, cleaig, maiteace ad repair, machies must i geeral be switched off ad isolated where power is ecessary, how to work safely, for example by usig: writte systems of work permits to work o complex or hazardous plat, ad warig sigs how to maitai metalworkig fluids to miimise health risks. The Provisio ad Use of Work Equipmet Regulatios 1998 outlied (equipmet icludes machiery) Employers ad others must esure that: suitable equipmet is provided for the jobs ivolved iformatio ad istructio are adequate equipmet is maitaied i good workig order ad repair traiig is provided for operators ad supervisors equipmet is safeguarded to prevet risks from mechaical ad other specific hazards equipmet is provided with appropriate ad effective cotrols maiteace is carried out safely some work equipmet is subject to ispectio to esure that is safe to use (see page 46). The Regulatios also cotai requiremets relatig to mobile work equipmet (see page 31) ad power presses (see page 65). The Provisio ad Use of Work Equipmet Regulatios 1998 impose requiremets relatig ot just to prevetig access to dagerous parts of machiery, but also to the followig: iformatio ad istructio ispectio safe maiteace operatios startig ad stoppig machies safely (icludig emergecy stops) cotrol systems meas of isolatig work equipmet from sources of eergy stability lightig markigs warig devices. You will eed to carry out risk assessmets o your existig machiery i order to idetify whether it complies with all of the requiremets. You ca use the risk assessmet proforma i Appedix 3 to help. Key referece: Provisio ad Use of Work Equipmet Regulatios 1998 ACOP ad Guidace o Regulatios L22 HSE Books ISBN Health ad safety i egieerig workshops Page 45 of 147

46 Health ad Safety Ispectio of work equipmet Ispectio of work equipmet should be carried out where a sigificat risk of ijury (oe which could foreseeably result i a major ijury or worse) may result from: icorrect istallatio or reistallatio of the equipmet deterioratio of the work equipmet leadig to dager, or as a result of exceptioal circumstaces which could affect the safe operatio of the work equipmet (for example, if it is damaged). Ispectio will be ecessary whe equipmet or parts of equipmet deteriorate ad lead to dager ad where this will ot be adequately cotrolled through operator checks ad ormal servicig regimes. It will ot therefore apply to everyday risks at work equipmet, which ca be detected ad rectified durig routie operator checks ad maiteace. The purpose of a ispectio is to idetify whether the equipmet ca be operated, adjusted or maitaied safely ad that ay deterioratio (such as damage or wear) ca be detected ad remedied before it results i uacceptable risks. Ispectios should iclude visual ad fuctioal checks of the equipmet, ad sometimes testig. This will deped o the complexity of the equipmet, o where ad how it is used, ad o what the risks to health or safety could be if the equipmet is operated i a usafe coditio. A risk assessmet should be carried out to determie whether a ispectio is ecessary ad, if so, what form it should take. The assessmet should also state the itervals at which ispectios should be carried out. Records of the assessmet ad the ispectios should be kept. Some examples of equipmet which is likely to be subject to ispectio: Hydraulic presses ad press brakes No-liftig parts of fork lift trucks Die-castig machies Health ad safety i egieerig workshops Page 46 of 147

47 Health ad Safety Computer cotrolled (CNC) machiig How most accidets happe From trappig at, or cotact with, tools, clamps, tables, swarf removal equipmet, chucks ad other work hadlig equipmet, durig ormal operatig cycles whe clearig blockages ad swarf, loadig/uloadig, cleaig ad makig adjustmets. May accidets also occur durig fault fidig, settig, ad repair ad maiteace because safeguardig is iadequately specified, poorly desiged, ot uderstood by the user, ad/or misused. Most ill health arises i the same ways as at covetioal machies, from poor hadlig (see page 22), metalworkig fluids (see page 52), ad oise (see page 55), but risks from: aerosol mists from metalworkig fluids may be higher because of higher operatig pressures ad speeds, ad oise, particularly from high-speed cuttig (ad especially from groups of machies operatig together) may be higher. Key safety measures As the degree of computer cotrol may vary from: complete cotrol of several differet machies workig together with associated equipmet (such as loadig/uloadig devices), to partial cotrol of oe aspect of a sigle machie (such as costat surface speed cuttig o a microprocessor ehaced lathe) provide safeguards appropriate to the risks posed. For example, at a fully programmable CNC lathe (where may sequeces of high-speed, high-power machie movemets may be uder computer cotrol) complete eclosure by fixed ad iterlockig guards or their equivalets is appropriate. At a microprocessor ehaced mechaical lathe, however, where oly costat surface speed cuttig is uder computer cotrol, complete eclosure may ot be ecessary ad safeguards more appropriate to a maually operated lathe may suffice. Where the speed ad power of machie movemets uder computer cotrol leads to risks of ijury: provide fixed ad iterlockig guards (or equivalet safeguards) to prevet access to all such machie movemets, ot oly to metalcuttig tools work zoe eclosures may be ecessary arrage iterlockig so that power to dagerous machie parts is removed whe iterlockig guards are ope or movemets are limited to safe icremets or speeds, which are automatically preveted from risig to usafe levels Health ad safety i egieerig workshops Page 47 of 147

48 Health ad Safety use eclosig guards to help reduce oise, ad cotrol emissios of mists, fume ad vapour, either from metalworkig fluids or the material beig machied make sure you uderstad which safety fuctios deped o computer cotrol ad how to check ad maitai them. If you do t uderstad, ask your supplier to explai check that visio paels iteded to cotai parts which may be ejected from the machie are suitably desiged ad costructed, have sufficiet stregth ad are well maitaied. A rage of CNC systems are available that ca be fitted to previously maually operated machie tools, such as millig machies or lathes. Theses systems provide a selectio of features which ca sigificatly improve the productivity of the machie ad the quality of the work produced. Whe machies are retrofitted, ew hazards ad the icreased risks to the operator that are associated with CNC machies may be itroduced. Automatio also chages the way the operator iteracts with the machie ad, to some extet, the way the hazards may be preseted to the operator. Because of the chage from maual to automatic operatio a retrofitted machie should be subject to a risk assessmet. Fixed ad iterlocked guards which prevet access to the dager zoe durig the automatic cycle should be ormally provided. Where it is ecessary to have powered movemet of a machie elemet, with the iterlocked guard ope, eg for settig purposes, this should be doe uder limited speed coditios with hold-to-ru cotrols. Detailed cosideratio should be give to the safety-related parts of the machie s cotrol system. A umber of BS EN stadards provide specific guidace o this matter ad further iformatio should be available from the cotrol system compoet supplier. Key refereces: Provisio ad Use of Work Equipmet Regulatios 1998 ACoP ad Guidace o Regulatios L22 HSE Books ISBN Egieerig machie tools: Retrofittig CNC EIS19 HSE Books (free) Health ad safety i egieerig workshops Page 48 of 147

49 Health ad Safety Buyig ad sellig machiery New* A buyer of ew machiery should look for the CE mark, which should idicate: the supplier s claim to coformity with the Supply of Machiery (Safety) Regulatios, which implemets the Machiery Directive i the UK the machiery meets essetial health ad safety requiremets to elimiate risks of ijury from most sources there should be little if aythig further to do to make the machiery safe if Istructios for use are followed. If you buy a machie with a CE mark, assess that it is safe ad without risks to health by, for example, checkig it agaist the stadards o ay similar machies you may already have; it should at least meet curret stadards. You ca use the risk assessmet proforma i Appedix 3 to help check the machie. A outlie of what is defied as machiery from the Supply of Machiery (Safety) Regulatios A assembly of liked parts or compoets, at least oe of which moves icludig the appropriate actuators, cotrol ad power circuits, joied together for a specific applicatio, i particular for the processig, treatmet, movig or packagig of a material A assembly of machies which, i order to achieve the same ed, are arraged ad cotrolled so that they fuctio as a itegral whole Iterchageable equipmet modifyig the fuctio of a machie which is supplied for the purpose of beig assembled with a item of machiery by the operator himself save for ay equipmet which is a spare part or tool A safety compoet placed o the market separately from machiery to fulfill a safety fuctio whe i use ad the failure or malfuctio of which edagers safety or health. For a seller of ew machiery the CE mark amog other thigs should be a claim for the most commoly used machie tools i egieerig that at least: hazards, where reasoably practicable, have bee desiged out mechaical dagers are safeguarded with guards ad safety devices fitted ad workig together with clear istructios provided o how risks ot safeguarded are to be avoided the machie is as quiet as is reasoably practicable with oise reduced at source or eclosed (the oise emissio level must be stated i Iformatio for use ) steps have bee take to cotrol emissios of harmful substaces whe the machie is workig by, for example, cotaimet or by providig for coectio to extractio equipmet * New meas ew to the Europea Uio. A old, secod-had machie from the Far East or Easter Europe, for example, is regarded as ew to the Europea Uio for the purposes of the Supply of Machiery (Safety) Regulatios Carryig out substatial refurbishmet, such as fittig a CNC cotrol to a previously maual machie, may also result i a ew machie subject to these Regulatios. Health ad safety i egieerig workshops Page 49 of 147

50 Health ad Safety istructios for use are provided to idicate clearly i Eglish how the machie may be safely istalled, operated, maitaied, removed or dismatled; where it is ot immediately clear how safeguards work as o some computer cotrolled machiery clear iformatio should be provided o: how they work how they may be checked how to maitai them, ad what to do i case of faults/failures iformatio o vibratio is provided ad vibratio miimised for had-held machies metalworkig fluids ca be cooled where ecessary, delivered ad removed safely with risks of cotamiatio miimised, eg from filter blockages or high workig temperatures; iformatio for use should specify how to use fluids safely at the machie. Supply of Machiery (Safety) Regulatios 1992 ad Amedmet Regulatios 1994 outlied If you are a resposible perso for the supply of ew machiery or, from outside the EU, ew or secodhad machiery for the first time: AS A COMPLETE MACHINE (such as a lathe) AS INTERCHANGEABLE EQUIPMENT TO MODIFY THE FUNCTION OF ANOTHER MACHINE (such as a iteral gridig attachmet for a cetre lathe) make sure it complies with essetial health ad safety requiremets (of the Machiery Directive, listed i the Supply of Machiery (Safety) Regulatios) keep relevat iformatio o its desig, costructio ad use so that a techical file (or part of oe) may be assembled if a eforcig authority asks for it provide Istructios for use i the laguage of the coutry where it will be used issue a Declaratio of Coformity to your customer attach the CE mark esure that it is safe AS A SAFETY COMPONENT take all the above steps but do ot attach the CE mark AS PART OF ANOTHER MACHINE, which caot fuctio idepedetly, (eg a swarf coveyor iteded for icorporatio ito aother machie) take all the above steps ad issue a Declaratio of Icorporatio istead of Coformity to your customer, i which case do ot attach the CE mark SPECIAL REQUIREMENTS apply to presses ad other highly dagerous machies ad some safety compoets, which must either coform to the BS EN C stadard or have EC-type examiatio. Health ad safety i egieerig workshops Page 50 of 147

51 Health ad Safety Secod-had Sellers of secod-had machiery from outside the Europea Uio must comply with the law o ew machiery. Refurbished machiery from iside the Europea Uio may also be ew withi the meaig of the law, ad have to comply. The degree of refurbishmet will decide whether the machiery is ew or ot. A substatial refurbishmet which gives machiery ew fuctios, such as computer cotrol, which it did t have before, is likely to make the machiery ew. A ew coat of pait ad the straight replacemet of wor-out items, o the other had, most likely would ot. Cosult your local HSE ispector where it is ot clear. Buyers of secod-had machiery should make sure that it complies with the requiremets of the Provisio ad Use of Work Equipmet Regulatios 1998 (see pages 44 48). The risk assessmet proforma i Appedix 3 ca be used to help check compliace. The Health ad Safety at Work etc Act 1974 sectio 6, o the supply of machiery, ew or old, from whatever source, outlied It must be: so far as is reasoably practicable desiged ad costructed so that it is safe ad without risks to health accompaied by adequate iformatio for use. Oly a writte udertakig from the buyer that specified steps will be take to safeguard the machie he/she is buyig relieves the supplier of his duties i relatio to secod-had machies from withi the EU. Key refereces: Product stadards: Machiery DTI (tel: ) Supplyig ew machiery INDG270, Buyig ew machiery INDG271 HSE Books Health ad safety i egieerig workshops Page 51 of 147

52 Health ad Safety Metalworkig fluids Correctly maagig your metalworkig fluids will reduce the risk of ill health, prolog the life of the fluid, icrease tool life, ad improve the machiig performace. Ill health from metalworkig fluids, used eat or mixed with water, most commoly arises from: (a) ski cotact durig preparatio, applicatio ad removal of fluid hadlig of workpieces splashig whe machiig chagig ad settig of tools maitaiace ad cleaig of machies causig ski irritatio ad dermatitis, ad (b) breathig i aerosols, mist ad fumes whe machiig causig irritatio of the eyes, ose ad throat ad occasioally breathig difficulties such as brochitis ad asthma. As most metalworkig fluids, either as cocetrates or whe i use, are or cotai hazardous substaces, the strategy for cotrollig them outlied o pages is almost always relevat ad useful. I particular: maitai them i good coditio (see ext page) operate ad maitai processes to miimise mist, fume, vapour ad splashig make suitable arragemets to clea cotamiated overalls ad clothig do ot use urefied mieral oils ad mildly refied distilled oils which may cause cacer ad for which safer alteratives are available. Cases of oil ace (folliculitis irritatio of the hair roots from prologed ad regular cotact with eat oils) ad ski cacer must be reported to HSE (see pages ). Where there is sigificat ski cotact or exposure to fume, mists or aerosols, health surveillace is likely to be eeded. Appoit a resposible perso to: ecourage high stadards of persoal hygiee udertake regular ski ispectios (about oce a moth) check that cotrols are effective ecourage employees to complete questioaires (about oce a year) for both ski ad breathig symptoms review absece records advise those with problems to seek further medical advice. Appedix 2 (pages ) gives examples of useful questioaires. Key referece: Workig safely with metalworkig fluids (pack) HSE Books ISBN Health ad safety i egieerig workshops Page 52 of 147

53 Health ad Safety Safe workig with metalworkig fluids Miimise risks by Maitaiig fluids i good coditio Do read ad follow supplier s guidace use fluids compatible with machies, eg those that will ot: strip pait from the machie to block filters, or dissolve metals beig worked such as cobalt, chromium ad ickel which may cause health problems later if ihaled or i cotact with ski make use of special expertise, ad develop i-house competece to maitai fluids by, for example, keepig a weekly record of: visual sump ispectios for fluid ad tramp oil leaks cocetratio ad ph measuremets, ad bacteria dip slide measuremets top up i accordace with suppliers istructios keep machies clea ad free from debris clea sumps, pipework ad machies before refillig with fluids which should be recetly mixed outside the machie i clea cotaiers addig cocetrate to drikig quality water use a refractometer to check stregths. Do t store fluids outside, where strog sulight or frost may damage water-mix fluids ad moisture may lead to the cotamiatio of eat oils add too much biocide which will icrease the risks of ski sesitisatio ad respiratory irritatio use fluids beyod their ormal workig life allow other oils used to lubricate the machie to cotamiate metalworkig fluid Operatig machies safely Do trai ad istruct employees i the hazards ad safeguards eclose sources of emissios ad aerosols maitai fluid flow at correct volumes ad pressures, as: isufficiet flow will lead to higher workig temperatures ad more fume higher pressures may lead to more mist formatio larger volumes may icrease risks of splashig provide local exhaust vetilatio at machies to remove fume ad mist at harmful levels ad have the vetilatio system examied ad tested by a competet perso every 14 moths. Do t allow fluids to overheat as this icreases risks of biological cotamiatio allow water-mix fluids to stagate whe ot i use (for example, use small circulatio pumps or pass air getly through the fluid) use air lies to blow compoets clea use a vacuum-type cleaer istead. Health ad safety i egieerig workshops Page 53 of 147

54 Health ad Safety Maitaiig high stadards of persoal hygiee Do use machies, eclosures ad extractio equipmet properly to miimise splashig ad breathig aerosols ad mists wash with soap ad water regularly to remove metalworkig fluids use a after-work cream each time after washig ad dryig wear clea overalls ad keep oily rags out of pockets cover cuts ad abrasios with waterproof dressigs. Do t wear jewellery, rigs or watch straps uder which fluids may collect ad be difficult to clea eat, drik or smoke i workig areas. Key referece: Workig with metalworkig fluids INDG365 HSE Books (sigle copies free; ISBN for priced packs of 10) Health ad safety i egieerig workshops Page 54 of 147

55 Health ad Safety Noise Too much loud oise damages hearig by causig: deafess, or permaet tiitus (rigig i the ear). If you caot hear clearly what someoe is sayig (i a ormal voice) 2 m away, the oise level is likely to be 85dB(A) or higher: Typical miimum oise levels ext to operatios where o steps have bee take to reduce oise: Actual oise levels ca be higher tha those show above. db(a) air exhaustig from peumatic equipmet gridig o pedestal grider dischargig metal objects ito metal tis/chutes geeral oise level i fabricatio shop usig vibratory bowl feeders hammerig steel guillotiig multi-spidle automatic turig circular sawig metal pressig blakig puch pressig rivetig Measurig oise Key referece: Reducig oise at work: Guidace o the Noise at Work Regulatios 1989 L108 ISBN ; HSE website: www. hse.gov.uk/oise Exposure to oise is measured i decibels usually writte as db(a). The oise level (loudess) is measured as a scale from a silet zero db(a) to 140dB(A) for the oisiest situatios. For most jobs risk depeds ot oly o oise levels but how log people are exposed to them. The total amout of oise exposure over the whole workig day is called the daily persoal oise exposure (usually shorteed to L EP,d ). May egieerig workshops may eed to have their oise levels measured. This should be doe by people who uderstad ad ca apply HSE s guidace o how to measure oise. Health ad safety i egieerig workshops Page 55 of 147

56 Health ad Safety Noise at Work Regulatios 1989 outlied Actio to be take where L EP,d is likely to be 85dB(A) 90dB(A) Employers must: reduce risk of hearig damage to lowest level reasoably practicable * * have oise assessed by a competet perso * * keep records of assessmet util a ew oe is made * * reduce exposure to oise as far as is reasoably practicable by meas other tha ear protectors * provide iformatio, istructio ad traiig to employees * * mark ear protectio zoes with otices, as far as is reasoably practicable * esure so far as is practicable that ear protectors are: provided to all who ask for them * provided to all exposed * maitaied ad repaired * * used by all exposed * esure so far as is reasoably practicable that all who go ito marked ear protectio zoes use ear protectors * esure that all equipmet issued uder the Regulatios is used ad maitaied * * Employees must, so far as is practicable: use ear protectors * use ay other protective equipmet * * report ay defects. * * Health ad safety i egieerig workshops Page 56 of 147

