Hse.health and Safety in Engineer In Workshops

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Health and Saety

Executive

Health and safety in

engineering workshops

This is a ree-to-download, web-riendly version o HSG129 (Second

edition, published 1999). This version has been adapted or online use. The

printed version is no longer available.

Health and safety in engineering workshops describes how most serious and

frequent hazards arise, how to assess the risks involved, and how to eliminate orcontrol them.

It contains guidance from over 200 separate HSE publications in one easy to

read and follow guide as well as providing a comprehensive list of references

and other sources of help.

HSE Books


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Crown copyright 1999

First published 1995

Second edition 1999

Reprinted with amendments 2002

Reprinted 2004, 2010

ISBN 978 0 7176 1717 3

You may reuse this inormation (excluding logos) ree o charge in any ormat or

medium, under the terms o the Open Government Licence. To view the licence

visit www.nationalarchives.gov.uk/doc/open-government-licence/, write to the

Inormation Policy Team, The National Archives, Kew, London TW9 4DU, or email

[email protected].

Some images and illustrations may not be owned by the Crown so cannot be

reproduced without permission o the copyright owner. Enquiries should be sent [email protected].

This guidance is issued by the Health and Saety Executive. Following the guidance

is not compulsory and you are ree to take other action. But i you do ollow the

guidance you will normally be doing enough to comply with the law. Health and

saety inspectors seek to secure compliance with the law and may reer to this

guidance as illustrating good practice.

2004 Reprint

In general, the amendments included in this reprint relect updated publications andregulations. The overall guidance has not changed.

HSE grateully acknowledges the help o El Oil Industrial Lubricants Division in the

preparation o the cover illustration.


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Health and Saety

Executive

Foreword 5

Managing health and saety 6

How most accidents and cases o work-related ill health arise 7

Instant action checklist 9

How to use this book to start your risk assessment 10

Five steps to risk assessment 12

Working in and moving around the workshop 14

Lighting 16General ventilation, temperature and toilets 17

Liting equipment 19

Moving goods saely by hand 20

How to lit saely 21

Liting and handling 22

Ergonomic machine operation, assembly and packing 25

Moving vehicles saely 27

Lit trucks 28

Controlling hazardous substances 30

Local exhaust ventilation (LEV) 32

Electricity 34

Portable electrical equipment 35Common problems with lexible leads, their plugs and sockets and how to avoid

them 37

Pressurised plant and systems 39

Machining 40

Computer controlled (CNC) machining 43

Buying and selling machinery 45

Metalworking luids 48

Noise 51

Vibration 57

Milling and machining centre work 58

Drilling (and reaming) 60

Pressing 62Turning 64

Grinding 66

Sawing 68

Bending 69

Guillotining 70

CNC punch pressing 72

Combination metalworking machines 73

Horizontal boring machines 74

Cleaning and degreasing 75

Vapour degreasing tanks 76

Welding and lamecutting 78Fume control 80

Saety measures at resistance welding machines 82

Lasers used or welding and cutting 83

Contents


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Radiography 84

Painting 85

Spray painting booths and enclosures 87

Paints containing isocyanates 89

Powder coating 90

Personal protective equipment (PPE) 92

Oices 94

Organising health and saety 96

Accidents and emergencies 98

First aid 101

How to obtain publications and urther assistance 102

Further reading and inormation 104

HSE oices 112Some useul addresses or selecting a health and saety consultancy 112

Appendices

Liting checklist 114

Metalworking luids questionnaires 121

Work equipment risk assessment 123

Key standards or engineering workshops 129

Fire-resistant materials or DIY spray booths 133

Record o examination and test o local exhaust ventilation (LEV) plant 135

Answers to requently asked questions about work in engineering workshops 136


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ForewordThis guidance has been written or people who run and work in small engineering

workshops, ranging rom those who

make their own products,n

to those who

maintain and repair plant and machinery either independently or as part on

larger enterprises.

It is intended to help them manage their own health and saety and work in saer

and healthier ways.

As engineering is a wide ranging activity the booklet does not deal with everyhazard which may arise or every precaution which can be taken. It does, however,

outline the most serious and requent hazards and the best ways o dealing with

them.