57 Health ad Safety A ew Europea Directive dealig with oise has bee agreed. It is expected that ew oise at work legislatio will come ito force i 2006, whe the above actio levels will be reduced. The law* o oise assessmets outlied Noise assessmets must: idetify persos at risk eable employers to: reduce oise where reasoably practicable other tha by the provisio of ear protectio provide the right sort of ear protectio establish the correct protectio zoes give suitable iformatio to employees be reviewed whe circumstaces chage. * Noise at Work Regulatios Regular hearig checks (health surveillace) may be required uder the Maagemet of Health ad Safety at Work Regulatios 1992 (see page 6) depedig o how oisy the workshop is. It is good practice to carry out hearig checks o all employees whose daily persoal oise exposure regularly equals or exceeds 90dB(A). You should take oise risks ito accout whe buyig ew work equipmet. Make sure that you get proper iformatio about the levels of oise likely to be produced by the equipmet. Cosider a policy of purchasig oly low-oise equipmet. Key referece: Noise at Work: Advice for employers INDG362 HSE Books (sigle copies free; ISBN for priced packs of 10) Health ad safety i egieerig workshops Page 57 of 147

58 Health ad Safety How to make the most of oise assessmets TASK 1 Operatig a power press carryig out a blakig operatio Sample Leq* db(a) 98 for 3 hours givig fractioal exposure f value 2.37 TASK 2 Sortig metal compoets ito metal bis, aroud workshop Sample Leq db(a) 93 for 4 hours givig fractioal exposure f value 1.00 TASK 3 Breaks take at/ear machies Sample Leq db(a) 88 for 1 hour givig fractioal exposure f value 0.08 Total f = 3.45 Assessed LEP,d = 95 db(a) REDUCE NOISE Use protective measures as for Task 2 util tools desiged to use shear/skew cut ad/ or feed automated ad/or discharge chutes/bis lied with oise absorbet material ad/or press eclosed, to give 85dB(A). Maitai oise reductio measures. Make ear protectio available. Provide iformatio, istructio, traiig. Lie metal bis with oise absorbet materials, to give db(a). Mark ear protectio zoes. Provide ad maitai ear protectors ad warig sigs. Make sure protectors are wor. Provide iformatio, istructio, traiig. Review whe circumstaces chage. Provide quiet rest/break room, to give <85 db(a). For most idustrial situatios LEP,d ca be calculated usig Figure 2 from the key referece below. * (Leq is a cotiuous equivalet soud level). Key referece: Reducig oise at work: Guidace o the Noise at Work Regulatios 1989 L108 ISBN ; HSE website: Health ad safety i egieerig workshops Page 58 of 147

59 Health ad Safety How to reduce oise Noise may be reduced by: Examples of successful oise reductio elimiatig the eed for the process cocered, all of the time......or part of the time by substitutig a quieter machie or process icreasig precisio i castigs, more accurate metal cuttig (eg by laser, by maitaiig guillotie blades) may reduce the eed to trim, grid or chip excess material operatig a air ejector o a press oly for the time required to eject the compoet weldig istead of rivetig usig quieter rivetig machies usig a mechaical istead of peumatic ejector o a press by chagig the way a operatio is carried out, or a machie works applyig a shear edge to press tools for blakig usig oly sufficiet air pressure to operate the machie reliably avoidig or cushioig impacts betwee oisy parts by, for example, usig rubber coveyors or chutes ad bis lied with rubber or plastic by providig effective meas of vibratio isolatio dampig vibratig surfaces to reduce the tedecy of metal surfaces to rig by usig surface coatigs or plates, as o metal cuttig circular saw blades usig silecers to reduce oise caused by turbulece at air exhausts ad jets by maitaiig machiery usig tie bars o C-frame presses where provided lubricatig movig parts as appropriate Key referece: Reducig oise at work: Guidace o the Noise at Work Regulatios 1989 L108 ISBN ; HSE website: by eclosig the machie or process i eclosures......or i separate areas/rooms by usig oise absorbet material ear oisy operatios. fittig oise absorbet paels as for example aroud cold headig machies, power ad puch presses fittig oise absorbet room dividers such as plastic curtais to separate oisy from quiet operatios fittig suspeded oise absorbers i a fabricatio workshop to lower high itermittet oise levels. Health ad safety i egieerig workshops Page 59 of 147

60 Health ad Safety Egieerig cotrol I may circumstaces egieerig cotrol may be the most cost effective way of reducig oise. Expert aalysis of oise sources, ad idetificatio of the right cotrol measures are ecessary. Egieerig cotrol has bee effective i may ways. For example: Operatio vibratory feeders, ad coveyors hydraulic power packs for guilloties machiig of castigs blakig blakig blakig Method dampig high frequecy vibratio without affectig performace moutig the motor pump uit o a rigid frame, isolatig it ad the valve bak from the machie body reducig the vibratio of the castig by usig a pair of dampig straps itroducig small amouts of stagger ad shear ito the press tools isolatio of the press frame from its fabricated legs usig 6 mm composite pads fittig dyamic vibratio absorbers to the flywheel from which bell-like toes radiated Reductio 95 db(a) Leq to 73 db(a) Leq 96 db(a) Leq to 79 db(a) Leq 104 db(a) Leq to 88 db(a) Leq 98 db(a) Leq to 91 db(a) Leq 101 db(a) Leq to 92 db(a) Leq 99 db(a) Leq to 89 db(a) Leq Traiig specifics Traiig for those who work i oisy areas should iclude: what the risk is to their hearig how to use ay oise eclosure provided who to report defective eclosures to how to follow systems of work desiged to reduce exposure whe ad how to use ear protectors provided, who to report defective oes to, ad how to keep them clea that hearig problems must be reported to a doctor, with details of the oise ivolved. Key refereces: Soud solutios HSG138 HSE Books ISBN Protect your hearig or lose it INDG (sigle copy free; ISBN for priced packs of 10 copies) HSE Books Health ad safety i egieerig workshops Page 60 of 147

61 Health ad Safety Vibratio Vibratio White Figer (VWF), kow as dead figer or dead had, is widespread i some workshops ad is the most obvious symptom of had-arm vibratio sydrome (HAVS): Attacks are paiful ad ca result i the loss of sese of touch ad of the ability to grip properly The most commo causes are work with: hammers ad chisels powered percussive metalworkig tools icludig hammers for rivetig, clichig ad flagig taggig machies to shape bar material pedestal ad had-held gridig ad polishig machies although ay regular prologed use of ay high-vibratio tool or machie which causes tiglig or umbess after five to te miutes is a possible cause. Persoal protective equipmet will ot ormally reduce the amout of vibratio reachig the worker s hads. The law o vibratio outlied Ulike oise there are curretly o specific regulatios dealig with vibratio, but where the hazard exists the Maagemet of Health ad Safety at Work Regulatios (see page 6) ad Provisio ad Use of Work Equipmet Regulatios (see page 45) apply. However, a Europea Directive which deals with had-arm vibratio risks has bee agreed ad will result i UK Regulatios i To miimise harm Key refereces: Had-arm vibratio HSG88 HSE Books ISBN Vibratio solutios HSG170 HSE Books ISBN Power tools: How to reduce vibratio health risks INDG338 (sigle copies free; ISBN for priced packs of 15); HSE website: vibratio Idetify hazardous jobs Cosider chagig the process or product desig to elimiate or reduce the use of vibratig machiery For example: Mechaise or automate Use hydraulic rather tha peumatic impulsive rivetig Rough machie rather tha had grid Choose low vibratio equipmet such as: properly balaced gridig wheels, rotary rather tha impact or impulse actio-powered screwdrivers, ut ruers ad torque wreches for assembly work, ad low-vibratio or recoilless chippig hammers or machies icorporatig vibratio reducig features such as isolatig hadles Maitai equipmet properly by keepig cuttig tools sharp, dressig gridig wheels properly, ad replacig ati vibratio mouts to maitai their effectiveess Reduce the amout of had force eeded whe gridig, for example, by supportig heavy workpieces ad usig jigs with ati-vibratio mouts Carry out health surveillace of exposed workers uder the geeral supervisio of a medical practitioer, ad Have symptoms ivestigated further by someoe able to assess them medically Esure that heatig is adequate to keep hads ad body warm. Health ad safety i egieerig workshops Page 61 of 147

62 Health ad Safety Millig ad machiig cetre work How most accidets happe Etaglemet ad cotact with rotatig cutters whe: loadig/uloadig compoets removig swarf measurig adjustig coolat flow. These cause etaglemet ijuries such as broke boes, ad dislocatios, amputatios ad laceratios Not wearig eye protectio whe machiig, cleaig ad removig swarf. Traiig specifics As well as uderstadig geeral rules for the safe operatio of machiery (see pages 44 45), operators eed to kow how to: remove swarf adjust coolat flow load ad uload compoets safely. Most ill health arises from: usafe hadlig (see pages 22 29), harmful metalworkig fluids (see pages 52 54), ad too much oise (see pages 55 60), but i particular hadlig heavier workpieces at larger machies which may require mechaical aids such as hoists oise (which may be difficult to predict ad reduce at source) from cutters operatig agaist workpieces. Key safety measures For a maual horizotal millig machie used for a variety of workpieces: Fixed guard adjustable by meas of a tool False table to help restrict access to cutter. Key safety measures For a vertical millig machie used for batch productio work: Fixed ad iterlockig moveable guards to prevet access to the cutters ad chip ejectio For a vertical millig machie used for a variety of oe-off jobs (icludig toolroom applicatios) Fixed ad iterlocked moveable guards, or a adjustable table guard Compoet securely fixed i all cases. Health ad safety i egieerig workshops Page 62 of 147

63 Health ad Safety Key safety measures For a small machiig cetre: Slidig iterlockig guards to prevet access to dagerous movemets whe guards are ope If access to machie movemets is ecessary whe the guards are ope, safe slow movemets uder hold-to-ru cotrol may be provided Guards also help cotrol metalwork fluid ad swarf Exhaust vetilatio fitted or capable of beig coected. Key refereces: BS EN 13128: 2001 Machie tools Safety Millig machies (icludig borig machies); BS EN 12417: 2001 Machie tools Safety Machiig cetres Health ad safety i egieerig workshops Page 63 of 147

64 Health ad Safety Drillig (ad reamig) How most accidets happe Hair caught o rotatig spidles, chucks or tools Etaglemet of gloves, clothig, badages ad rigs, usually at the drill tip Violet spiig of the workpiece because of poor clampig causig scalpig ijuries, broke boes Not wearig eye protectio causig eye ijuries from machie cleaig, swarf removal ad ueclosed machiig Swarf causig cuts. Key safety measures For a maually operated machie used for batch productio: If appropriate to compoet sizes ad umbers fixed guard feed magazie discharge slide to prevet access to all dagerous parts Most ill health arises from: usafe hadlig (see pages 22 29) harmful metalworkig fluids (see pages 52 54) too much oise (see pages 55 60) but i particular risks from hadlig ad metalworkig fluids may be higher at maually operated machies used for batch productio because of more frequet loadig/uloadig ad cotact with fluids. Traiig specifics I additio to geeral rules for safe operatio (see pages 44 45) users should be traied: to wear eye protectio, ad NOT to wear jewellery, loose clothig or log hair ot tied back to wear gloves uless complete eclosure of rotatig chucks, spidles ad attached rotatig parts is provided to leave chuck keys i chucks. Health ad safety i egieerig workshops Page 64 of 147

65 Health ad Safety Key safety measures For a small CNC drillig machie: Slidig iterlockig guards to prevet dagerous movemets whe guards are ope If access to machie movemets is ecessary whe the guards are ope, safer, slower movemets uder hold-to-ru cotrol may be permitted Exhaust vetilatio fitted or capable of beig coected. Key safety measures For a maually operated radial arm drillig machie: Use suitable trippig device ad regularly check its operatio Vertical trip ot more tha 75 mm from the tool ad positioed withi the first 90 of rotatio from the operator s positio Clamp workpiece securely to machie table Alteratively fixed, adjustable guards may be used. Key safety measures For a small maually operated bech drillig machie used for a variety of oe-off jobs: Fixed adjustable guard adjusted so that spidle ad drill tip is guarded to the greatest extet practicable Vice clamped securely to table. Key refereces: Guidace Note PM83 Drillig machies: Guardig of spidles ad attachmets HSE Books ISBN BS EN 12717: 2001 Machie tools Safety Drillig machies Health ad safety i egieerig workshops Page 65 of 147

66 Health ad Safety Pressig How most accidets happe Figers or had are amputated or crushed betwee closig tools whe loadig ad uloadig compoets whe settig up. Most ill health arises from: usafe hadlig (see pages 22 29) ad too much oise (see pages 55 60), but i particular oise from the impact of tools o workpieces, air ejectio, ad hadlig of workpieces durig highly repetitive batch productio. Provisio ad Use of Work Equipmet Regulatios 1998 as applied to power presses By law every metalworkig press ad press brake with a flywheel ad clutch ad its guards must be thoroughly examied by a competet perso : before use o first istallatio, whether ew or secodhad periodically, presses with oly fixed guards every 12 moths; other presses: every 6 moths Reports of defects must be otified i writig to factory occupiers ad copied to the eforcig authority. Setters who prepare presses for use: must be: competet specifically desigated i writig properly traied must carry out a ispectio of safety devices after ay work o the tools which ivolves ay alteratio to or disturbace of ay safety device ot later tha four hours after the start of each workig day or shift must sig a certificate, kept ear the press, that safety devices are i efficiet workig order. from a isurace compay, for example. Health ad safety i egieerig workshops Page 66 of 147

67 Health ad Safety All other presses, icludig hydraulic ad peumatic, should have similar arragemets to achieve the same objectives a plaed, regular system of ispectios ad tests by competet ad authorised persos to eable the safety of the press ad its safety devices to be regularly siged for by a authorised perso o behalf of the compay. These ispectios may be carried out as described o page 46 uder the regulatio ispectio requiremets of PUWER. Key safety measures For a mechaical press: Guards as oise eclosures Loadig/uloadig compoets without access betwee tools usig automatic feed. Guards ope to show oise absorbet liigs Key referece: Safe use of power presses L112 ISBN Health ad safety i egieerig workshops Page 67 of 147

68 Health ad Safety Key safety measures For a mechaical power press usig iterlockig guards: Esure that closig gates overlap by at least 10% of total movemet before clutch ca be operated Prevet loose ad slack movemet of coected parts of the guard by good maiteace Shroud foot pedals Repair distorted or damaged bars. Key safety measures For a hydraulic press brake usig photoelectric guards: Esure that the back ad sides of the press are guarded ad that o-oe ca stad betwee the light curtai ad machie, or reach uder, aroud or over the light curtai or guards to dagerous parts Esure that photoelectric light curtai whe iterrupted brigs dowward movemet to a halt before dagerous parts ca be reached Mutig (switchig the beam off to permit metal sheets to be iserted ad bet through the light curtai) must oly occur whe there is a safe distace* betwee the bottom of the top tool ad the top surface of the compoet. Key safety measures For a peumatic had-fed bech press usig iterlockig guards: Chairs used by operators should be adjusted to the right height ad provide good support for the back. Provide foot rests Stillages should be positioed to miimise twistig ad turig whe liftig ad lowerig compoets Use two peumatic circuits to cotrol ad check iterlockig fuctios or a automatic scotch to prevet tools closig whe guards are ope Esure overlap of guard ad table before press will operate Iterlock the peumatic power supply to the press with the movemet of the guard. Key refereces: BS EN 692: 1996; BS EN 693: 2001; BS EN 12622: 2001 Health ad safety i egieerig workshops Page 68 of 147

69 Health ad Safety Turig How most accidets happe A fatal accidet arisig from etaglemet o rotatig parts happes every year or so i the UK Etaglemets o workpieces, chucks, carriers ad uguarded stock bars cause most accidets May accidets happe usig had-held emery cloth to smooth ad polish compoets Direct cotact with movig parts causes may ijuries Eye ijuries from machie cleaig, swarf removal ad ueclosed machiig whe eye protectio is ot wor are frequet Chuck keys ejected from rotatig chucks. A large proportio of ijuries result i amputatio of figers, broke boes ad tor ligamets. Most ill health arises from: usafe hadlig (see pages 22 29), harmful metalworkig fluids (see pages 52 54) ad too much oise (see pages 55 60), but i particular oise levels from stock bars rotatig i stock bar tubes which ca be very high, particularly o multi-spidle machies risks from breathig i mists ad aerosols may be higher at higher speed machies, ad throughout the workshop from groups of machies operatig together. If required surface fiish or dimesioal accuracy caot be achieved by turig techiques, cosider usig dedicated gridig, hoig or polishig machies as appropriate istead of had-held emery cloth. Key safety measures For a small CNC turig machie: Slidig iterlockig guards to prevet access to dagerous movemets whe guards are ope If access to machie movemets is ecessary whe guards are ope, safer, slower movemets uder hold to ru cotrol may be permitted whe guards are ope Exhaust extractio fitted or capable of beig coected A strog properly maitaied visio pael, capable of withstadig foreseeable ejectios. Health ad safety i egieerig workshops Page 69 of 147

70 Health ad Safety Key safety measures For a maually operated turret lathe: Fixed guard at rear of machie Chuck guard Feed ad lead screws guarded or well back from operator Splashguard for suds ad swarf. Backig board Traiig specifics Wear eye protectio Do t wear jewellery, loose clothig or log hair if it s ot tied back. If usig emery cloth caot be avoided, i additio to geeral rules for safe operatio (see page 44), users should be traied about the dagers of usig emery cloth: Tool post Never use emery cloth at CNC lathes If required fiish may oly be obtaied holdig emery cloth agaist rotatig compoets, the use: a backig board a tool post a utcracker had-held abrasive-impregated wire brushes Nutcracker Key refereces: BS EN 12415: 2000; 12478: 2001; 12840: 2001; 13788: 2001 Accidets at metalworkig lathes usig eergy cloth EIS2 HSE Books (free) Health ad safety i egieerig workshops Page 70 of 147

71 Health ad Safety Gridig How most accidets happe Ijuries from cotact with rotatig abrasive wheels Impact ijuries from burstig wheels, (sometimes fatal) Cuttig ad crushig ijuries from trappig betwee the wheel ad workrest Fires ad explosios arise from the poor cotrol of gridig dust cotaiig alumiium magesium ad similar materials Eye ijuries from the failure to wear eye protectio or use protective screes. Tips for operators As well as geeral rules for safe operatio (see page 44), users should be traied: to use the right wheel ad machie for the job ot to grid o the sides of straight-sided wheels used for off had gridig to keep wheels used for off had gridig trued ad dressed to reduce out of balace ad eable workrests to be adjusted close to the wheel to lubricate spidles regularly to ru ew wheels free for about a miute with persos stadig clear to support heavy workpieces ad use jigs to reduce vibratio at pedestal ad bech gridig machies used frequetly for log periods (see page 61) particularly for tool sharpeig ot to stop wheels by applyig pressure to the wheel periphery or face ot to leave wheels immersed i coolat which may lead to out of balace; coolat should be switched off before wheels are stopped to eable them to dry to take care ot to isert oversize compoets ito cetreless griders to miimise risks of ejectio ad whee breakage to use wheel dressers which miimise risks of vibratio white figer. Most ill health arises from: usafe hadlig (see pages 22 29), harmful metalworkig fluids (see pages 52 54) vibratio from had fed or had-held gridig machies which may cause a coditio called vibratio white figer, which damages hads ad arms, sometimes permaetly (see page 61) too much oise from the gridig operatio itself (see pages 55 60) ad ihalig the harmful dust/fume geerated. Health ad safety i egieerig workshops Page 71 of 147

72 Health ad Safety The law* o abrasive wheels outlied The specific risks associated with moutig abrasive wheels require that such tasks are oly doe by people who have bee specifically desigated to do so. Adequate traiig must be provided for people moutig abrasive wheels. Such traiig should iclude: hazards arisig from the use of abrasive wheels ad precautios which should be observed methods of markig abrasive wheels as to type ad speed methods of storig, hadlig ad trasportig abrasive wheels methods of ispectig ad testig abrasive wheels to check for damage the fuctios of all compoets used with abrasive wheels, icludig flages, blotters, brushes ad uts used i moutig ad icludig kowledge of the correct ad icorrect methods of assemblig all compoets ad correct balacig of abrasive wheels the proper method of dressig abrasive wheels the adjustmet of the rest of a abrasive wheel. * Provisio ad Use of Work Equipmet Regulatios 1998, Regulatio 7. Key safety measures At a maually operated pedestal gridig machie used occasioally for tool sharpeig: Opeig i guard restricted to that eeded to eable work to be doe Guard of sufficiet stregth to cotai fragmets of burstig wheels Well-adjusted workrest rpm of spidle clearly marked Easily accessible ad operated o/off switch Clear floor area. Key safety measures For a maually operated surface gridig machie: As for machie above, plus: Provide extractio, maitai ad ispect ad test it every 14 moths, recordig the results Secure workpiece firmly. Key refereces: Safety i the use of abrasive wheels HSG HSE Books ISBN ; BS EN 13218: 2001 Machie tools Safety Statioary gridig machies Health ad safety i egieerig workshops Page 72 of 147

73 Health ad Safety Sawig Usig maually-fed pivotig-head metal-cuttig circular saws How most accidets happe Cotact with the ruig saw blade whe: feedig, adjustig or removig worpieces cleaig the machie or removig swarf. Most ill health arises from: usafe hadlig (see pages 22 29) harmful metalworkig fluids (see pages 52 54) ad too much oise (see pages 55 60) from the actio of the blade agaist the workpiece Noise Noise high eough to damage hearig is commo at may saws, especially highspeed saws for o-ferrous (eg alumiium) cuttig. Reduce at source by, for example: clampig workpieces securely usig oise/vibratio absorbig materials o feed tables avoidig the use of damaged saw blades eclosig the cuttig head i oise absorbig materials usig damped saw blades. Key safety measures Fixed adjustable guards Likage operated movig guard to prevet cotact with the blade i the raised positio exposure of the blade durig cuttig Gravity operated guards may oly be used with hold to ru cotrols Where fixed guards oly are used, workpieces should be fed ad removed through opeigs small eough to prevet access to blades Esure the head sprig balace (if fitted) is properly adjusted. Traiig i good sawig techique may help miimise hadlig problems ad oise. Key refereces: Safety at maually-fed pivotig-head metal-cuttig circular saws EIS12 HSE Books (free) BS EN 13898: 2003 Machie tools Safety Sawig machies for cold metal Health ad safety i egieerig workshops Page 73 of 147

74 Health ad Safety Bedig Usig 3 roll bedig machies How most accidets happe Hads are frequetly draw ito couter-rotatig rollers, particularly durig iitial feedig of the workpiece Hads are ofte trapped betwee a workpiece ad a roller Wearig gloves icreases the risks of trappig May ijuries are serious; amputatios are ot ucommo. Key safety measures Hold to ru cotrols should automatically retur to stop o release Brakig may be required to achieve a safe stoppig time Positio trip devices to be easily activated by ay perso draw towards them at both sides of the machie to brig it to a stop before serious ijury Emergecy stop buttos requirig maual reset after use Use feed tables ad rollers to help avoid grippig workpieces close to the rolls. Most ill health arises from: usafe feedig/uloadig of workpieces which are too heavy/sharp/awkward (see pages 22 29). Traiig specifics I additio to geeral rules for safe operatio (see page 44), users should be traied to: ot wear gloves durig the iitial feedig of workpieces avoid grippig workpieces close to the rolls; feed tables ad rollers ca help avoid slips ad trips aroud the machie by keepig the area clear clear rolls ad maitai oly whe the machie is switched off ad isolated. Key referece: Safeguardig 3 roll bedig machies EIS7(rev1) HSE Books (free) Health ad safety i egieerig workshops Page 74 of 147

75 Health ad Safety Guillotiig How most accidets happe Feedig ad removig workpieces ear uguarded blades at the frot, sides ad rear of machies causig cut ad amputated figers. Key safety measures For a medium-sized power guillotie: Opeig i frot guard isufficiet to reach clamp(s) or blade Built i lightig ad marker to see cuttig lie Sloped discharge chute to eable workpieces to be retrieved without opeig guard. Rear iterlockig guard Shrouded foot pedal. Noise may be reduced by: oise hoods rollers to reduce vibratios durig sheet feedig rubber bases fitted to clamps miimisig the distace workpieces ad scrap fall liig bis with oise absorbet material. Reduce cuts from hadlig by providig good quality gloves, such as chromed leather. Most ill health arises from: usafe hadlig (see pages 22 29), particularly heavy ad/or sharp edged workpieces too much oise (see pages 55 60), particularly from cut workpieces fallig, clampig ad cuttig operatios, ad high speed cotiuous shearig. Traiig specifics I additio to geeral rules for safe operatio ad maiteace (see page 44), operators ad others should kow how to: work safely at the rear of guilloties fitted with powered back gauges ad mechaical hadlig devices, particularly o CNC machies, where cotrol systems may be complex chage blades safely maitai powered machies to prevet blades droppig uder gravity. Health ad safety i egieerig workshops Page 75 of 147

76 Health ad Safety Special attetio should be paid to the safety of youg people (uder the age of 18) usig guilloties. The law* requires that employers assess risks to youg people before they start work, takig ito accout their iexperiece, lack of awareess of potetial risks ad their immaturity. You should take accout of the risk assessmet i determiig whether the youg perso should use the equipmet. Proper traiig ad supervisio will be essetial. * Maagemet of Health ad Safety at Work Regulatios 1992, regulatio 3. Key referece: Safety i the use of metal cuttig guilloties ad shears HSG42 HSE Books ISBN Health ad safety i egieerig workshops Page 76 of 147

77 Health ad Safety CNC puch pressig How most accidets happe Betwee the tools durig tool chagig, cleaig ad fault fidig, causig crushig ijuries to the hads at movig tables, causig laceratios to figers. Most ill health arises from: usafe hadlig (see pages 22 29) ad too much oise (see pages 55 60), but particularly from: hadlig large ad/or sharp edged workpieces oise from tool impacts. Key safety measures For a CNC puch press: Turret guardig by fixed ad iterlockig guards to permit, whe ope, oly slower movemets uder hold-to-ru cotrol Leave a safe distace betwee movig parts/workpieces ad fixed structures Hazardous areas may be safeguarded by fixed perimeter feces with iterlockig access gates ad/or pressure sesitive mats ad/or presece sesig devices to prevet dagerous parts movig where persos have access to them Where turret guard ad table do ot prevet access to closig puch tools safety devices such as pressure sesitive mats or photo-electric guards should be provided Large tool carousels ad chagers should be safeguarded by fixed ad iterlockig guards or equivalet meas which may also prevet access to traps betwee movig sheets ad tool gaps i the table Safety devices may be overridde to permit machie movemets at slow speeds uder hold-to-ru cotrol, for settig or maiteace. Noise may be reduced by: usig cushioed or ati-vibratio moutigs esurig the right shear agle o tools usig o-metallic clampig faces eclosure of the tool area. Health ad safety i egieerig workshops Page 77 of 147

78 Health ad Safety Combiatio metalworkig machies How most accidets happe Workig small workpieces at a workstatio, resultig i amputatios of figers. Key safety measures Guards should: prevet access to closig tools, puches or blades from all sides provide a view of the operatio where eeded Workpieces should be properly supported by guides ad stops The take off side should also be guarded to allow oly workpieces to pass through Do ot take off pieces by had: use a chute which discharges ito a box for smaller pieces ad a table or roller track for larger oes. Whe bedig, either restrict the gap betwee the tools to a safe distace (see pages 68 ad 138) or provide photo-electric or other safeguards as for press brakes (see page 68). Special attetio should be paid to the safety of youg people (uder the age of 18) usig combiatio metalworkig machies. The law* requires that employers assess risks to youg people before they start work, takig ito accout their iexperiece ad their immaturity. You should take accout of the risk assessmet i determiig whether the youg perso should use the equipmet. Proper traiig ad supervisio will be essetial. * Maagemet of Health ad Safety at Work Regulatios 1992, Regulatio 3. Most ill health arises from: usafe hadlig (see pages 22 29) ad too much oise (see pages 55 60), but particularly from: hadlig large ad/or sharp edged workpieces oise from tool impacts. Key referece: Safeguardig of combiatio metalworkig machies EIS13(rev) HSE Books (free) Health ad safety i egieerig workshops Page 78 of 147

79 Health ad Safety Horizotal borig machies How most accidets happe Most ijuries occur durig activities such as settig/adjustmet, swarf removal, or observatio for the purpose of process cotrol. The largest sigle cause of ijury is etaglemet at revolvig tools. Crushig ad trappig hazards at tools ad the movig worktable are also very sigificat causes of ijury. Ijuries are ofte very severe ad iclude limb ad skull fractures ad amputatios. The potetial for fatal ijury at these machies should ot be uderestimated. Most ill health arises from: usafe hadlig (see pages 22 29) harmful metalworkig fluids (see pages 52 54) Key safety measures Prevet access to the work zoe by fixed ad/or iterlocked guards. Trip probes with breakig devices may be used i some circumstaces, but these will oly provide limited protectio, stoppig the machie quickly i the evet of cotact with revolvig tools. They do ot provide protectio agaist crushig ad trappig hazards. Where access to the work zoe is eeded for settig purposes, dagerous machie movemets should be cotrolled usig a hold-to-ru cotrol arragemet or eablig device. Guard other hazardous parts such as trasmissio elemets icludig shafts, gears, pulleys etc usig fixed guards. Follow safe systems of work for cleaig, maiteace, settig ad adjustmet, loadig of workpieces etc. Activities such as swarf removal should ormally be carried out with the spidle stopped. Key referece: Safeguardig at horizotal borig machies EIS28 HSE Books (free); BS EN 13128: 2001 Health ad safety i egieerig workshops Page 79 of 147

80 Health ad Safety Cleaig ad degreasig May cleaig ad degreasig substaces used are hamful if ot used properly, either through direct ski or eye cotact or through breathig i mist or vapour give off, commoly causig dermatitis ad arcotic effects. Some cleaers give off vapour which is easily igited. To miimise hazards: reduce the eed to clea by, for example, avoidig cotamiatio i the first place compare safety data sheets from suppliers to fid the least harmful cleaer ad the cleaer which is o-flammable or the least flammable (with a higher flashpoit) (differet hazards posed by solvets may eed to be balaced to esure that overall, hazards to health ad safety are miimised) avoid spills ad evaporatio by keepig lids o cotaiers ad trasferrig liquids betwee cotaiers by pipework or pump mark stores ad their cotets clearly provide appropriate persoal protective equipmet such as gloves, overalls, eye ad foot protectio, to prevet cotact where ecessary you may eed to draw up a emergecy pla (see pages ) to cope with gross spillages of some cleaig ad degreasig substaces. Whe usig liquids to clea by dippig, wipig or sprayig: avoid halogeated solvets such as trichloroethylee ( trike ). perchloro ethylee ( perk ) methylee chloride ad -propyl bromide (PB) uless they are eclosed ad extractio vetilatio ad other ecessary protective equipmet is provided; other solvets may also eed similar cotrols use the least flammable (with flashpoits ideally above 45 C) hydrocarbo solvets such as petroleum distillates, terpees ad alcohols adopt precautios ecessary to miimise risks from cotact with alkalie or acid water-based solutios or ihalatio of fume or dust arisig from them avoid work i cofied spaces (iside metal fabricatios for example) uless absolutely ecessary i which case make a separate special assessmet of the hazards posed by the cleaig liquid ad system of work proposed. (Special precautios, icludig compressed airlie breathig apparatus, a safety haress ad a secod perso stadig by, may be ecessary, see page 82.) Key referece: Safe use of solvet degreasig plat EIS40 HSE Books (free); Maiteace ad cleaig of solvet degreasig plat EIS20(rev1) Health ad safety i egieerig workshops Page 80 of 147

81 Health ad Safety Vapour degreasig taks Usig them badly may expose operators ad others to harmful levels of vapour which if ihaled ca cause drowsiess ad i extreme cases ucosciousess or eve death. Direct cotact with the vapour or liquid ca cause irritatio ad dermatitis, ad should ever be frequet or prologed. Solvet degreasig should be carried out i a eclosed system where reasoably practicable. Otherwise, the process should be eclosed as far as possible. To miimise exposure: Do positio tak i a area free from draughts stack compoets iside the degreaser so they drai properly allow them to dry i the freeboard zoe before removig them use covers whe ot usig the tak use a mechaical hoist whe loadig/uloadig compoets. Do t move, load or remove compoets too quickly, pushig or draggig vapour out ru hoists at more tha three metres per miute vertically spray above the vapour layer. Maiteace miimises risks to operators ad others: from escapig vapour from the build up of oil ad grease which ca catch fire ad ca prevet the eed to eter i order to remove baked-o residues. Gettig ito vapour degreasig taks causes a sizeable proportio of all fatal accidets i small egieerig workshops. Always set thermostats correctly ad balace heatig ad coolig systems check ad maitai the effectiveess of extractio systems pump i fluid below the existig liquid level repair leaks treat pits i which degreasig taks are set as extesios of the tak itself maitai the correct solvet level check the solvet coditio esure adequate freeboard height esure the bath has a bottom drai for removig solvet. Key referece: Surface cleaig ad preparatio: Choosig the best optio GG354 Available free from Evirowise o Eviromet ad Eergy Helplie Tel: Website: Health ad safety i egieerig workshops Page 81 of 147

82 Health ad Safety To avoid etry: Fix a sig o or ear the degreaser prohibitig etry without authorisatio ad breathig equipmet Regularly moitor cotamiatio by measurig the temperature of boilig solvet; distil off solvet ito a storage drum; drai mobile residues ito a suitable cotaier, ad Use a log-hadled scraper to remove remaiig sludge, or Pump dirty solvet directly ito a cotaier for recovery. The law* o etry ito degreasers No perso shall eter a degreasig tak for ay purpose (such as to clea it), uless it is ot reasoably practicable to achieve that purpose without such etry. If a degreasig tak is etered, this must be doe i accordace with a safe system of work that allows it to be doe safely ad without risks to health. * Cofied Spaces Regulatios If etry caot be avoided: Establish a safe system of work i writig usig a formal permit-to-work system for etry authorised by a resposible perso Remove as much solvet ad sludge as possible before eterig Use suitable self-cotaied breathig apparatus or air lie compressed air equipmet, ad a safety haress or belt ad rope held or secured outside the degreaser to pull the perso out if ecessary a secod perso stadig by to raise the alarm ad start the rescue (it is ulikely that oe perso could pull someoe out sigle-hadedly have a rescue pla ready) Provide additioal breathig apparatus ad other suitable protective equipmet capable of beig used for rescue Make oxyge resuscitatio equipmet immediately available Wear protective clothig resistat to the solvet ivolved Check ad maitai breathig apparatus ad air lie compressed air equipmet, haresses ad lifelies at least oce a moth, ad keep records Fully trai all who may become ivolved. If, while all the above precautios are beig take: the tak is thoroughly cleaed, tested ad certified as safe for etry, ad a adequate supply of breathable air is maitaied breathig apparatus may ot be eeded for further work (but see page 80, fial paragraph, ad pages 83 84, Weldig). Key referece: Maiteace ad cleaig of solvet degreasig plat EIS20(rev1) HSE Books (free) Health ad safety i egieerig workshops Page 82 of 147

83 Health ad Safety Weldig ad flamecuttig Commo causes of ill health are: ihalatio of harmful weldig fume usafe hadlig of workpieces ad weldig equipmet, particularly gas cyliders oise, particularly from plasma arc cuttig, gougig operatios ad weld preparatio bur from ultra violet radiatio, icludig arc eye vibratio durig gridig for weld preparatio discomfort from heat ad ucomfortable postures. Commo causes of accidets are: As a result of: fallig gas cyliders particles eterig uprotected eyes durig chippig after weldig electric shocks from arc weldig equipmet fires started by flames, sparks ad hot material from weldig ad cuttig processes figers beig crushed betwee the electrodes of fixed resistace weldig machies. Key safety measures for arc weldig: Extractio equipmet Provide appropriate protective clothig ad esure it is wor, eg overalls, protective apro, gloves, safety boots, respiratory protectio (if ecessary) Use weldig screes ad eye protectio (to BS 679) to prevet arc eye Local isolatio switch Weldig set trasformer Workpiece earth whe required Isulated electrode holder Isulated box for electrode holder Proper cable coectios Suitable fire extiguisher easily accessible Weldig leads should be isulated, robustly costructed ad big eough to carry the curret safely Residual curret devices may ehace safety Work i cofied spaces ad o large structures supported o maipulatig devices eeds special precautios (see Further readig, page 117). Traiig specifics for arc weldig: Kow how to use extractio equipmet Do ot wear metallic jewellery, rigs, or watch straps Kow how to chage electrodes safely Use a isulated box or hook to rest the electrode holder NOT the face shield, clothig or rags. Health ad safety i egieerig workshops Page 83 of 147