The Further reading section:

lists HSE and other publications which give more detail on the subjects dealtn

with;

provides inormation on other sources o help.n

In this guidance:

must denotes a legal obligation; outlines o the law applying to engineering

workshops are provided in lined boxes on a blue background just like this

paragraph;

do and dont, should and should not and other recommendations such asn

use, it and prevent represent good practice, which, i adopted, will usually

be what is reasonably practicable in the given circumstances although there

may be other legally acceptable ways o achieving the same objective.

text in italics (where it is not a reerence, sub-heading or caption) outlinesn

requirements o Approved Codes o Practice which have been approved by theHealth and Saety Commission and give advice on how to comply with the law.

I you are prosecuted or a breach o health and saety law, and it is proved

that you have not ollowed the relevant provisions o the Code, a court will ind

you at ault, unless you can show you have complied with the law in some

other way

tips on good practice are indicated by phrases such as think about andn

consider

the early sections deal with how to tackle health and saety issues common ton

most engineering workshops; later sections deal with more speciic activities

which may not be carried on in all workshops.


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Managing health and safetySuccessul health and saety management in small engineering workshops is about

identiying the most requent and serious risks and adopting the right precautions,

taking account o time, money and resources.

This book identiies how most serious accidents happen and how most ill health is

caused in engineering workshops.

I you use machines or processes which are not described in this booklet, see

where they are similar to those described and work out whether they pose the

same hazards and whether the precautions suggested would be right, as well as

seeking urther advice.

The Management o Health and Saety at Work Regulations 1999outlined

Employers must:

assess risks to the health and saety o their employees and non-employeesn

arising in, or rom, the workshop, and review them when there is signiicant

change. Records o signiicant indings o the assessment must be kept where

there are ive or more employees

plan, organise, control, monitor and review the preventative and protectiven

measures taken as a result o the assessment

provide health surveillance where necessary (see pages 3031), or example ton

help control health risks rom metalworking luidsappoint any competent person(s) needed to help them comply with legaln

obligations, or example, when having liting equipment thoroughly examined

set out what should be done in case o serious and imminent danger in then

workshop, such as the spillage o a large amount o degreasing solvent

tell employees about the risks and precautions involved in their workn

train employees to work saely.n

You may need help beyond that given in this book. I you do, trade and employer

associations, such as EEF The Manuacturers Organisation, the Manuacturing

Technologies Association (or machine suppliers) or local Chambers o

Commerce, oer a range o advice and support. These sources o inormation are

given on page 102. HSE inspectors are always willing to help (see page 112 orinormation on HSE Oices).

Employers must also consult with all their employees (including sel-employed

workers classed as employed persons under health and saety law) on health

and saety matters. This will involve not only giving inormation but also listening

to and taking account o what employees say beore any health and saety

decisions are taken.

Key reerence:Management of health and safety at wor

Approved Code o Practice L21 HSE Books 2000 ISBN 0 7176 2488 9


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How most accidents and cases

of work-related ill health ariseAccident and ill-health data or such a wide and varied sector is available rom a

number o sources, including published HSE material, research papers, industry

statistics, and trade association and trade union publications, although it is diicult

to see the whole picture. The interpretation o the available data in this booklet is

based upon the experience o health and saety inspectors gained over many years

in dealing with the sector.

Accidents and ill health

There are many thousands o accidents and cases o ill health reported every yearin small engineering workshops. Almost two-thirds o all such accidents reported to

HSE arise rom the movement o people, goods and vehicles into, around and out o

workshops. O these movement accidents:

about hal involve liting and moving goods, andn

about hal involve slips, trips and alls and hitting stationary or moving plant andn

equipment.

Non-movement accidents usually arise rom the use o machinery; these account

or between 10 and 15% o all accidents.

Electrical accidents are not uncommon and requently have the potential or moreserious injuries than those recorded.

The most common occupational diseases are dermatitis, deaness, asthma and

vibration white inger, and back, hand, arm, shoulder and neck problems.

In any particular workshop risks which are relevant should be assessed. Those

likely to be o most concern include:

movement o people, goods and vehicles around the workshop, particularlyn

manual handling

machinery saeguardingn

hazardous substances, particularly metalworking luids, degreasing solvents, andn

dust or ume rom welding, brazing, soldering, coating and paintingnoise, andn

vibration.n

Costs

The costs o accidents and ill health to small engineering workshops may be

disproportionately high. Many employees are key workers whose loss through

injury or ill health severely disrupts production and lowers proitability.