84 Health ad Safety Maitai weldig vetilatio ad protective equipmet Have local exhaust vetilatio examied ad tested by a competet perso every 14 moths (see page 35) Examie respiratory protective equipmet thoroughly every moth (testig air fed equipmet at the same itervals, checkig the volume ad quality of breathig air supplied) Examie flexible gas ad oxyge hoses regularly ad replace damaged oes; ever repair them with tape Check ad maitai other safeguards as appropriate. Never apply heat to cotaiers, taks or drums which may cotai flammable residues. Either use cold, o-sparkig methods or clea ad make them gas free first. Store ad use weldig gas cyliders safely Store full ad empty cyliders i a safe, well-vetilated place preferably outside buildigs Never keep cyliders below groud level ext to drais, basemets ad other low-lyig places heavy gases will ot disperse easily Do ot leave charged hoses where vetilatio is poor for exteded periods i case of leakig gases or oxyge Some gas cyliders, for example acetylee, cotai liquid store them with their valves uppermost Protect cyliders from damage, for example by chaiig ustable cyliders i racks or o trolleys Provide suitable trolleys with restraiig chais for movig oxy-acetylee sets ad other cyliders Miimise damage by usig the correct hoses, clamps, couples ad regulators for the particular gas ad appliace beig used Never apply grease oil or other lubricats to oxyge fittigs Prevet damage to hoses. Do ot ru them uprotected, for example, across traffic routes Tur off cylider valves at the ed of each day s work Chage cyliders away from sources of igitio i a well-vetilated place Miimise weldig flame flash-back ito hoses or cyliders by traiig operators i correct lightig up ad workig procedures ad by fittig effective o-retur valves ad flame arresters Use soap or deterget ad water solutios to test for leaks ever a flame Do ot use oxyge as a substitute for compressed air to power peumatic tools. Key refereces: Electrical safety i arc weldig HSG118 HSE Books ISBN The safe use of compressed gases i weldig, flame cuttig ad allied processes HSG139 HSE Books ISBN Health ad safety i egieerig workshops Page 84 of 147

85 Health ad Safety Fume cotrol Cotrollig of fume ad gases at weldig, flamecuttig ad similar processes such as solderig Fume from weldig, flamecuttig, brazig ad solderig varies greatly i compositio ad cocetratio. Differet jobs lead to differet levels of exposure to differet susbtaces. Fume from weldig ad flame cuttig may cause: dryess of the throat, ticklig, coughig, tightess of the chest ad difficulty i breathig a acute flu-like illess (metal fume fever) log-term chages i the lug. Weldig or cuttig processes releasig the greatest quatities of harmful fume iclude: work o metallic coatigs such as cadmium or zic platig ad chromium, magaese, cobalt ad/or ickel hard surfaces work o paited surfaces which cotai lead, zic, chromium or cadmium pigmets mechaised flame cuttig flame gougig frequet ad regular maual metal arc weldig flux cored electrode weldig higher curret metal iert gas shielded weldig particularly o stailess steel, ad alumiium, copper, ickel ad their alloys oxyge arc cuttig ad gougig usig cadmium-cotaiig solder. Miimise risks by: avoidig weldig ad flamecuttig, usig other bodig ad cuttig techiques where reasoably practicable usig safer filler materials, such as cadmium free silver solder cotrollig exhaust fume by providig local exhaust vetilatio uless a detailed ad thorough risk assessmet shows that harmful fume is ot beig geerated or that it may be cotrolled by geeral vetilatio providig respiratory protective equipmet, but oly if cotrol measures are uable to reduce fumes to safe levels esurig workshops have eough low-level ilets ad high-level outlets for air chages ot weldig ear (10 m for most weldig; 20 m for alumiium) cleaig processes usig chloriated solvets; the heat ad arc from weldig may break dow the solvets ito more harmful substaces. Health ad safety i egieerig workshops Page 85 of 147

86 Health ad Safety Flexible arm Filter Air velocity at weld about 1 ms _1 Face velocity of at least 0.5 ms _1 Flaged head: keep the distace betwee the head opeig ad the weld less tha the smallest dimesio of the opeig Mobile extractio Cosider o-gu extractio particularly with semi-automatic Mig weldig gus ad flux cored wires without gas shieldig. Weldig bech/booth Extracted air may be filtered electro-statically, for example, ad retured to the workshop to prevet heat losses. Health ad safety i egieerig workshops Page 86 of 147

87 Health ad Safety Safety measures at resistace weldig machies How most accidets happe Trappig betwee the electrodes, causig crushed ad amputated figer tips Spatter flyig ito uprotected eyes. Key safety measures for fixed resistace weldig machies: Fit a effective scree to protect eyes. Use eye protectio if this is ot possible Limit the gap betwee the electrodes to 6 mm or less where practicable Where the operator does ot eed to hold the compoet, use: iterlockig guards or o-cotact, eg photoelectric, protective devices with fixed guards or, where these are ot practicable, two-had cotrol Where the operator eeds to hold the compoet use sesig or low pressure approach systems to prevet full closig pressure of the weldig heads util withi a safe distace of the compoet. If the operator uses oe had to support the compoet, use a remote operatig butto ad ot a footswitch Always shroud foot pedals. Most ill health arises from the usafe hadlig of workpieces (see pages 22 29), ad too much oise (see pages 55 60), particularly from groups of machies together. Priciple of operatio of sesig guard Machie clear for loadig Obstructio prevets machie from operatig No obstructio machie operates Key referece: Safeguardig of resistace weldig machies Iformatio Documet HSE ID 668/23 (see Health ad safety i egieerig workshops Page 87 of 147

88 Health ad Safety Lasers used for weldig ad cuttig The most serious hazards arise from exposure to: laser radiatio either direct or reflected from process materials or surroudigs which may cause severe tissue damage. The eye is particularly vulerable with the greatest risk arisig from Nd-YAG lasers. fume, which may harm breathig (see page 85) cotact with live electrical parts durig maiteace, which may cause burs ad/or shock (CO 2 lasers operate at extremely high voltages which may remai lethal because of stored eergy after isolatio of the electrical supply) dagerous machie movemets which may physically ijure. Laser emissios may also be a fire hazard, especially where powers exceed a few watts. IEC : 1993 (Editio 1: 1993 cosolidated with amedmets 1: 1997 ad 2: 2001) Safety of laser products, available from BSI, is a comprehesive itroductio for maufacturers ad users to the reductio of risks from laser radiatio. The maximum permissible exposure limits (MPE) give i this stadard are regarded as reasoably practicable limits to be achieved uder the Health ad Safety at Work etc Act 1974, Sectios 2, 3 ad 6. Key safety measures Make sure the right safety measures ad iformatio for use have bee supplied. (Questio your supplier i the first istace if there is aythig you are ot sure of.) Maitai i particular: ati-scatter guards at cuttig/weldig heads istallatio eclosures, fixed guards ad iterlockig access doors to cotai reflectios from high power machies vetilatig equipmet safeguards prevetig access to dagerous machie movemets laser safety eyewear. Traiig specifics I additio to geeral rules for safe machie operatio ad maiteace (see page 44), trai users ad others to observe the rules for safe: etry ito eclosures (use trapped or key exchage systems where provided) beam aligmet or adjustmet workig with electricity use of eye protectio where ecessary. Key referece: IEC : 1993 (icludig 1997 ad 2001 amedmets) Health ad safety i egieerig workshops Page 88 of 147

89 Health ad Safety Radiography X-rays, gamma rays ad other forms of radiatio used for o-destructive testig (NDT) may ijure by causig burs, dermatitis, cacer, cell damage, blood chages or cataracts. The Ioisig Radiatio Regulatios 1999 outlied If radiography is carried out i your workshop you (or, if a cotractor is doig the work, they) must: otify HSE before startig work cosult a suitable radiatio protectio adviser carry out a prior risk assessmet arrage for medical examiatios/reviews ad routie dose assessmets of employees whom you desigate as classified persos appoit oe or more of your employees to supervise radiatio work provide local rules ad traiig make arragemets to deal with stuck radioactive sources, x-ray exposures failig to termiate, etc ad rehearse them get authorisatio for the use, storage ad safe disposal of radioactive substaces from the Eviromet Agecy/SEPA, as appropriate. Other o-destructive testig techiques, such as magetic particle ad dye peetrat techiques may ivolve the sprayig of harmful solvets. Exposure to harmful levels of such solvets eeds to be assessed i lie with COSHH (see page 34) ad preveted or cotrolled. Health ad safety i egieerig workshops Page 89 of 147

90 Health ad Safety To miimise risks: always carry out routie radiography of readily moveable articles iside a permaet shielded eclosure, sufficiet to limit dose rates outside the eclosure to less tha 7.5 microsieverts a hour make sure there are o people ear ope-topped eclosures (i offices, or overhead crae cabs, for example) who may be affected if you chage your geerator or source you may have to upgrade the eclosure have to had a emergecy pla ad the equipmet ecessary to put the pla ito effect (for radioactive sources to iclude bags of lead shot, a shielded pot ad log-hadled tools) ad rehearse the pla wear your dosemeter whe required ad make sure it is ot damaged or exposed to radiatio whe ot beig wor use a maitaied ad tested radiatio dose rate meter to check radiatio levels aroud the cotrolled area ad always use the moitor whe approachig the source cotaier to check the that the sealed source has fully retracted or x-ray geerator is o loger producig x-rays maitai radiography cotrols, for example widouts ad guide tubes for sealed source equipmet, ad warig devices. If you ca t do the work i a shielded eclosure, you must: otify HSE at least seve days i advace of each occasio o which you propose to work pla the work to esure radiatio exposures are suitably restricted by use of collimatio ad localised shieldig, barriers, warig sigals, lightig ad other meas to demarcate the cotrolled area. Key referece: Idustrial radiography: Maagig radiatio risks IRIS1(rev1) available from HSE Books (free) Health ad safety i egieerig workshops Page 90 of 147

91 Health ad Safety Paitig The hazards of usig paits, thiers or solvets iclude: breathig i vapour direct ski or eye cotact swallowig causig irritatio ad diseases of the ski, eyes ad lugs, ad fires from the igitio of flammable vapours. The risks of harm actually occurrig are highest whe: usig paits cotaiig large proportios of toxic materials such as lead or isocyaates paitig i cofied spaces sprayig i uvetilated ope workshops. To reduce risks Use the least hazardous materials for the job (water based paits for example ad alteratives to lead for rust prevetio are widely available) Follow the rules for work i cofied spaces (see pages 80 ad 82) ad Always cotrol spray by usig vetilated booths, eclosures or separate workspaces. Take care with paits by: usig protective clothig ad eye protectio usig ay pre-work barrier or protective coditioig cream provided removig rigs or watches which ca trap pait agaist the ski takig care with solvets whe cleaig brushes, spray gus etc ever eatig, drikig or smokig while paitig keepig overalls ad respirator i a clea state by regular washig washig hads before eatig, ad showerig or bathig at the ed of the day leavig protective clothig at work to reduce the risk of harmful substaces beig take home. The law o the mai hazards associated with paitig outlied Hazardous substaces i paits must be cotrolled i lie with the Cotrol of Substaces Hazardous to Health Regulatios (see page 34). The Highly Flammable Liquids ad Liquefied Petroleum Gases Regulatios 1972 specify steps which must be take to miimise the risks of igitig vapours from paits ad solvets which are classified as highly flammable liquids (flash poit less tha 32 C). Do t forget to obtai a licece for the storage of petroleum products from your local petroleum officer who works for your Fire Brigade or local Tradigs Stadards Departmet. Health ad safety i egieerig workshops Page 91 of 147

92 Health ad Safety Storig ad mixig paits I order to miimise the flammable (ad to some extet other) risks from vapours give off by may paits ad solvets: keep oly small quatities (ot more tha 50 litres) o their ow i a metal cupboard or bi for immediate use at the workplace ad larger stocks i a fire-resistig store with spillage retetio ad good vetilatio keep lids o cas ad cotaiers closed to stop vapour escapig. Cotai spillages by decatig pait over a tray. Have absorbet material readily available to soak up spillages. Keep cotamiated material i a lidded metal bi ad dispose of its cotets safely exclude sources of igitio ad use suitable electrical equipmet. Do ot smoke where paits are stored or used esure adequate vetilatio where paits are mixed. Breathig protectio may be eeded treat cotaiers emptied of liquid the same as full oes; they will ofte be full of vapour. Key referece: EIS 32 Chromate primer paits HSE Books (free) Health ad safety i egieerig workshops Page 92 of 147

93 Health ad Safety Spray paitig booths ad eclosures If you make your ow spray booth or eclosure: use fire-resistat materials (see list i Appedix 5) keep uprotected electrical equipmet outside (for example by istallig lights outside booths ad shiig them through fixed ad sealed fire resistig wired glass paels) get advice from a competet vetilatio egieer ad: extract to a safe place i the ope air away from people, sources of igitio ad earby buildigs ad equipmet use a cetrifugal or bifurcated fa (with the motor outside the ductig i a vapour free area drivig the fa through a gas tight shaft seal). Use flexible armoured cable for electrical wirig to withstad fa vibratio rather tha mieral isulated metal sheathed cable use filters to prevet deposits of pait o motor casigs, fa blades ad iside ducts; deposits may cause fas to vibrate ad ru out of balace ad direct deposits may also cause motors to overheat ad igite provide access poits for ispectio ad cleaig iside ductig. To maximise the efficiecy of ay booth or eclosure: provide meas to idicate whe dry filters eed replacemet. The air speed i the immediate viciity of the sprayer i a dry filter spray booth or eclosure may be the lowest i the booth because of the accumulatio of spray deposits o the filter. Hece the air speed teds to be slowest where it is most eeded keep uecessary equipmet out of booths. Large drums of pait for example ca disturb the air flow patter ad cause recirculatio of cotamiated air ito the sprayer s breathig zoe provide sufficiet ad suitably protected lightig i the booth to remove the temptatio to spray outside it give traiig i the techiques of spray paitig to teach how to spray with the miimum amout of overspray ad bouceback, to obtai the correct balace betwee air ad liquid flow rates, ad to esure that the miimum pressure for good atomisatio is always used cosider the efficiecy of the sprayig equipmet used. Some equipmet geerates lower levels of solvet vapour ad overspray tha others. Maitaiig booths ad eclosures: Check booths ad eclosures regularly for leaks, have them thoroughly examied ad tested every 14 moths by a competet perso (eg a isurace compay egieerig surveyor or represetative of the supplier) ad keep the reports Maitai a miimum average air velocity of 0.7 m/s at the frot of ope-froted booths ad eclosures Where a sprayer works iside a side draught booth or eclosure the average air velocity where the sprayer stads should be ot less tha 0.5 m/s with a miimum measured value of 0.4 m/s The sprayer should ever stad betwee the article beig sprayed ad the poit of extractio; a turtable to rotate articles as ecessary should be used Health ad safety i egieerig workshops Page 93 of 147

94 Health ad Safety Where a sprayer works iside a dow draught booth or eclosure, air velocity (measured to poits aroud a typical article sprayed) should average 0.4 m/s with a miimum measured value of 0.3 m/s Esure that airflow or air pressure differetial switches are workig to war if desiged exhaust vetilatio flow rates are ot maitaied Maitai ay iterlocks fitted betwee spray gus ad exhausts vetilatio Repair damaged spray booth ad eclosure paels to maitai the fire resistace of the uit Keep escape routes ad access to rescue equipmet clear Esure that air itakes are ot obstructed ad that discharge vets are correctly sited ad i good repair. Sprayig large articles Where articles too large to eclose are sprayed use a separate room after: esurig adequate half-hour fire resistat separatio from adjoiig rooms removig all sources of igitio such as directly fired heaters or domestic-type electric ad gas fires ad turig off ad isolatig electrical equipmet which is ot explosio protected providig vetilatio to a safe place while sprayig, ad esurig adequate persoal protectio is wor ad that o-oe else uprotected i the workroom or earby will be exposed to the spray or vapour. Key refereces: Itroductio to local exhaust vetilatio HSG37 HSE Books ISBN The maiteace, examiatio ad testig of local exhaust HSG54 HSE Books ISBN Health ad safety i egieerig workshops Page 94 of 147

95 Health ad Safety Paits cotaiig isocyaates Health hazards Two-pack spray paits cotaiig isocyaates are ofte used to achieve hard, durable, easy to clea fiishes. I these paits, isocyaate hardeers or activators are added to liquid resi ad pigmets to produce a polyurethae film. Vapours ad spray mists cotaiig isocyaates are highly irritat to the eyes ad respiratory tract ad are kow to cause asthma. Isocyaates are respiratory sesitisers. This meas they ca cause a allergic reactio called sesitisatio. Oce a perso is sesitised to isocyaates, further exposure, eve to the tiiest trace will cause symptoms, eg: sore eyes ruig ose sore throat coughig wheezig, tight chest fever ad breathlessess. At first these complaits may clear up at weekeds or durig holidays, but are likely to retur whe back at work. Exposure to isocyaate cotaiig glues durig assembly may cause similar problems ad require similar avoidace, cotrol ad/or protective measures. How ca health be protected? Key refereces: Safety i motor vehicle repair: Workig with 2-pack isocyaate paits INDG388 HSE Books (sigle copies free ISBN X for priced packs of 10); Prevetig asthma at work: How to cotrol respiratory sesitisers L55 HSE Books 1994 ISBN Cosider o-isocyaate two-pack paits which are available Assess the hazards ad risks ad prevet or cotrol exposure i lie with the COSHH Regulatios (see page 34) Idetify isocyaate-cotaiig two-pack paits from their labels or suppliers data sheets If you suffer from chroic respiratory disease such as chroic asthma do ot work with two-pack paits cotaiig isocyaates Cosult a occupatioal health professioal before workig with isocyaatecotaiig two-pack paits for advice o a suitable health surveillace programme Spray oly i mechaically vetilated booths or separate workrooms adequately vetilated Use oly mechaically vetilated oves for acceleratig curig. Ru them uder egative pressure Vetilate vapour ad spray, after filtratio, to a safe place i the ope air where they will ot be draw back ito the workroom or ito earby premises Whe mixig ad sprayig wear protective clothig icludig gloves ad eye protectio; wear air fed or compressed airlie breathig apparatus (depedig o the outcome of your risk assessmet) eve for small sprayig jobs If a full facepiece caister respirator is wor for mixig or similar jobs chage the caister before its recommeded life (ofte as little as 15 miutes) is exceeded. Gauze facemasks do ot provide protectio Maitai ad keep respiratory protective equipmet clea. Health ad safety i egieerig workshops Page 95 of 147