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Injuries in engineering industries as reported to HSEs Field Operations

Directorate and local authorities 1998/99 2000/01

Non-fatal

98/99 99/00 00/01

(provisional)

Total

o which main cause involved:

15 267 15 078 14 668

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

Being struck (eg by alling

objects, moving machinery)

2826 (19%) 2872 (19%) 2698 (18%)

Slipping and tripping 2318 (15%) 2386 (16%) 2349 (16%)

Machinery 1778 (12%) 1734 (12%) 1641 (11%)

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

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


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Instant action checklistIf you want to start checking conditions right away use this instant action checklist

Check Instant action Long-term solution

Are xed machine guards in

position and secured?

Replace discarded guards and

secure them by a xing which

needs a tool to undo it.

I xed guards are being removed

or requent access (more than

once per shit) replace with

interlocking guards.

Are interlocking guards tted and

working?

I not, restore or repair them. Start a programme o preventative

maintenance.

Are all work area and passagewayfoors in good condition, kept clearand ree rom tripping and slippinghazards?

Keep all areas tidy and clean, andavoid trailing leads. Repair holes infoors and clear up spillages.

Provide non-slip foor suraces.

Mark gangways. Train and instruct

employees to keep workplace

unobstructed.

Is anyone required to lit or

carry heavy or bulky items and

equipment unaided?

Mark each load with its weight and

train all employees to lit and carry

saely.

See how the job may be avoided.

Provide mechanical aids where

possible.

Are any employees suering rom

dermatitis?

Get them to see their GPs and

provide suitable gloves i these

wont add to risks at machinery.

Try to remove the cause, eg

redesign the work so that handling

the source o contamination is

avoided.

Do metalworking fuids smell

unpleasant, particularly ater a

break rom machining?

Replace with clean fuid, ater

cleaning the machine and sump.

Try to nd and eliminate cause o

contamination.

Is there a visible ume mist or haze

in the workshop? Is there much

visible dust rom grinding, polishing

or blasting?

Check existing controls and

ventilation, remedy and, i

necessary, improve general

ventilation.

Prevent ume, mist, vapour or dust

rom being generated or capture

it close to source beore it can be

breathed and remove it rom the

workshop.

I you cant hear someone 2 m

away talking in a normal voice.

Make sure noise/machine

enclosures are closed and hearing

protection is being worn.

Assess, remove, reduce or enclose

noise at source.

Are vibration levels o hand-held

tools as low as possible?

Check suppliers data on

vibration levels. Keep equipment

maintained.

Buy and use reduced-vibration

tools wherever possible.

I all vehicles (including ork-lit

trucks) and pedestrians are kept.

Ensure that all drivers on site are

properly trained and ork-lit truck

operators authorised. Enorce

speed limits and reduce the need

or reversing.

Review all transport movements,

including delivery and customer

vehicles. Consider one-way

systems and clearly mark and sign

trac routes.


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How to use this book to start

your risk assessmentHere are some questions or inding out how dangerous or unhealthy your

workshop might be, and what to do about it.

Generally I the answer is yes

Think about the times when people have

been o work recently:

Could their absences be put down ton

conditions at work?

Is there a pattern to any o them?nHave the lessons o any recentn

accidents, near misses or cases o

work-related ill-health been missed?

Are there health or saety aspects o anyn

processes/operations you eel uneasy

about?

Investigate the possible causes

urther. The most likely ones are

outlined in this booklet.

The workshop itsel I the answer is yes

Are there any parts which are:

dirtyn

darknobstructedn

poorly ventilatedn

unnecessarily wet, orn

otherwise dangerous or unhealthy ton

move around or work in?

See pages 1417 or details o the

standards required.

Moving and working with articles by

hand; loading/unloading machines;

assembly and packing

I the answer is yes

Has anyone complained about or been o

work with a bad back, or persistent hand,

arm, shoulder or neck problems whichcould be put down to work?

What about the loads being moved?

Are they too:

heavyn

sharpn

largen

awkwardn

hot or cold?n

Does the job involve a lot o requent,

orceul or awkward movements?

Complete the more detailed

questionnaire on pages 114115

(or liting) and pages 116120 (orhandling). I you have problems,

the solutions suggested on pages

2027 may help.


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Vehicles (including ork-lit trucks) I the answer is yes

Is there any damage to the workshop or

plant and machinery rom vehicles?

Do vehicles operate close to pedestrians?

Are vehicles required to reverse?

This may indicate too ast/careless

driving or a poorly laid out

workplace and also potential or

injuries. Investigate urther.

Does anyone use vehicles without being

properly selected and trained?

See pages 2729 or advice

on the selection and training o

drivers.

Are the conditions in which they operate

too dark, obstructed, wet or otherwise

dangerous?

See pages 1417 or the minimum

standards required or workshops.

Metalworking machining and welding I the answer is yes

Is it dicult to hear someone talking (in a

normal voice) 2 m away at any point in the

workshop?

Carry out a noise assessment

pages 5156 tell you how to do this

and make the most o it and how to

reduce and control excessive noise.

Is it possible to reach (DONT TRY!) any

pressing, shearing, rotating, cutting or sawing

tools especially when: loading/unloading

components; removing swar; or making

adjustments?

See the individual machining

sections o this booklet, pages

5874, or advice on how to guard

machinery.

Is there any visible ume, dust, mist or

spray, or can it be smelt?

Viewing any suspected source with

a strong light (eg a Tyndall beam

or video light) behind it will show

where the ume is. See pages

3033 on how to avoid or control

harmul ume, dust, mist and spray.

See pages 122123 or guidance

on checking the health o people

working with metal cutting fuids.

Do some operators requently have to

manipulate or load/unload components which

are too heavy, hot, awkward or sharp?

See pages 2026 or advice on

liting and handling.

Do you machine, weld or work withcomponents containing cadmium, lead,

chrome or similarly hazardous substances?

See pages 3033 or advice onhow to control exposures to

hazardous substances.

Do employees complain about numb or

tingling ngers, dead hands on cold days

or nger blanching.

See page 57 or advice on how to

deal with hand-arm vibration.


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Cleaning and fnishing I the answer is yes

Do you use:

a vapour degreaser?n

other means o degreasing?n

See pages 7577 or how to

maintain it and prevent the need

to get in and clean it.

See page 75 or how to avoid

and control exposures to harmul

cleaners.

Do you paint components, or use coating

powders?

See pages 8591 or how to avoid

and control exposures to harmul

substances in paints and coating

powders.

Five steps to risk assessmentFor a longer look, take ive steps to your risk assessment

The Five Steps

Look or the hazardsn

Decide who might be harmed and hown

Evaluate the risks and decide whether precautions are adequate or moren

should be done

Record your indingsn

Review you assessment rom time to time and revise it i necessaryn

Key reference: 5 Steps to ris assessment INDG163(rev1)

(single copy ree or priced packs o 10 ISBN 0 7176 1565 0)


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Usingtheinormationontheprecedingpagesa

ndtherestothisbooklet,identiy

:

Possiblehazards

(changean

d/orinsertyourown

asnecessa

ry)

Whom

ightbeharmed

Whetherexisting

measuresare

adequate

Whatmoreneeds

tobedone

Dat

eofthenextreview

Handling

Transportandvehiclemovements

Metalworkin

gfuids

Cleaninganddegreasingsolvents

Machinery(includingsettingand

maintenance)

Weldingpro

cessesandmaterials

Noise

Vibration


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Working in and moving around

the workshopAbout two thirds o all accidents in small engineering workshops happen during the

movement o vehicles, people and goods. A sae, well-lit, clean workplace can help

prevent many o these.

Workplace (Health and Saety and Welare) Regulations 1992 andApproved Code o Practice outlined