96 Health ad Safety Powder coatig Health hazards Powder coatig is a alterative fiishig process to spray paitig. The hazards of usig coatig powders iclude: direct ski cotact with the powders breathig i powders i the air swallowig powders. Some curig or hardeig agets used i powders, especially TGIC (triglycidl isocyaurate) ad TMA (tri-mellitic ahydride) ca cause direct irritatio of the ski, eyes ad lugs or allergic ski reactios. There is cocer that some curig agets may cause asthma. The risks of harm occurrig are highest whe: usig powders cotaiig curig agets such as TGIC or TMA sprayig powder i poorly vetilated powder-coatig booths followig poor systems of work, such as leaig ito the coatig booth whe sprayig carryig out powder trasfer, maiteace ad cleaig work. To reduce risks Esure that you have chose a powder coatig that presets the lowest risk to your workers health ad safety, ad to the eviromet. Talk to your supplier or trade associatio for advice. For example, you should oly use TGIC-based coatig powders whe these are eeded for techical reasos. Ask your supplier whether you eed to use them. Take care whe selectig a alterative powder coatig as some also cotai other hazardous substaces such as isocyaates Miimise the amout of maual sprayig carried out may coatig-booths are automatically operated Esure that your spray booth is workig at its optimum so that the air eterig the system is at least 0.5 metres per secod If usig coveyorised spray booths stad outside the booth to spray; do ot lea iside Never spray towards aother operator The amout of powder sprayed should be kept to the level that miimises its usage ad achieves the desired fiish, by cotrollig gu settigs Provide suitable persoal protective equipmet ad make sure it is wor properly Trai your employees i safe powder coatig techiques to miimise exposure Practise good housekeepig by keepig work areas aroud the spray booths clea. Use a idustrial vacuum cleaer rather tha sweepig up with a broom Follow safe systems of work for cleaig ad maiteace activities; i particular, the use of compressed air for cleaig should be kept to a miimum ad operators should avoid stadig iside the booth to clea it by usig loghadled rubber scrapers (ot brushes) ad compressed air laces Esure good stadards of persoal hygiee by keepig overalls clea by regular washig, ad by washig hads before eatig ad drikig. Health ad safety i egieerig workshops Page 96 of 147

97 Health ad Safety The law o the mai hazards associated with powder coatig outlied Hazardous substaces i coatig powders must be cotrolled i lie with the Cotrol of Substaces Hazardous to Health Regulatios (see page 34). Other precautios to take iclude: miimise the risk of a fire or explosio by regular cleaig to prevet build up of dust ad exclude sources of igitio, such as aked flames, cigarettes, etc from powder coatig work areas miimise the risk of electric shock by esurig good earthig of work equipmet ad regular maiteace of electrical equipmet maitai compressed air systems associated with powder coatig equipmet (see page 42). Key refereces: Cotrollig exposure to coatig powders HSG HSE Books ISBN Workig safely with coatig powders INDG319 HSE Books 2000 (sigle copy free or priced packs of 10 ISBN ) Health ad safety i egieerig workshops Page 97 of 147

98 Health ad Safety Persoal protective equipmet (PPE) If you are thikig of usig persoal protective equipmet (PPE) to cotrol employees exposure to substaces hazardous to health remember that COSHH (see page 34) limits its use to situatios where it is ot reasoably practicable to use other measures. The Persoal Protective Equipmet at Work Regulatios 1992 outlied Employers must: provide suitable PPE free of charge to protect employees agaist risks which have ot bee cotrolled by other meas take all reasoable steps to esure it is properly used before providig PPE, assess risks to health ad safety which have ot bee avoided by other meas ad defie the characteristics which PPE must have agaist those risks; the compare those characteristics agaist PPE available maitai PPE provided i clea ad efficiet workig order with appropriate accommodatio for it whe ot i use give iformatio, istructio ad traiig. Employees must: use PPE provided report ay loss or obvious defect to the employer. Respiratory protective equipmet (RPE) Choosig Whe choosig breathig protectio cosider i detail the job to be doe. For example, are the isides or udersides of large articles to be sprayed? It is likely that the vetilatio will be less effective i these areas. Differet types of RPE offer differet levels of protectio ad the correct type has to be matched to the job ad the wearer. For most spray jobs with the sprayer iside the booth, compressed airlie breathig apparatus with a full facepiece or air fed equipmet may be most suitable. Before choosig, assess the work carefully ad cosult your suppliers of pait ad protective equipmet. Maitaiig Thoroughly examie ad, where appropriate, test RPE at least oce a moth ad more frequetly where coditios are severe. (This does ot apply to oe-shift disposable respirators.) Half-mask respirators used oly occasioally agaist dust or fumes of relatively low toxicity may be examied at loger itervals, but ot less tha oce every three moths. Esure that breathig air supplied to equipmet is satisfactory; proprietary equipmet to do this is widely available. Health ad safety i egieerig workshops Page 98 of 147

99 Health ad Safety Ear protectio Protectors should: be suitable for coditios i which they are to be used Provide sufficiet atteuatio to reduce the oise exposure level to below 90dB(A) ad preferably to below 85dB(A) oly be issued o a persoal basis ever be removed i a oisy eviromet be compatible with other forms of ecessary persoal protective equipmet. I relatio to ear protectio, the Noise at Work Regulatios 1989 require i outlie: ear protectio to be made available o request if the daily oise exposure exceeds 85dB(A) ear protectio to be wor if the daily oise exposure exceeds 90dB(A). Eye protectio Will have to be provided ad used (sometimes throughout the whole workshop) where work which puts eyes at risk is carried out, eg: machiig (particularly gridig) ad the use of had tools which leads to the ucotrolled ejectio of metallic particles, ad the use of harmful substaces, such as metalworkig fluids, paits or solvets which may splash ito the eye. The provisio ad use of foot protectio will also have to be cosidered i most egieerig workshops where there are risks of ijury to the feet, for example from heavy compoets beig moved. Where ay PPE is eeded to help cotrol a risk to health or safety of a employee, it must be provided ad maitaied (icludig cleaig of overalls) free of charge to the employee. Key refereces: Persoal Protective Equipmet at Work Regulatios Guidace o Regulatios L25 HSE Books ISBN The selectio, use ad maiteace of respiratory protective equipmet HSG53 HSE Books ISBN Protect your hearig or lose it INDG HSE Books (sigle copy free or priced packs of 25 ISBN ) Health ad safety i egieerig workshops Page 99 of 147

100 Health ad Safety Offices Accidets ad cases of ill health are geerally less frequet ad severe i offices. To miimise risks: Do clear up spillages replace/repair tor floor coverig also see the geeral advice o the workplace (see pages 15 20) follow legal requiremets (see Key referece below) for cotiuous or extesive use of VDUs, esure adequate breaks ad provide workstatios which are reasoably adjustable for comfort (see pages o how to avoid upper limb disorders). Do t allow trailig leads to create trippig hazards. Electricity i offices ca cause the most serious accidets from electric shock ad fire; defective plugs, sockets ad leads cause more accidets tha appliaces themselves. Do provide eough socket outlets; avoid or miimise the use of adaptors test ay residual curret devices fitted visually ispect plugs ad leads ad get them repaired by someoe competet if ecessary cosider whether more detailed tests are eeded (for example, is the equipmet faulty or oly workig itermittetly?) switch off ad uplug before cleaig. Do t use taped joits i electrical cables (see pages 40 41). Health ad safety i egieerig workshops Page 100 of 147

101 Health ad Safety Key referece: The law o VDUs: A easy guide HSG90 HSE Books ISBN Health ad safety i egieerig workshops Page 101 of 147

102 Health ad Safety Orgaisig health ad safety What the law requires Uder the HSW Act, you have to esure the health ad safety of yourself ad others who may be affected by what you do or fail to do. This icludes people who: work for you, icludig casual workers, part-timers, traiees ad subcotractors; use workplaces you provide; are allowed to use your equipmet; visit your premises; may be affected by your work, eg your eighbours or the public; use products you make, supply or import; or use your professioal services, eg if you also desig as well as make machiery. The Act applies to all work activities ad premises, ad everyoe at work has resposibilities uder it, icludig the self-employed. Basic legal requiremets outlied You must: have a writte, up-to-date health ad safety policy if you employ five or more people carry out a risk assessmet (ad if you employ five or more people, record the mai fidigs ad your arragemets for health ad safety) otify occupatio of premises to your local ispector if you are a commercial or idustrial busiess display a curret certificate as required by the Employers Liability (Compulsory Isurace) Act 1969 if you employ ayoe display the Health ad Safety Law poster for employees or give out the leaflet otify certai types of ijuries, occupatioal diseases ad evets cosult your employees, either directly or via appoited uio safety represetatives o certai issues, such as ay chages which might affect health ad safety ad ay iformatio ad traiig which has to be provided. You must ot: employ childre of uder school leavig age, apart from o authorised work experiece schemes, if you are a idustrial udertakig. Eforcig the law Health ad safety laws relatig to your firm will usually be eforced by a health ad safety ispector from the HSE, but where the workshop is part of a larger eterprise, such as a large departmet store where health ad safety law is eforced by the local authority, by a local authority ispector. Ispectors may visit workplaces without otice but you are etitled to see their idetificatio before they come i. They may wat to ivestigate a accidet or complait, or ispect safety, health ad welfare i the workshop. They have the right to talk to employees ad safety represetatives, take photographs ad samples, ad eve i certai cases to impoud dagerous equipmet. They are etitled to co-operatio ad aswers to questios. Health ad safety i egieerig workshops Page 102 of 147

103 Health ad Safety Ispectors will be aware of the mai risks i egieerig workshops ad will give you help ad advice o how to comply with the law. If there is a problem they may issue a formal otice requirig improvemets or, where serious dager exists, oe which prohibits the use of a process or equipmet. Ispectors have powers to prosecute a firm (or a idividual) for breakig health ad safety law. Key referece: Essetials of health ad safety at work HSE Books ISBN X Health ad safety i egieerig workshops Page 103 of 147

104 Health ad Safety Accidets ad emergecies Before the evet I ay workshop, thigs sometimes go wrog. You eed to be ready to deal with these uplaed evets. Look at icidets which have caused ijuries ad ill health or other damage what ca you lear? Thik about emergecies pla for the worst that ca happe. You must have the right first-aid arragemets. Some evets eed to be reported this chapter tells you how to do this. The law o accidets ad emergecies outlied The Maagemet of Health ad Safety at Work Regulatios 1992 cover emergecies. The requiremets for first aid are i the Health ad Safety (First Aid) Regulatios 1981, ad for reportig icidets i the Reportig of Ijuries, Diseases ad Dagerous Occurreces Regulatios 1995 (RIDDOR). The Dagerous Substaces (Notificatio ad Markig of Sites) Regulatios 1990 cover sites where at least 25 toes of certai dagerous substaces are held. Emergecy procedures Whe thigs go wrog, people may be exposed to serious ad immediate dager. Special procedures are ecessary i egieerig workshops for emergecies such as serious ijuries, explosio, poisoig, electrocutio, fire, release of radioactivity ad chemical spills. Write a emergecy pla if a major icidet at your workplace could ivolve risks to the public, rescuig employees or the co-ordiatio of emergecy services. Thik about: The worst that ca happe if thigs go wrog How the perso i charge ad others will deal with the problems. You should look at ay particular resposibilities ad traiig eeds Is everyoe adequately prepared ad could emergecy services get to the site? Poits to iclude i emergecy procedures: Cosider what might happe ad how the alarm will be raised. Do t forget ight ad shift workig, week-eds ad (possibly) times whe the premises are closed, eg holidays Pla what to do, icludig how to call the emergecy services. Assist the emergecy services by clearly markig your premises from the road. Cosider drawig up a simple pla marked with the locatio of hazardous items If you have at least 25 toes of certai dagerous substaces you must otify the fire authority ad put up warig sigs Decide where to go to reach a place of safety or to get rescue equipmet. Provide emergecy lightig if ecessary You must make sure there are eough emergecy exits for everyoe to escape quickly, ad keep emergecy doors ad escape routes uobstructed ad clearly marked Nomiate competet persos to take cotrol Health ad safety i egieerig workshops Page 104 of 147

105 Health ad Safety Decide who the other key people are such as first aiders Pla essetial actios such as emergecy plat shut-dow or makig processes safe; clearly label importat items like shut-off valves ad electrical isolators for plat ad machiery You must trai everyoe i emergecy procedures Do t forget the eeds of people with disabilities. Ivestigatig evets Whe a accidet happes: take ay actio required to deal with the immediate risks, eg first-aid, put out the fire, isolate ay dager, fece off the area assess the amout ad kid of ivestigatio eeded if you have to disturb the site, take photographs ad measuremets first ivestigate fid out what happeed ad why take steps to stop somethig similar happeig agai also look at ear misses ad property damage. Ofte it is oly by chace that someoe was t ijured. Checklist To help with your ivestigatios, fid out the followig: Details of ijured persoel Details of ijury, damage or loss What was the worst that could have happeed? Could it happe agai? What happeed? Where? Whe? What was the direct cause? Were there stadards i place for the premises, plat, substaces, procedures ivolved? Were they adequate? Were they followed? Were the people up to the job? Were they competet, traied ad istructed? What was the uderlyig cause? Was there more tha oe? What was meat to happe ad what were the plas? How were the people orgaised? Would ispectio have picked up the problem earlier? Had it happeed before? If so, why were t the lessos leart? Most accidets have more tha oe cause so do t be too quick to blame idividuals try to deal with the root causes. Health ad safety i egieerig workshops Page 105 of 147

106 Health ad Safety The law o reportig ijuries ad other evets outlied The Reportig of Ijuries, Diseases ad Dagerous Occurreces Regulatios 1995 (RIDDOR) apply to all employers ad the self-employed ad cover everyoe at work. The mai poits are that you must: otify your ispector immediately, ormally by telephoe, if aybody dies, receives a major ijury or is seriously affected by, for example a electric shock or poisoig otify your ispector immediately if there is a dagerous occurrece, eg a fire or explosio, which stops work for more tha 24 hours, or a overtured crae cofirm i writig withi seve days o F2508 report withi seve days (o form F2508) ijuries which keep a employee off work or uable to do their ormal job for more tha three days report certai diseases suffered by workers who do specified types of work as soo as possible o learig about the illess. Use form F2508A. Cases of occupatioal asthma (from isocyaate paits, for example) oil ace vibratio white figer dermatitis may arise i some egieerig workshops. keep details of the icidets reported. Icidet Cotact Cetre (ICC) I additio to the above procedures, ew arragemets were itroduced for reportig icidets which occurred o or after April Icidets ca ow be reported to the ICC by telephoe, fax, post or via the Iteret ( or Key referece: Guide to the Reportig of Ijuries, Diseases ad Dagerous Occureces Regulatios 1995 L73 HSE Books ISBN Health ad safety i egieerig workshops Page 106 of 147

107 Health ad Safety First aid A first-aid box should cotai a sufficiet quatity of suitable first-aid materials ad othig else o lotios, medicies or treatmets (icludig paracetamol). The box of a typical small workshop with o additioal or special hazards may iclude: Item Quatity Guidace Card IND(G) 4 (P) Rev 1 Idividually wrapped sterile adhesive dressigs (assorted size) 20 Sterile eye pads, with attachmet 2 Idividually wrapped triagular badages 6 Safety pis 6 Medium sized idividually wrapped sterile umedicated woud dressigs (approx 10 cm x 8 cm) Large sterile ad idividually wrapped umedicated woud dressigs (approx 13 cm x 9 cm) Extra large sterile idividually wrapped umedicated woud dressigs (approx 28 cm x 17.5 cm) If work i cofied spaces, such as large metal fabricatios or vapour degreasig taks is carried out, resuscitatig equipmet should be provided ad maitaied, ad persos traied i its use. If cyaide or other especially hazardous substaces are used, appropriate atidotes, equipmet ad traiig should also be provided, ad the suppliers of the substaces cocered, or EMAS, cosulted i the first istace. Health ad Safety (First Aid) Regulatios 1981 outlied You must have: someoe who ca take charge i a emergecy. (The miimum requiremet is for a appoited perso to be available wheever people are at work ad is the lowest grade of first aid cover) a first-aid box otices tellig people where the first-aid box is ad who the appoited perso is a qualified first aider where the situatio demads, eg if your work gives rise to special hazards, such as those from toxic materials or dagerous machiery a first-aid room if you are a log way from emergecy medical services. Health ad safety i egieerig workshops Page 107 of 147

108 Health ad Safety As your compay grows, look agai at your eed for qualified first aiders. They must be properly traied ad have a valid first aid at work certificate. These certificates are issued for three years but ca be reewed followig refresher traiig ad re-examiatio. Traiig orgaisatios are registered with the Employmet Medical Advisory Service ask your Employmet Nursig Adviser at the local HSE office. Key refereces: Basic advice o first aid at work INDG347 (sigle copy free or priced packs of 20 ISBN ) First aid at work. Approved Code of Practice ad Guidace L74 HSE Books ISBN Health ad safety i egieerig workshops Page 108 of 147

109 Health ad Safety How to obtai publicatios ad further assistace HSE Publicatios HSE priced ad free publicatios ca be viewed olie or ordered from or cotact HSE Books, PO Box 1999, Sudbury, Suffolk CO10 2WA Tel: Fax: Website: HSE priced publicatios are also available from bookshops. For iformatio about health ad safety rig HSE s Ifolie Tel: Fax: [email protected] or write to HSE Iformatio Services, Caerphilly Busiess Park, Caerphilly CF83 3GG. Textphoe: You ca also visit HSE s website: Egieerig sector pages: HSC Newsletter is available o subscriptio from: HSE Books Subscriptios Departmet PO Box 1999, Sudbury, Suffolk CO10 2WA Tel: Fax: Other sources of iformatio British Safety Coucil Natioal Safety Cetre, 70 Chacellors Road Lodo W6 9RS Tel: Fax: Royal Society for the Prevetio of Accidets Edgbasto Park, 353 Bristol Road Birmigham B5 7ST Tel: Fax: The Maufacturig Techologies Associatio 62 Bayswater Road, Lodo W2 3PS Tel: Fax: Website: Surface Egieerig Associatio Cofederatio House 10 Vyse St Birmigham B18 6LT Tel: Fax: EEF. The Maufacturers Orgaisatio Broadway House, Tothill Street Lodo SW1H 9NQ Tel: Fax: Website: Health ad safety i egieerig workshops Page 109 of 147