A safe place of work

You must have:

buildings in good repairnprecautions such as ences or rails to stop people or materials alling romn

open edges *

space or sae movement and access, eg to machineryn

safe glazing where necessary, mared to mae it easy to seen

loors, corridors and stairs ree o obstructionn

good drainage at wet processes such as washing and cleaningn

windows that can be opened (i openable) and cleaned saely.n They should be

designed to stop people falling out or bumping into them when open. You may

need to fit anchor points if window cleaners have to use harnesses

outdoor routes kept sae during icy conditions, eg salted/sanded and swept.n

Safe movement

You must have:

sae passage or pedestrians and vehicles n you may need separate routes

level, even suraces without holes or broken boardsn

handrails on stairsn and ramps where necessary

sae doors, eg vision panels in swing doorsn

suraces which are not slipperyn

well lit outside areas.n

Work stations

Work stations and seating must it the worker and the work.Make sure that:

bac rests support the small of the bac and foot rests are provided wheren

necessarywor surfaces are at a sensible heightn

there is easy access to controls.n

Cleanliness

You must:

provide clean loors and stairs, which are drained where necessary and notn

slippery

provide clean premises, urniture and ittingsn

provide containers or waste materialsn

remove dust, reuse and trade-waste regularlyn

clear up spillages promptlyn

keep internal walls/ceilings clean.n They may need painting to help easycleaning.

* Particularly on the flat roofs of offices provided in small industrial units, which are often used for storage; proper stairs

should be provided for frequent access to these areas.


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Maintenance

Maintaining the workshop and the equipment in it may pose dierent hazards rom

those encountered in the normal run o production work. Contractors as well as

your own employees may be at increased risk, particularly during the repair and

cleaning o plant containing toxic, lammable or hazardous materials, machinery and

during work at heights or in conined spaces.

Key reerence:Worplace health, safety and welfare

Approved Code of Practice and Guidance on Regulations

HSE Books 2000 ISBN 0 7176 0413 6


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LightingPoor lighting is oten a actor in accidents and can also increase visual atigue.

The law* on lighting outlined

You must provide:

good lightn use natural light where possible but try to avoid glare

a good level o local lighting at work stations where necessaryn

suitable orms o lighting (luorescent tubes operating at mains requency mayn

be dangerous with rotating machinery when the rotating part can appear to

have stopped)

special ittings or lammable and explosive atmospheres, eg in spray booths, ton

reduce risks o ignition and explosion.

* Worplace Health, Safety and Welfare Regulation 1992.

Problems Typical activity Average

illuminance

lux (lx) in

work areas

Minimum

measured

illuminance (lx)

at any point or

a suitable place

General hazards

rom the movement

o people, machines

and vehicles in and

around the workshopand visual atigue rom

work requiring limited

perception o detail

General work in the

workshop, assembly

o large components

100 50

Visual atigue rom work

requiring perception o

detail

Sheet metal work,

general machining,

oce work

200 100

Visual atigue rom work

requiring perception o

ne detail

Drawing oce

work, assembly o

electronic and other

ne components

500 200

Avoid:

large dierences in the lighting o adjacent areasn

glare rom direct sunlight by providing blinds, or example, and rom directlyn

visible lamps by excluding them suiciently rom lines o sight when necessary

strobe eects by:n

supplying adjacent runs o light ittings rom dierent phases

providing a high requency supply

washing out the eect with local tungsten ilament lighting

i high intensity tungsten halogen or mercury lamps are used to provide local

lighting, manuacturers ilters should always be kept in place.

For the electrical saety o lighting systems see pages 3438.

Key reerence:Lighting at worHSG38 HSE Books ISBN 0 7176 1232 5


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General ventilation, temperature

and toiletsFans and/or additional air inlets (at low level) and outlets (at high level) may be

needed in workshops where there are no means o ventilation other than air leaking

in and out (particularly in units on some actory estates) and where:

work generates hazardous airborne pollutantsn

workshops have been sealed to conserve energy.n

Provide at least ive litres/second per occupant (eight is recommended or comort)

and air movement in the workshop o at least 0.1 to 0.15 metres/second.

Measure velocities, using specialist help i needed, at inlet ducts (to calculate airlows inwards) and inside the workshop (to calculate air movements).

The law on temperature outlined

You must provide:

a reasonable temperature and a thermometer inside workshops.n

The temperature should be at least 16C unless wor involves severe physical

effort, in which case the minimum should be 13C.

The law on toilets and washing acilities outlined

You must provide:

suitable and suicient (and adequately ventilated and lit) sanitary conveniencesn

and (nearby) washing acilities kept clean and orderly,in the minimum numbers

outlined below

separate rooms or men and women, except where they are or the use o onen

person and are capable o being secured rom the inside

hot and cold, or warm water with means o cleaning and drying.n

No o people in workshop No o WCs and wash stations

15 1

625 2

2650 3

5175 4

76100 5


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Alternatively, for sanitary accommodation used only by men, the following numbers

are recommended:

No o men No o WCs No o urinals

115 1 1

1630 2 1

3145 2 2

4660 3 2

6175 3 3

7690 4 4

91100 4 4

Mae separate calculations where groups such as office worers have separate

accommodation.