110 Health ad Safety AMICUS AEU Egieerig Sectio Terry Duffy House, Thomas Street Holloway Circus, Queesway West Bromwich B70 6NT Tel: Fax: Evirowise Harwell Oxfordshire OX11 0RA Tel: Fax: Other publicatios British Stadards ca be obtaied i PDF or hard copy formats from the BSI olie shop: or by cotactig BSI Customer Services for hard copies oly Tel: [email protected]. The Statioery Office publicatios are available from The Statioery Office, PO Box 29, Norwich NR3 1GN Tel: Fax: [email protected] Website: (They are also available from bookshops.) Statutory Istrumets ca be viewed free of charge at HSE videos are available from HSE Books. Health ad safety i egieerig workshops Page 110 of 147

111 Health ad Safety Further readig ad iformatio Uless otherwise idicated, the followig titles are available from HSE Books. Maagig health ad safety HSG65 Successful health ad safety maagemet rev 1997 ISBN HSG96 The costs of accidets at work rev 1997 ISBN L21 Maagemet of health ad safety at work. Maagemet of Health ad Safety at Work Regulatios Approved Code of Practice ad guidace (Secod editio) HSE Books 2000 ISBN INDG324 Startig your busiess. Guidace o preparig a health ad safety policy documet for small firms (sigle copy free; ISBN for priced pack of 5 copies) HSC13(rev1) Health ad safety regulatio: a short guide 2003 (free) HSE40 Employers Liability (Compulsory Isurace) Act (free) HSE34 HSE ad you 2000 (free) HSE38 HSE: Workig with employers 2000 (free) INDG275 Maagemet of health ad safety. Five steps to success 1998 (sigle copy free; ISBN for priced packs of 10 copies) INDG163(rev1) 5 steps to risk assessmet 1998 (sigle copies free; L87 ISBN for priced packs of 10 copies) Safety represetatives ad safety committees (Third editio) HSE Books 1996 ISBN HSG137 Health risk maagemet 1995 ISBN Essetials of health ad safety at work 1994 ISBN X SCB 014 INDG355 Be safe: A guide to health ad safety i traiig available from Departmet for Educatio ad Skills, tel Reduce risks - cut costs: The real cost of accidets ad ill health at work 2002 (sigle copy free; ISBN for priced packs of 15 copies) INDG322 Need help o health ad safety? 2000 (sigle copy free; ISBN for priced packs of 10 copies) HSC14 What to expect whe a health ad safety ispector calls 1998 INDG232 INDG218 HSG165 (free) Cosultig employees o health ad safety: A guide to the Law (sigle copies free; ISBN for priced packs of 15 copies) Guide to risk assessmet requiremets: Commo provisios i health ad safety law (sigle copies free; ISBN for priced packs of 5 copies) Youg people at work: A guide for employers (Secod editio) 2000 ISBN A guide to the Workig Time Regulatios DTI tel HSG218 Tacklig work-related stress: A maager s guide 2001 ISBN HSG183 Five steps to risk assessmet: Case studies 1998 ISBN Health ad safety i egieerig workshops Page 111 of 147

112 Health ad Safety L95 A guide to the Health ad Safety (Cosultatio with Employees) Regulatios ISBN Improvig maiteace: A guide to reducig huma error 2000 ISBN Workshops HSG194 Thermal comfort i the workplace: Guidace for employers 1999 ISBN L64 Safety sigs ad sigals. The Health ad Safety (Safety Sigs ad Sigals) Regulatios Guidace o Regulatios 1996 ISBN L24 Workplace health, safety ad welfare. Workplace (Health Safety ad Welfare) Regulatios Approved Code of Practice ad Guidace 1992 ISBN INDG244 Workplace health, safety ad welfare: A short guide 1997 (sigle copies free; ISBN for priced packs of 10 copies) HSG38 Lightig at work 1998 ISBN INDG63(rev) INDG225 INDG36(rev2) HSG165 HSG122 HSG155 Passive smokig at work: Workplace air pollutio 1992 (sigle copies free; ISBN for priced packs of 10 copies) Prevetig slips, trips ad falls (sigle copies free; ISBN for priced packs of 15 copies) Workig with VDUs (sigle copies free; ISBN for priced packs of 10 copies) Youg people at work: A guide for employers (Secod editio) 2000 ISBN New ad expectat mothers at work: A guide for employers (Secod editio) 2002 ISBN Slip ad trips. Guidace for employers o idetifyig hazards ad cotrollig risks 1996 ISBN Liftig equipmet L113 Safe use of liftig equipmet. Liftig Operatios ad Liftig Equipmet Regulatios. Approved Code of Practice ad guidace 1998 ISBN PM55 Safe workig with overhead travellig craes 1985 ISBN Maual hadlig L23 INDG90(rev2) INDG143(rev1) INDG171 Maual hadlig. Maual Hadlig Operatios Regulatios Guidace o Regulatios (Secod editio) 1998 ISBN Uderstadig ergoomics at work: Reduce accidets ad ill health ad icrease productivity by fittig the task to the worker 2003 (sigle copies free; ISBN for priced packs of 15 copies) Gettig to grips with maual hadlig: A short guide for employers 2000 (sigle copies free); ISBN for priced packs of 15 copies Achig arms (or RSI) i small busiesses: Is ill health due to upper limb disorders a problem i your workplace? 2003 (sigle Health ad safety i egieerig workshops Page 112 of 147

113 Health ad Safety copies free; ISBN for priced packs of 15 copies) HSG60 Upper limb disorders: A guide to prevetio (rev) 2002 ISBN HSG57 Seatig at work 1998 ISBN HSG115 Maual hadlig: Solutios you ca hadle 1994 ISBN HSG121 A pai i your workplace? Ergoomic problems ad solutios EIS ISBN Prevetig ijuries from the maual hadlig of sharp edges i the egieerig idustry (free) INDG390 Choosig a weldig set? Make sure you ca hadle it 2003 (sigle copy free; ISBN X for priced packs of 10 copies) Trasport (ad storage) L117 Rider operated lift trucks - operator traiig. Approved Code of Practice ad guidace 1999 ISBN HSG6 Safety i workig with lift trucks 2000 ISBN INDG148 Reversig vehicles 1993 (sigle copies free; ISBN for priced packs of 15 copies) HSG76 Health ad safety i retail ad wholesale warehouses 1992 ISBN HSG136 Workplace trasport safety 1995 ISBN INDG199 Maagig vehicle safety at the workplace 1995 (sigle copies free; ISBN for priced packs of 10 copies) INDG313 Safe uloadig of steel stock 2000 (sigle copies free or priced packs of 15 ISBN ) Hazardous substaces L132 Cotrol of lead at work. Cotrol of Lead at Work Regulatios Approved Code of Practice ad guidace (Third editio) HSE Books 2002 ISBN EH40/2002 Occupatioal exposure limits ISBN Supplemet 2003 ISBN HSG37 A itroductio to local exhaust vetilatio 1993 ISBN HSG54 The maiteace, examiatio ad testig of local exhaust vetilatio 1998 ISBN INDG174 A short guide to the Persoal Protective Equipmet at Work Regulatios 1992 (sigle copies free; ISBN for priced packs of 10 copies) INDG233 Prevetig dermatitis at work (sigle copies free; ISBN for priced packs of 15 copies) INDG95(rev2) Respiratory sesitisers ad COSHH (sigle copies free; ISBN for priced packs of 15 copies) INDG188 Asbestos alert for buildig maiteace, repair ad refurbishmet workers (pocket card) 1995 (sigle copies free; ISBN for priced packs of 25 copies) INDG223(rev1) Maagig asbestos i workplace buildigs 1996 (sigle copies free; ISBN for priced packs of 10 copies) INDG136(rev2) COSHH: A brief guide to the Regulatios (sigle copies free; ISBN for priced packs of 10 copies) HSG126 CHIP for everyoe 2002 ISBN X Health ad safety i egieerig workshops Page 113 of 147

114 Health ad Safety L5 Cotrol of substaces hazardous to health. The Cotrol of Substaces Hazardous to Health Regulatios Approved Code of Practice ad guidace (Fourth editio) HSE Books 2002 ISBN L8 Legioaires disease. The cotrol of legioella bacteria i water systems. Approved Code of Practice ad guidace (Secod editio) HSE Books 2002 ISBN INDG181 The idiot s guide to CHIP (sigle copies free; ISBN for priced packs of 5 copies) HSG53 The selectio, use ad maiteace of respiratory protective equipmet: A practical guide rev 1998 ISBN L25 Persoal protective equipmet at work. Persoal Protective Equipmet at Work Regulatios Guidace o Regulatios HSE Books 1992 ISBN MS25 Medical aspects of occupatioal asthma rev 1998 L55 ISBN Prevetig asthma at work: How to cotrol respiratory sesitisers HSE Books 1994 ISBN HSG61 Surveillace of people exposed to health risks at work 1999 ISBN X EH1 Cadmium: health ad safety precautios 1995 ISBN EH13 Beryllium: health ad safety precautios 1995 ISBN EH60 Nickel ad its iorgaic compouds: Health ad safety precautios 1997 ISBN HSG193 COSHH essetials: Easy steps to cotrol chemicals. Cotrol of Substaces Hazardous to Health Regulatios (Secod editio) 2003 ISBN It ca also be freely accessed at HSG188 Health risk maagemet: A guide to workig with solvets 1999 HSG110 ISBN Seve steps to successful substitutio of hazardous substaces 1994 ISBN HSG173 Moitorig strategies for toxic substaces 1997 ISBN HSG203 Cotrollig exposure to coatig powders HSG ISBN INDG319 Workig safely with coatig powders 2000 (sigle copy free or priced packs of 10 ISBN ) Electricity HSR25 Memoradum of guidace o The Electricity at Work Regulatios 1989, 1989 ISBN HSG85 Electricity at work: Safe workig practices 2003 ISBN HSG107 Maitaiig portable ad trasportable electrical equipmet 1994 ISBN BS 7671:2001 Requiremets for electrical istallatios. IEE Wirig Regulatios ISBN GS38 Electrical test equipmet for use by electricias 1995 INDG231 ISBN X Electrical safety ad you (sigle copies free; ISBN for priced packs of 15 copies) PM29 Electrical hazards from steam/water pressure cleaers 1995 ISBN Health ad safety i egieerig workshops Page 114 of 147

115 Health ad Safety INDG68 Do you use a steam/water pressure cleaer? You could be i for a shock 1997 (free) INDG354 Safety i electrical testig at work: Geeral guidace 2002 (sigle copy free or priced packs of 5 ISBN ) Pressurised plat ad systems L122 Safety of pressure systems. Pressure Systems Safety Regulatios Approved Code of Practice. HSE Books 2000 ISBN X GS 4 Safety i pressure testig 1998 ISBN PM60 Steam boiler blowdow systems rev 1998 ISBN HSG39 Compressed air safety rev 1998 ISBN Machiery safeguardig Product stadards: Machiery - guidace otes o UK regulatios Ref (free) Departmet of Trade ad Idustry, tel: SI 1992/3073 Supply of Machiery (Safety) Regulatios 1992 (as ameded by SI 1994/2063) L22 Safe use of work equipmet. Provisio ad Use of Work Equipmet Regulatios 1998 Approved Code of Practice ad guidace 1998 ISBN EIS12 Safety at maually-fed pivotig-head metal-cuttig circular saws 1998 (free) EIS7 Safeguardig 3 roll bedig machies 1998 (free) EIS13 Safeguardig of combiatio metalworkig machies 2000 (free) EIS33 CNC turig machies: Cotrollig risks from ejected parts 2001 (free) EIS2 Accidets at metalworkig lathes usig emery cloth 1993 (free) PM83 Drillig machies: guardig of spidles ad attachmets 1998 L112 ISBN Safe use of power presses. Provisio ad Use of Work Equipmet Regulatios 1998 as applied to power presses. Approved Code of Practice ad guidace 1998 ISBN HSG17 Safety i the use of abrasive wheels 2000 ISBN HSG42 Safety i the use of metal cuttig guilloties ad shears 1988 ISBN HSG43 BS EN Idustrial robot safety: Your guide to the safeguardig of idustrial robots 2000 ISBN Safety of laser products. Part 1: 1994 Equipmet classificatio, requiremets ad user s guide IEC :1993 Safety of laser products (icludig 1997 ad 2001 amedmets) EIS19 Egieerig machie tools: retrofittig CNC 1997 (free) EIS28 Safeguardig at horizotal borig machies 1998 (free) HSG236 Power presses: Maiteace ad thorough examiatio 2003 ISBN HSG180 Applicatio of electro-sesitive protective equipmet usig light curtais ad light beam devices i machiery 1999 ISBN Video Power presses Parts 1 ad ISBN X Health ad safety i egieerig workshops Page 115 of 147

116 Health ad Safety Metalworkig fluids INDG365 Workig safely with metalworkig fluids 2003 (sigle copy free; ISBN for priced packs of 10 copies) Exposure to hard metals i metalworkig fluids durig machiig operatios British Lubricats Federatio 1994, Video package available from BLF, tel: Metalworkig fluids: Effective coolat care ad the cotrol of risks to health 1994 ISBN Pack Workig safely with metalworkig fluids 2002 ISBN Noise L108 Reducig oise at work. Guidace o the Noise at Work Regulatios ISBN INDG362 Noise at work: Advice for employers (sigle copy free; ISBN for priced packs of 10 copies) INDG363 Protect your hearig or lose it! 2002 (sigle copy free; ISBN for priced packs of 25 copies) HSG138 Soud solutios: Techiques to reduce oise at work 1995 ISBN INDG201 Protect your hearig or lose it (sigle copies free; ISBN for priced packs of 25 copies) PM56 Noise from peumatic systems 1985 ISBN INDG362 (rev) Noise at work. Advice for employers 1995 (sigle copies free; ISBN for priced packs of 10 copies) EIS26 Noise i egieerig 1998 (free) EIS29 Cotrol of oise at power presses 1998 (free) Vibratio INDG126(rev1) Health risks from had-arm vibratio: Advice for employees ad the self-employed 1998 (sigle copies free; ISBN for priced packs of 15 copies) INDG175 Health risks from had-arm vibratio: Advice for employers rev 1998 (sigle copies free; ISBN for priced packs of 10 copies). HSG88 Had-arm vibratio 1994 ISBN HSG170 Vibratio solutios 1997 ISBN INDG338 Power tools: How to reduce health risks. Guide for employers (sigle copy free or priced packs of 15 ISBN ) Cleaig ad degreasig INDG98 Permit-to-work systems 1991 (sigle copies free; ISBN for priced packs of 15 copies) L101 Safe work i cofied spaces. Cofied Spaces Regulatios Approved Code of Practice, Regulatios ad guidace ISBN EIS20(rev1) Maiteace ad cleaig of solvet degreasig taks 1998 (free) EIS21 Immersio ad cold cleaig of egieerig compoets (free) GG354 Surface cleaig ad preparatio: Choosig the best optio Evirowise (see page 80) Health ad safety i egieerig workshops Page 116 of 147

117 Health ad Safety EIS40 EIS34 Safe use of solvet degreasig plat 2003 (free) Surface cleaig: Solvet update icludig the reclassificatio of trichloroethylee 2002 (free) Flamecuttig ad weldig HSG118 Electrical safety i arc weldig 1994 ISBN HSE8 Oxyge: Fire ad explosio hazards i the use ad misuse of oxyge 1992 (free) CS15 Cleaig ad gas freeig of taks cotaiig flammable residues 1985 ISBN Health ad safety i weldig ad allied processes (4th Ed) N.Balchi, Weldig Istitute 2002 ISBN (available from Woodhead Publishig, tel: ) Weldig fume: A welder s guide 1985 Weldig Istitute (available from Woodhead Publishig, Tel: ) BS EN ISO Health ad safety i weldig ad allied processes. Samplig of : 2001 airbore particles ad gases i the operator s breathig zoe British Stadards Istitutio BS EN 169: 2002 Persoal eye-protectio. Filters for weldig ad related techiques British Stadards Istitutio BS EN 166: 2002 Persoal eye-protectio. Specificatios British Stadards Istitutio BS EN 175: 1997 Persoal protectio. Equipmet for eye ad face protectio durig weldig ad allied processes British Stadards Istitutio HSG139 The safe use of compressed gases i weldig, flame cuttig ad allied processes 1997 ISBN HSG204 Health ad safety i arc weldig 2000 ISBN INDG327 Take care with acetylee 2000 (sigle copy free or priced packs of 10 ISBN X) Radiography L121 Work with ioisig radiatio. Ioisig Radiatios Regulatios Approved Code of Practice ad guidace. HSE Books 2000 ISBN IRIS1(rev1) Idustrial radiography: Maagig radiatio risks 2000 (free) IRIS2(rev1) Radiatio doses: Assessmet ad recordig 2000 (free) Radiatio safety for site radiography Egieerig Costructio Idustry Associatio tel: ISBN (o/p; updated versio due 2004) Paitig HSG51 Storage of flammable liquids i cotaiers (rev 1998) ISBN HSG140 Safe use ad hadlig of flammable liquids 1996 ISBN EH16 Isocyaates: Health hazards ad precautioary measures 1999 ISBN Code of safe practice: Applicatio of thermosettig coatig powders by electrostatic sprayig 1997 available from the British Coatig Federatio, tel: Health ad safety i egieerig workshops Page 117 of 147