Key reerence:Worplace Health, Safety and Welfare Regulations 1992

Approved Code of Practice and Guidance on Regulations L24

HSE Books ISBN 0 7176 0413 6


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Lifting equipmentAlthough liting, supporting and handling equipment can lighten the load o manual

handling when properly used, many accidents happen when loads are dropped

rom liting equipment, either because o poor slinging, or equipment ailure or

overloading.

Always:

maintain all liting equipment, including that used only occasionally, such asn

attachments to ork-lit trucks

train all users, particularly in the use o slings where necessaryn

plan lits in advancen

ensure that the weight and the distribution o any load is not beyond then

capacity o the equipment being used

provide sae places o work rom which to maintain hoists and lits, particularlynat heights; do not allow overhead travelling cranes to work within 6 m o

persons on crane tracks

check the condition, type and size o any eyebolts used and ensure that then

thread type matches the hole into which it is to be screwed.

The law* on liting equipment outlined

The same regulations now apply to all liting equipment, which includes any

equipment used at work or liting or lowering loads, and liting accessories such

as chains, slings, eyebolts etc.

You should ensure that:

liting equipment is suiciently strong, stable and suitable or the proposed use,n

and marked to indicate its sae working load;

liting equipment is positioned or installed to minimise the risk o injury, eg romn

the equipment or the load alling or striking people;

every part o a load (including, or example, pallets and stillages) and anythingn

attached to the load and used in liting (including or example the liting points

on skips) is o adequate strength;

liting operations are planned, supervised and carried out in a sae manner byn

people who are competent;

liting equipment (including accessories) is thoroughly examined or any deectn

beore it is put into service or the irst time (unless it is new and is coveredby an EC declaration o conormity which is less than 12 months old). Where

the saety o liting equipment depends on installation conditions, it must be

thoroughly examined ater installation and beore being put into use or the irst

time. Periodic thorough examinations are also required at six-monthly intervals

or accessories and equipment used or liting people, and at least annually or

all other equipment; or at intervals laid down in an examination scheme drawn

up by a competent person.

* Lifting Operations and Lifting Equipment Regulations 1998.

Key reerence:Safe use of lifting equipment: Lifting Operations and LiftingEquipment Regulations 1998 L113HSE Books ISBN 0 7176 1628 2


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Moving goods safely by handThe unsae movement o goods by hand, either by liting or handling causes more

accidents and ill health in small engineering workshops than any other single

activity, especially to those most at risk, including the younger more inexperienced

employees, the older and/or less physically it, and those who may make an

existing injury worse.

Back injuries are very common as are hand, arm, shoulder and neck injuries,

particularly rom unsae, highly repetitive work. Cuts and abrasions rom sharp

edges are also very numerous.

Manual Handling Operations Regulations 1992 outlined

Employers must:

avoid the need or hazardous manual liting and handling i reasonablyn

practicable

assess the risk o injury rom any hazardous manual liting and handling whichn

cannot be avoided; and

reduce the risk o injury accordingly.n

Employees must:

ollow sae systems o work laid down by their employersn

use mechanical aids provided by their employers properlyn

remember to use the training provided on liting.n

Sharp edges

These cause as many as a third o all accidents in some engineering workshops,

resulting in cuts, abrasions, inected wounds, dermatitis, amputations and

occasionally ractures.

Those working with sheet metal, either lat or coiled, heavy sharp items, such as

tools and cutters, and scrap metal and swar are most at risk.

Consider how to avoid handling sharp edges, and i this is not reasonably

practicable, reduce exposure to them.

Reducing the risks

Ask your supplier to remove or protect sharp edges, eg by machining outn

sharp edges or itting plastic covers or padding.

Remove sharp edges or protect them beore handling.n

Avoid handling by using, or example, trays, jigs, holders or baskets.n

Minimise handling by automating processes by using, or example, conveyors,n

eed and discharge chutes.