118 Health ad Safety SI 2002/2776 The Dagerous Substaces ad Explosive Atmospheres Regulatios 2002 The Statioery Office ISBN INDG227 Safe workig with flammable substaces (sigle copies free; ISBN X for priced packs of 15 copies) EIS15 Cotrol of exposure to triglycidyl isocyaurate (TGIC) i powder coatigs 1998 (free) HSG178 The sprayig of flammable liquids 1998 ISBN Offices INDG236 INDG36(rev1) L26 INDG173 HSG90 Maitaiig portable electrical equipmet i offices ad other low risk eviromets (sigle copies free; ISBN for priced packs of 10 copies) Workig with VDUs 1998 (sigle copies free; ISBN for priced packs of 10 copies) Work with display scree equipmet. Health ad Safety (Display Scree Equipmet) Regulatios 1992 as ameded by the Health ad Safety (Miscellaeous Amedmets) Regulatios Guidace o Regulatios (Secod editio) HSE Books 2003 ISBN Officewise 1994 (sigle copies free; ISBN for priced packs of 10 copies) The law o VDUs: A easy guide. Make sure your office complies with the Health ad Safety (Display Scree Equipmet) Regulatios 1992 (as ameded 2002) 2003 ISBN Accidets ad emergecies L74 First aid at work. Health ad Safety (First Aid) Regulatios Approved Code of Practice ad guidace 1997 ISBN Form F2508/ Report of a ijury or dagerous occurrece or case of disease Form F2508A 1996 ISBN L73 Guide to the Reportig of Ijuries, Diseases ad Dagerous Occurreces Regulatios ISBN HSE31(rev1) RIDDOR explaied 1999 (sigle copies free; ISBN for priced packs of 10 copies) INDG214 First aid at work your questios aswered 1997 (sigle copies free; ISBN for priced packs of 15 copies) INDG215 Basic advice o first aid at work 2002 (sigle copies free; ISBN for priced packs of 20 copies) While every effort has bee made to esure the accuracy of the refereces listed i this publicatio, their future availability caot be guarateed. Health ad safety i egieerig workshops Page 118 of 147

119 Health ad Safety HSE offices (See for up-to-date list of HSE local offices) Health ad safety i egieerig workshops Page 119 of 147

120 Health ad Safety Some useful addresses for selectig a health ad safety cosultacy Associatio of Cosultig Egieers Alliace House, 12 Caxto Street Lodo SW1H OQL Associatio of Noise Cosultats 6 Trap Road, Guide Morde, Herts SG8 OJE British Occupatioal Hygiee Society Georgia House, Great Norther Road Derby DE1 1LT British Safety Coucil Chacellors Road, Lodo W6 9RS Chartered Istitute of Buildig Services Egieers Delta House, 222 Balham High Road Lodo SW12 9BS Coucil of Idepedet Ispectig Authorities 14 St Mary s Parsoage, Machester M60 9AP EEF. The Maufacturers Orgaisatio Broadway House, Tothill Street Lodo SW1H 9NQ The Egieerig Society Devoshire House, Devoshire Square Loughborough, Leics LE11 3DW Idepedet Safety Cosultats Associatio c/o Hito ad Higgs, The Firs Marcham Road, Abigdo, Oxo OX14 1AA The Istitute of Acoustics PO Box 320, St Albas, Herts AL1 19Z The Istitute of Chemical Egieers Railway Terrace, Rugby, Warwicks CV21 3HQ The Istitutio of Electrical Egieers Savoy Place, Lodo WC2R OBL The Istitute of Evirometal Health Officers Chadwick House, Rushworth Street Lodo SE1 OQT British Istitute of No-Destructive Testig 1 Specer Parade, Northampto NN1 5AA The Istitutio of Mechaical Egieers 1 Birdcage Walk, Lodo SW1 9JJ The Istitute of Occupatioal Hygieists Georgia House, Great Norther Road Derby DE1 1LT The Istitute of Occupatioal Safety & Health The Grage, Highfield Drive Wigsto, Leics LE18 1NN The Istitute of Radiatio Protectio 64 Dalkeith Road, Harpede, Herts AL5 5PW The Royal College of Nursig Society of Occupatioal Health Nursig RCN North Wester Area, 18 Fox Street Presto, Lacs PR1 2AB The Royal Evirometal Health Istitute of Scotlad 3 Maor Place, Ediburgh EH3 7DH The Royal Society of Chemistry Burligto House, Piccadilly, Lodo W1V OBN The Royal Society for the Prevetio of Accidets Edgbasto Park, 353 Bristol Road, The Health ad safety i egieerig workshops Page 120 of 147

121 Health ad Safety Priory, Queesway, Birmigham B5 7ST The Society of Occupatioal Medicie 6 St Adrew s Place, Regets Park Lodo NW1 4LB The Society for Radiological Protectio 148 Buckigham Palace Road Lodo SW1W 9TR Natioal Certificatio Scheme for I-Service Ispectio Bodies (NCSIIB) 1 Birdcage Walk, Westmister Lodo SW1H 9JJ Key referece: Need help o health ad safety? INDG322 HSE Books (sigle copies free; ISBN for priced packs of 15) Health ad safety i egieerig workshops Page 121 of 147

122 Health ad Safety Appedix 1 Liftig checklist Sectio A Summary of assessmet Operatios covered by this assessmet: Overall priority for remedial actio: Nil/Low/Med/High Remedial actio to be take: Locatios: Persoel ivolved: Date by which actio is to be take: Date for reassessmet: Assessor s ame: Date of assessmet: Sigature: Sectio A Prelimiary: Q1 Do the operatios ivolve a sigificat risk of ijury? Yes / No If Yes go to Q2. If No the assessmet eed go o further. If i doubt aswer Yes Q2 Ca the operatios be avoided/mechaised/automated at reasoable cost? Yes / No If No go to Q3. If Yes proceed ad the check that the result is satisfactory. Q3* Are the operatios clearly withi the umerical guidelies for assessmet cotaied i the guidace o the Maual Hadlig Regulatios (pages 60 62)? Yes / No If No go to Sectio B. If Yes you may go straight to Sectio C if you wish. * This questio ca oly be aswered by usig pages of the publicatio refereced below. Sectio C Overall assessmet of risk: Q What is your overall assessmet of the risk of ijury? Isigificat/Low/Med/High If ot Isigificat go to Sectio D. If Isigificat the assessmet eed go o further. Sectio D Remedial actio: Q What remedial actio should be take, i order of priority? i... ii... iii... iv... v... Ad fially: complete the SUMMARY above compare it with your other maual hadlig assessmets decide your priorities for actio TAKE ACTION...AND CHECK THAT IT HAS THE DESIRED EFFECT Key referece: Maually Hadlig Operatios Regulatios Guidace o Regulatios L23 (Secod editio) HSE Books ISBN Health ad safety i egieerig workshops Page 122 of 147

123 Health ad Safety Sectio B Sectio B More detailed assessmet, where ecessary: Questios to cosider: (If the aswer to a questio is Yes place a tick agaist it ad the cosider the level of risk) The tasks do they ivolve: holdig loads away from the truk? twistig? stoopig? reachig upwards? large vertical movemet? log carryig distaces? streuous pushig or pullig? upredictable movemet of loads? repetitive hadlig? isufficiet rest or recovery? a work-rate imposed by a process? Level of risk: (Tick as appropriate) Yes Low Med High Possible remedial actio: (Make rough otes i this colum i preparatio for completig Sectio D) The loads are they: heavy? bulky/uwieldy? difficult to grasp? ustable/upredictable? itrisically harmful (eg sharp/hot)? The workig eviromet are there: costraits o posture? poor floors? variatios i levels? hot/cold/humid coditios? strog air movemets? poor lightig coditios? Idividual capability does the job: require uusual capability? pose a risk to those with a health problem? pose a risk to those who are pregat? call for special iformatio/traiig? Other factors Is movemet or posture hidered by clothig or persoal protective equipmet? Decidig the level of risk will ievitably call for judgemet. Whe you have completed Sectio B go to Sectio C. Health ad safety i egieerig workshops Page 123 of 147

124 Health ad Safety Checkig whether hadlig problems are causig upper limb disorders Compay/Departmet: Workstatio: Completed by: Task: Worker: Date: Risk factor Tick your aswer Actio required NO YES Does your job ivolve a lot of: FREQUENT grippig (a tool or workpiece)? or squeezig (eg tool hadles)? FORCEFUL twistig? or reachig? If you have o ticks i the YES colum o this page, you are ulikely to have ay hadlig problems caused by work. You eed ot go o to the followig questios. AWKWARD movig thigs (pushig, pullig, liftig)? figer/had movemet (eg keyboard work)? Are there ay warig sigs of had/shoulder/ eck problems? For example: Actual cases i this or similar work? However, if you have ay ticks i the YES colum o this page, there may be a risk i your workplace. You should go o to do the full risk assessmet. Complaits by workers, eg aches ad pais i hads, wrists, arms, shoulders etc? Ask your employees if they have ay of these symptoms. Home-made, improvised chages to work-statios or tools (eg hadles cushioed or made loger)? Health ad safety i egieerig workshops Page 124 of 147

125 Health ad Safety RISK FACTOR FULL RISK ASSESSMENT Are there ay factors i the job that make ULDs likely, such as: Is risk preset? NO YES Need for a lot of force Does the job ivolve: strog force at the same time as awkward movemets or posture, eg bet wrists, work with arms raised or fully exteded? forceful use of had/forearm muscles? tryig to make do with ill-fittig compoets by forcig them ito place? tools ot ideal for repetitive or frequet use particularly if squeezig, twistig, or hammerig actios are required? usig equipmet desiged for a larger or stroger perso (eg wome usig tools desiged for me)? Rapid, awkward or frequet movemet Does the job ivolve: machie pacig, eg to keep up with coveyor? frequet repetitio of the same small umber of movemets? awkward movemets such as twistig or rotatio of wrist, movemet of wrist from side to side, very bet figers ad wrist, or had or arm movemets beyod a comfortable rage? pressures o employees to work fast, eg from piecework or bous systems? Health ad safety i egieerig workshops Page 125 of 147

126 Health ad Safety POSSIBLE SOLUTIONS RECOMMENDATION FOR ACTION Tick whe actio take Redesig workstatios, eg: Repositio supply of compoets to reduce reachig required. Move cotrols to more coveiet positio. Redesig job, workstatio, ad/or tools to avoid overuse of the had or forearm. Maitai tools, eg keep them sharp ad lubricated, for ease of use. Improve quality of compoets, or provide suitable tools for fittig them. Replace domestic or DIY had tools with tools desiged for repetitive idustrial use. Redesig tool hadles to achieve eve distributio of force across had (power grip preferable to pich grip) ad straight rather tha bet wrists. Cosider replacig had tools with power tools. Reduce squeezig forces by usig weaker sprigs to triggers etc. Redesig equipmet or tool (eg couter-balacig to reduce force required). Provide powered versio. Self pacig is preferable. Repla work, eg to break up pause/repetitio cycles or spread movemet across both hads. Cosider addig extra activities to job, to give variety. Cosider scope for automatio or use of power tools. Redesig workstatio, cotrols or shape of tool hadles. Cosider eed for such systems (but employees may resist chage). Better traiig i risks may help. Health ad safety i egieerig workshops Page 126 of 147

127 Health ad Safety RISK FACTOR Is risk preset? NO YES Awkward or static posture Does the job ivolve: cramped body positio, ad/or ot eough space to chage posture? arms stretched or overhead for log periods? work at awkwardly high or low height (crouchig, stoopig, or reachig up)? Work for log periods without breaks or chages of activity Does the job ivolve: o chages to work routie or variatio of tasks? o breaks or ifrequet breaks? worker ot able to have short pauses whe desired? No special arragemets for ew employees (or those returig to work after a log break) Does the job ivolve: people havig to work at full pace as soo as they start (or resume) the job? o traiig i risks ad ways employees ca reduce risks? Poor evirometal coditios Is work carried out: i dim light, shadow or flickerig light? i cold or otherwise adverse coditios? with tools that vibrate? Health ad safety i egieerig workshops Page 127 of 147

128 Health ad Safety POSSIBLE SOLUTIONS RECOMMENDATION FOR ACTION Tick whe actio take Improve space available to worker. Provide adjustable workstatio (especially chair) for workers who are above or below average height or shape. Move materials or cotrols to more coveiet positio. Move materials or cotrols to more coveiet positio. If possible, vary tasks to provide chages i activity. If ot, check there are adequate rest breaks. Check that breaks are take, especially if work ivolves cotiuous effort such as holdig tools, or rapidly repeated movemets (eg typig). Redesig work to make short pauses possible. Allow recruits to build up their work rate sesibly as they gai experiece. Provide traiig i skills, posture, ad warig symptoms for all those at risk. Provide better lightig so that workers do ot have to adopt awkward postures to see properly. Cold (eg i hadlig froze foods) may icrease the risk. If it is ot possible to warm the workig eviromet, check that protective clothig is well desiged ad does ot affect posture or grip. Cosider whether the job ca be doe aother way to avoid eed for high-vibratio tools. Or provide vibratio-absorbig grip ad miimise vibratio by proper maiteace. Health ad safety i egieerig workshops Page 128 of 147

129 Health ad Safety Appedix 2 Metalworkig fluids questioaires Questioaire for detectio of ski abormalities To be completed by the employee NAME:... DATE:... DATE OF BIRTH:... JOB TITLE:... COMPANY:... 1 Sice your last review or i the last 12 moths have you had ay of the followig symptoms? (a) redess ad swellig of figers or hads; Yes No (b) crackig of ski o figers or hads; Yes No (c) blisters o figers or hads; Yes No (d) flakig or scalig of ski o figers or hads; Yes No (e) itchig of figers or hads with ski cracks or splits; Yes No (f) spots, redess, swellig of ay other part; Yes No 2 Did these problems last for more tha three weeks? Yes No 3 Did these problems occur more tha oce? Yes No 4 Does your ski get better with periods off work? Yes No 5 Have you lost time from work with ski problems sice your last Yes No assessmet? 6 Do you thik you kow what causes the problems? Yes No 7 Name the substace/material/cotact you thik is resposible: To be completed by the resposible perso: 8 Problems cofirmed by the resposible perso? Yes No 9 Actio take: Name of resposible perso: Date: Footote: Ay abormalities foud should be referred to the works occupatioal health physicia or urse if there is oe. If ot, employees should be advised to cosult their geeral practitioer. I either case, referral to a cosultat dermatologist may be appropriate. A copy of this completed questioaire should be supplied to the employee s geeral practitioer. Health ad safety i egieerig workshops Page 129 of 147

130 Health ad Safety Questioaire for detectio of lug problems To be completed by the employee NAME:... DATE:... DATE OF BIRTH:... JOB TITLE:... COMPANY:... Sice your last review or i the last 12 moths: 1 Have you had ay episodes of wheezes or chest tightess? Yes No If yes, at what time(s) of day? 2 Have you take ay treatmet for your chest? Yes No 3 Have you woke at ight with cough or chestiess? Yes No 4 Have you had ay episodes of breathlessess? Yes No If yes, at what time(s) of day? 5 Have you had ay time off work with chest disease? Yes No 6 Have you developed chest tightess or breathlessess after exercise? Yes No 7 Have you developed difficulty with breathig? Yes No If yes, at what time(s) of day? To be completed by the resposible perso: 8 Problems cofirmed by the resposible perso? Yes No 9 Actio take: Name of resposible perso: Date: Footote: If the aswer is yes to ay of these questios, the employee should be referred to the works occupatioal health physicia or urse if there is oe. If ot, employees should be advised to cosult their geeral practitioer. I either case, referral to a cosultat chest physicia may be appropriate. A copy of this completed questioaire should be supplied to the employee s geeral practitioer. Health ad safety i egieerig workshops Page 130 of 147

131 Health ad Safety Appedix 3 Work equipmet risk assessmet You may wish to use the proforma below to assess aspects of machiery safety as part of your risk assessmet. Where further actio is idicated, you should record what is doe as a result. Do t forget to make sure that you also cosider fully ay risks to health that may arise as a cosequece of usig the equipmet beig assessed. For mobile work equipmet, additioal requiremets will apply (see pages 31 32) Geeral equipmet descriptio DESCRIPTION:... LOCATION:... PLANT/REF No:... NAME OF ASSESSOR:...DATE OF ASSESSMENT:... Geeral descriptio of work equipmet, icludig details of acillary equipmet where relevat: Iteded fuctio of work equipmet: Assessmet of suitability for iteded fuctio: Health ad safety i egieerig workshops Page 131 of 147

132 Health ad Safety Work equipmet risk assessmet 1 Guardig of dagerous parts. Is access possible to ay part of machiery that could cause ijury? Machie part Locatio Part of body at risk Estimated ijury For the parts idetified above, what method of safeguardig is ecessary to miimise the risk? Machie part Fixed guard Other guard Other (jigs, holders etc) Where guards are curretly provided, do they satisfy the followig criteria? (Y/N) Guard/ device Suitable? Of good costructio Easily by-passed or disabled? Adequate distace from dager? Adequate view (if eeded)? Access oly for maiteace? Health ad safety i egieerig workshops Page 132 of 147

133 Health ad Safety 2 Maiteace What maiteace is eeded for guards ad protectio devices? Guards/protectio device Maiteace required Frequecy 3 Ispectio Is ispectio of the work equipmet ecessary? Ispectio required (Y/N) Details of ispectio Frequecy 4 Iformatio, istructio ad traiig What iformatio, istructio ad traiig must be provided for the followig groups? Operators Maiteace staff Maagers/supervisors Health ad safety i egieerig workshops Page 133 of 147

134 Health ad Safety 5 Other hazards What actio is eeded i respect of the followig possible additioal hazards? NOTE: The list i the table below is ot exhaustive ad is iteded as a GUIDE ONLY Hazard Occurrig? (Y/N) Actio required to miimise risk Ay article or substace fallig or beig ejected from the machie A rupture or disitegratio Overheatig or fire Uitetioal or premature discharge of dust, gas, liquid, vapour or other substace Ay part of the machie at a high or low temperature likely to cause ijury Ay other hazards? 6 Emergecy stop cotrols Is a suitable desig of emergecy stop cotrol located at appropriate cotrol ad operatig poits? Idetified cotrol/operatig poits Type of emergecy to stop cotrol 7 Isolatio How is the machie isolated or locked off from the followig eergy sources (where relevat)? Eergy source Method of isolatio Electricity Compressed air or gas Hydraulic Steam Other (eg gravity fall) Health ad safety i egieerig workshops Page 134 of 147

135 Health ad Safety 8 Cotrols Yes/No If o, what actio is required? Are cotrols clearly visible, idetifiable ad clearly marked where ecessary? Are cotrols located to esure that operators are ot exposed to risk? Ca the operator see ay other perso who may be exposed to risk whe the cotrols are operated? Are there systems of work to esure that o oe is likely to be at risk whe the machie starts? Are there suitable audible, visible or other warigs (if eeded)? 9 Workplace eviromet Yes/No If o, actio required? Is there adequate atural ad artificial light? Is lightig of cotrols satisfactory, without glare? Is lightig of parts of the machie that have to be viewed adequate? Is the workplace temperature i a rage of comfort for operators? Is suitable seatig required? Is there adequate space aroud the machie to allow safe ad easy access? Is storage for machie parts ad special tools eeded? Are fire extiguishers eeded close to the machie if so, what type? Health ad safety i egieerig workshops Page 135 of 147

136 Health ad Safety 10 Persoal protective equipmet (PPE) Yes/No If o, what actio required? Is PPE ecessary? If yes, what type? Are operators aware that PPE is required? Do operators kow how PPE should be wor? Is local storage ecessary ad provided? Is PPE subject to routie maiteace? 11 Safety sigs ad warigs Are adequate sigs fitted to the machie as follows? Yes/No If o, actio required? Hazardous surfaces Hazardous materials Hazardous parts or their movemet Prohibited actios Correct operatio Persoal protective equipmet (PPE) Emergecy actio Health ad safety i egieerig workshops Page 136 of 147

137 Health ad Safety Appedix 4 Key stadards for egieerig workshops To help desigers ad maufacturers of ew machies meet essetial health ad safety requiremets (see page 49 51), a rage of Trasposed Harmoised Stadards (BS ENs) has bee developed to offer four levels of guidace: A stadards o basic safety cocepts ad desig priciples commo to all machiery B1 stadards o basic safety aspects such as safety distaces ad oise B2 stadards o safety related devices such as guards ad iterlockig devices, ad C stadards which iterpret A ad B stadards ad give safety requiremets for a particular type or group of machies pr EN stadards are BS ENs uder developmet, available from BSI (see page 110) For machies used i egieerig workshops C stadards are plaed for the commoest metalworkig machies icludig mechaical, hydraulic ad peumatic presses ad press brakes; gridig machies of all kids; horizotal ad vertical turig machies, both CNC ad maually operated; machiig cetres, drillig, millig ad borig machies of all types; ad metalcuttig saws ad electro-discharge machies. These stadards will also be relevat to users of existig machiery to help them assess risks ad decide whether safeguards are adequate. Stadard ad title BS EN 292 : Part 1 : 1991 Safety of machiery. Basic cocepts, geeral priciples for desig BS EN 292 : Part 2 : 1991 Safety of machiery. Techical priciples ad specificatios Key cotets ad requiremets 1 Describes machiery hazards, defies safety terms, requires desigers to assess risks, remove or cotrol them. 2 All hazards from mechaical, electrical, thermal, oise, vibratio, radiatio, materials or ergoomic sources icludig ay combiatio, have to be cosidered over the lifetime of the machie. 1 Describes methods to reduce risks by desig. 2 Advises o selectio, desig ad costructio of safeguards for hazards which caot be elimiated by desig. 3 Describes iformatio for use to be provided for users by suppliers. Health ad safety i egieerig workshops Page 137 of 147

138 Health ad Safety BS EN 1050 : 1997 Safety of machiery. Risk assessmet BS EN Safety of machiery. Electrical equipmet of machies Part 1: Geeral requiremet BS EN 953 : 1998 Safety of machiery. Guards (fixed, movable) BS EN 1088 : 1996 Safety of machiery. Iterlockig devices with ad without guard lockig 1 Advises o the idetificatio of hazards ad provides criteria for assessig risks ad selectig safety measures cosistet with techical ad ecoomic restraits. 2 Outlies qualitative ad quatitative risk assessmet techiques ad risk reductio measures. 1 Applies to low voltage equipmet (1000vAC ad 1500vDC, ot exceedig 200Mz) from the poit of supply to its use at the machie. 2 Covers protectio agaist electric shock, measures to protect equipmet agaist overcurret, overspeed, overload ad from the eviromet, restartig a hazardous operatio from loss of power, geeral requiremets, electrical cotrols, the accessibility, layout ad idetificatio of cotrols, ergoomic requiremets for electrical cotrols, requiremets for cablig, wirig, accessories, lightig, documetatio ad testig. 1 Cotais defiitios of differet types of guard. 2 Sets requiremets for whe to use a particular type of guard ad how to desig guards to miimise hazards. 1 Defies basic cocepts ad geeral priciples for iterlockig devices cotrollig ay power source. 2 Specifies requiremets for electrical iterlockig devices, ad parts of guards which activate iterlockig devices. BS EN 294 : 1992 Safety of machiery. Safety distaces to prevet dager zoes beig reached by upper limbs BS EN 349 : 1993 Safety of machiery. Miimum distaces to avoid crushig parts of the huma body BS EN : 1995 Safety of machiery. Reductio of risks from hazardous substaces emitted by machiery Part 1: Priciples ad specificatios for machie maufacturers BS 5304 : 1988 Safety of machiery 1 Two values are give for reachig up to dager zoes ad two tables for reachig over protective structures. 2 Desiger must decide what is to be used depedig o whether situatios are high or low risk. 3 Stadard is ot cocered with prevetig climbig over barriers; 1800 mm may be sufficietly high for this. 1 Describes factors to be take ito accout i the assessmet to prevet crushig oly. 2 Miimum gaps for whole body, leg, head, foot, toes, arm, had, ad figer are give i a illustrated table. 3 Aex A (Iformative) illustrates three typical crushig zoes at a millig machie table. 1 Cotais iformatio o the types of hazards to be cosidered, with examples. 2 Aex A (Iformative) provides examples of how exposure to hazardous substaces may be reduced by elimiatig or reducig risks. A o-harmoised stadard cotaiig may useful priciples ad examples of safeguardig for machiery which is beig progressively replaced by harmoised stadards. Health ad safety i egieerig workshops Page 138 of 147

139 Health ad Safety Useful defiitios from BS EN 292: Part 1: 1991 Safety of a machie The ability of a machie to perform its fuctio, to be trasplated, istalled, adjusted, maitaied, dismatled ad disposed of, uder coditios of iteded use, without causig ijury or damage to health. Hazard A source of possible ijury or damage to health. Risk A combiatio of the probability ad degree of the possible ijury or damage to health i a hazardous situatio. Risk assessmet A comprehesive estimatio of the probability of possible ijury or damage to health i a hazardous situatio i order to select appropriate safety measures. Dager zoe Ay zoe withi ad/or aroud machiery i which a perso is exposed to risk of ijury or damage to health. Safety device Device (other tha a guard) which elimiates or reduces risk, aloe or with a guard. Iterlockig device Mechaical, electrical or other type of device, the purpose of which is to prevet the operatio of machie elemets uder specified coditios (geerally as log as guard is ot closed). Hold-to-ru cotrol device Cotrol device which iitiates ad maitais operatio of machie elemets oly as the maual cotrol (actuator) is actuated. The actuator returs automatically to the stop positio whe released. Guard Part of a machie specifically used to provide protectio by meas of a physical barrier. Fixed guard Guard kept i place (ie closed) either permaetly (eg by weldig) or by meas of fasteers (screws, uts etc) makig removal/opeig impossible without usig tools. Movable guard Guard geerally coected to the machie by mechaical meas (eg higes or slides) which ca be opeed without tools. Adjustable guard Fixed or movable guard which is adjustable as a whole or which icorporates adjustable part(s). The adjustmet remais fixed durig a particular operatio. Iterlockig guard Guard associated with a iterlockig device so that: the hazardous machie fuctio covered by the guard caot operate util the guard is closed if the guard is opeed while hazardous machie fuctios are operatig, a stop istructio is give Health ad safety i egieerig workshops Page 139 of 147

140 Health ad Safety whe the guard is closed, the hazardous machie fuctios covered by the guard ca operate, but the closure of the guard itself does ot iitiate their operatio. (To achieve this would require a cotrol guard.) Guard lockig with iterlockig Prevets the opeig of a iterlockig guard util hazardous motios are stopped, ad their restart util the guard is locked. Safeguard A guard or safety device. Two-had cotrol device Hold-to-ru cotrol device which requires at least the simultaeous operatio of two maual cotrols (actuatio) i order to trigger ad maitai operatio of the machie or machie elemets, thus affordig a measure of protectio for the perso operatig the actuators. Defiig hazards Hazards at machiery may arise from: mechaical movemets, such as shearig electricity heat oise vibratio radiatio substaces beig used eglectig ergoomic priciples i desig combiatios of hazards failures of eergy supply missig safety measures, ad beig trapped iside. Eablig (cotrol) device Additioal maually operated cotrol device used i cojuctio with a start cotrol ad which, whe cotiuously actuated, allows a machie to fuctio. Trip device Device which causes a machie or machie elemets to stop (or esures a otherwise safe machie coditio) whe a perso or a part of a body goes beyod a safe limit. Trip devices may be: mechaically actuated, eg trip wires, telescopic probes, pressure sesitive devices etc o-mechaically actuated, eg photo-electric devices, devices usig capacitive, ultra-soic etc meas to achieve detectio. Health ad safety i egieerig workshops Page 140 of 147

141 Health ad Safety Appedix 5 Fire-resistat materials for DIY spray booths Effective segregatio, vetilatio ad prevetio of igitio ca be achieved i homemade spray booths, but with professioal ad competet advice. Segregatio The separatio or isolatio should be fire resistat. Some examples of floor, wall ad door costructio that will provide a stadard of half-hour fire resistace are: Floors Plai edge boardig o timber joists ot less tha 38 mm wide with a ceilig of 12.5 mm plasterboard ad 12.5 mm gypsum plaster. Togued ad grooved boardig ot less tha 16 mm thick o timber joists ad ot less tha 38 mm wide with a ceilig of 12.5 mm miimum of plasterboard ad a skim coat of gypsum plaster. Plai edge boardig o timber joists ot less tha 38 mm wide with a ceilig of timber lath ad plaster, the plaster at least 16 mm thick, covered o the uderside with a 12.5 mm thickess of plasterboard. Walls 100 mm brick (uplastered). 50 mm woodwool slabs plastered at least 12.5 mm thick o both sides, framed costructio (o load-bearig). Steel or timber studdig with 12.5 mm portlad cemet plaster, portlad cemet/lime plaster or gypsum plaster o metal or timber lathig (o load-bearig coditios oly). Steel or timber studdig with 9.5 mm thick plasterboard o each side with the exposed facig of the boardig plastered with 5 mm thick eat gypsum plaster (o load-bearig coditios oly). Where existig walls or partitios are ot fire-resistig costructios, the stadard ca be achieved by addig 12.5 mm plasterboard; esure that the joits betwee the overlap are formed over the supportig framework or otherwise suitably costructed. Doors Fit: The door should be reasoably straight ad true ad lie flush agaist the stop whe closed; the gap betwee the door edge ad the frame should ot exceed 3 mm. Door frame: Should have a rebate or stop ot less tha 25 mm deep; existig plated stops may be replaced or additioal material screwed or pied ad glued o. Door furiture: Oe pair of metal higes, all parts of which are o-combustible ad have a meltig poit ot less tha 800º. Glazig: Ay plai glazig should be replaced by, or backed with, 6 mm wire reiforced glass ot exceedig 1.2m 2 i area ad fitted with solid wood beadig ot less tha 13 mm i cross sectio. Health ad safety i egieerig workshops Page 141 of 147

142 Health ad Safety Flush doors*: 6 mm wallboard cover to both sides of the door; fixig to be 32 mm screws at approximately 300 mm cetres, or aular ails at approximately 200 mm cetres, drive ito solid timber. Pael, framed, ledged ad braced doors*: Protectio as for flush doors to both faces of the door; or, if protectio agaist fire is eeded from oe side oly, the 9 mm isulatig board fixed to room-risk side of the door, as above, with the paels first made up with tightly fittig cutouts of plasterboard or solid wood. Electrics Uprotected electrical equipmet must be kept outside spray booths. Istall lights outside booths ad shie them through fixed ad sealed fire-resistig wired glass paels. Use oly explosio protected electrical equipmet iside the booth. * The importace of fixig caot be over-emphasised. Additioal material must be so fixed to the existig door that, uder coditio of fire where thermal movemet is likely to take place betwee the door ad protective material, the screws or ails are ot stressed so that they are pulled out. Health ad safety i egieerig workshops Page 142 of 147

143 Health ad Safety Appedix 6 Record of examiatio ad test of local exhaust vetilatio (LEV) plat A suitable record cotaiig at least the followig particulars should be kept i respect of each thorough examiatio ad test of LEV plat: (a) Name ad address of employer resposible for the plat (b) Idetificatio ad locatio of the LEV plat, process, ad hazardous substace cocered (c) Date of last thorough examiatio ad test (d) Coditios at time of test; ormal productio or special coditios (eg maximum use, stood dow) (e) Iformatio about the LEV plat which shows: (i) its iteded operatig performace for cotrollig the hazardous substace (ii) whether the plat ow still achieves the same performace (iii) if ot, the repairs required to achieve that performace (f) Methods used to make judgemet at (e)(ii) ad (e)(iii) above (eg visual, pressure measuremets, air flow measuremets, dust lamp, air samplig, filter itegrity tests) (g) Date of examiatio ad test (h) Name, desigatio ad employer of perso carryig out examiatio ad test (i) Sigature or uique autheticatio of perso carryig out examiatio ad test (j) Details of repairs carried out. Health ad safety i egieerig workshops Page 143 of 147

144 Health ad Safety Appedix 7 Aswers to frequetly asked questios about work i egieerig workshops Questio Is it all right to work aloe i the workshop? What are the rules o smokig? Aswer It would ot geerally be reasoable for employers to permit employees to work aloe, because there is usually some dagerous machiery about. (Fatal accidets have occurred followig etaglemets o cetre lathes which may have bee preveted had there bee aother perso to switch off the machie ad help the trapped worker.) However, if just low-risk work such as assembly or some cleaig is beig plaed, the provided other risks are miimised ad a system of checkig or lie of commuicatio established, it would be reasoable for a employee to work aloe. See page 6 o how to maage safety. Smokig should ot be permitted where flammable liquids are used, or aywhere ear degreasig operatios. Also, smokig may make ay dust, fume, mist or vapour more harmful if ihaled. There is also a slight geeral health risk to o-smokers from tobacco smoke i the workshop ad offices. Employers should develop a policy to miimise this risk. Rest room arragemets must protect o-smokers from discomfort caused by tobacco smoke. Health ad safety i egieerig workshops Page 144 of 147

145 Health ad Safety Questio Do I eed to keep a accidet book? Aswer No, but you eed to record details of accidets ad occurreces which must be reported (see page ). You may use the DSS B1510 Accidet Book, aother book or a computer to record the followig details: date ad time of accidet or occurrece full ame ad address of the perso ivolved ad the ijury or coditio suffered where the accidet or occurrece happeed a brief descriptio of the circumstaces i the case of a reportable disease the date of diagosis, the occupatio of the perso cocered ad the ame or ature of the disease. Keep the above iformatio for at least three years. What ca youg people do i the workshop? Employmet of childre uder 13 is forbidde, ad childre uder this age should ot ormally be allowed i a egieerig workshop. Childre over 13 but uder miimum school leavig age may oly work uder a official work experiece scheme. Youg people uder 18 are ofte exposed to risks to their health ad safety whe usig work equipmet as a cosequece of their immaturity, lack of experiece, ad absece of awareess of existig or potetial risks. Traiig ad proper supervisio of youg people is therefore of particular importace. If you employ a youg perso, the maagemet regulatios require you to assess risks to them before they start work, takig the above factors ito accout. You must use the risk assessmet to determie whether the youg perso should be prohibited from certai work activities, except where ecessary for their traiig. Health ad safety i egieerig workshops Page 145 of 147

146 Health ad Safety Questio Aswer Youg people should ot for example be allowed to use high-risk liftig machiery uless they have the ecessary maturity ad competece ad have successfully completed appropriate traiig. Your risk assessmet may idicate that similar prohibitios are appropriate for high-risk machies such as presses, guilloties ad millig machies. Sufficiet traiig ad adequate supervisio should, of course, be provided for all work for all employees. Do wome have to be treated differetly i the workshop? I geeral o, but where work with lead or ioisig radiatios is cocered, their work eeds careful assessmet so that it ca be maaged properly to prevet udue risks to ubor childre. What otices do I have to put up? The oly otice ow required to be displayed is the Health ad Safety Law poster (or a approved leaflet cotaiig the same iformatio ca be give to each employee) Electric shock ad first-aid at work placards are o loger required to be displayed by law but cotai advice for use i emergecies. The above posters may be obtaied from HSE Books i a ecapsulated format. What breaks are workers etitled to, ad what hours of work are required? A worker is etitled to a uiterrupted break of 20 miutes whe daily workig time is more tha six hours. Additioally, a worker is etitled to a rest period of 11 cosecutive hours betwee each workig day ad to a uiterrupted rest period of ot less tha 24 hours withi each 7-day period. The weekly workig time for a worker must ot exceed 48 hours per week, averaged over a 17-week period. Workers may idividually or collectively sig a agreemet with their employer to work over this limit. The ormal hours of ight workers must ot exceed a average of 8 hours for each 24 hours over a 17-week period. Key refereces: Youg people at work: A guide for employers HSG165 HSE Books ISBN New ad expectat mothers at work: A guide for employers (Secod editio) HSG122 HSE Books ISBN Health ad safety i egieerig workshops Page 146 of 147

147 Health ad Safety Questio Aswer Are eye tests required for users of VDUs? Users, ad those to become users, ca request a eye ad eyesight test that you have to pay for, if they are your employees. If the test shows they eed glasses specifically for their VDU work, you have to pay for a basic pair of frames ad leses. Users are etitled to further tests at regular itervals after the first test, ad i betwee if they are havig visual difficulties which may reasoably be cosidered to be caused by their VDU work. If users ormal glasses for other work are suitable for VDU work you do t eed to pay for them. You do t have to pay for facy frames, or leses. Eye ad eyesight testig is ot a etitlemet for the self-employed. Whe settig up a system for providig users with eye ad eyesight tests, these poits might help: cotact a umber of opticias ad ask what they charge for tests ad basic glasses ask if they will come to the firm to test the users ask for stadard iformatio about each user they test, if they eed glasses for VDU work ad whe they should be re-tested tell users what arragemets you have made make sure users uderstad what you will ad wo t pay for (eg tited leses, glasses for o-vdu purposes are ot your resposibility). Key refereces: A guide to Workig Time Regulatios (free) DTI: Workig with VDUs INDG36(rev1) HSE Books (sigle copy free; ISBN for priced packs of 10) Published by HSE 03/10 Page 147 of 147