Store articles correctly so that they are retrieved easily.n

Use personal protective equipment such as gloves, gauntlets and aprons, but only

where these do not add to other risks rom machinery, such as entanglement.

See Appendix 1 or checklists.

Key reerence:

Manual Handling

Operations Regulations

1992 Guidance onRegulations L23 1998

HSE Books

ISBN 0 7176 2415 3


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Executive

How to lift safelyHere are some important points, using a basic liting operation as an example.

Plan the lit. Where is the load to be placed?

Use appropriate handling aids i possible. Do you need help with the load?

Remove obstructions such as discarded wrapping materials. For a long lit, such as

loor-to-shoulder height, consider resting the load mid-way on a table or bench in

order to change grip.

Position the feet

Feet apart, giving a balanced and stable base or liting (tight skirts and unsuitable

ootwear make this diicult). Leading leg as ar orward as is comortable.

Adopt a good postureWhen liting rom a low level, bend the knees. But do not kneel or overlex the

knees. Keep the back straight (tucking in the chin helps).

Lean orward a little over the load i necessary to get a good grip. Keep the

shoulders level and acing in the same direction as the hips.

Try to keep the arms within the boundary ormed by the legs. The best position

and type o grip depends on the circumstances and individual preerence; but it

must be secure. A hook grip is less tiring than keeping the ingers straight. I you

need to vary the grip as the lit progresses, do it as smoothly as possible.

Keep close to the loadKeep the load close to the trunk or as long as possible. Keep the heaviest side o

the load next to the trunk. I a close approach to the load is not possible, slide it

towards you beore trying to lit.

Lit smoothly, keeping control o the load.

Dont twist the trunk when turning to the side.

I precise positioning o the load is necessary, put it down irst, then slide it into the

desired position.

(a) Plan the lit

(b) Determine the best liting

technique

(d) Pull the load in close to

your body

(c) Get a secure grip

Training or liting and handling

This should cover:

how to recognise harmul manual handlingn

appropriate systems o workn

use o mechanical aidsn

good handling technique.n


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Lifting and handling

Assessing risks

Assessment

Some o the important questions to ask

Job: Too high to lit/lower?

Too rushed?

Too ar to carry?

Too repetitive?

Too much twisting involved?

Load: Too heavy?Too large?

Too unstable?

Too hot/cold?

Too sharp?

Too diicult to grasp?

Work area: Too dark?

Too slippery?

Too obstructed?

Too many steps?

Individual: Fit or the job?In need o special consideration or training?


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Assessingrisks

Takingaction

Job

Short-terma

ction

Long-terma

ction

Loading/unloading

lorries/vansbyhand

Providehelporheavy

loads.Usetheright

personorthejob

Palletise

load(s).

Useork

-littrucks

Movingmaterials

to/rommachines

Breakdownloadsinto

easilyhandled

units/containers

Usecon

veyors/hoists/

ork-littrucks

Sorting/counting

compon

ents

Useapprop

riatetrained,

it,personnel

Asksup

plierstopre-sort

beored

elivery.Weigh

insteadocount.

Automatesorting


HealthandSafety

Executive


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Assessingrisks

Takingaction

Job

Short-terma

ction

Long-terma

ction

Loading/

unloading

machines

Raisestillages/binstoright

height/position

Automateload/unload

operations.Usehoists

and/or

mechanicalaids

Assemblingand

packing

Useappropriateit,trained,

personnelattherightplace.

Rotatethew

orktoprevent

toomuchre

petition

Provide

goodworking

environ

ment,welllitand

approp

riatemechanical

aidsan

dtoolstodo

theworkwithoutundue

strain.Designout

thenee

dormanual

assemblyandpacking

Preparing,

maintaining,moving

andrepa

iring

machinery

Useappropriateit,trained

personnel

Provide

unobstructed

access

andmechanical

aidsas

necessary


HealthandSafety

Executive


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Health and Saety

Executive

Ergonomic machine operation,

assembly and packingTo minimise risks

avoid applying too much orce or too long or too requently using an awkwardn

posture o the hand, wrist or arm.

Consider

Reducing the force involvedby, or example:

keeping cutting tools sharpnproviding a larger gripping arean

supporting tools by means o balancers or tensioners (which may also helpn

minimise vibration).

Reducing highly repetitive movementsby, or example:

restructuring jobs so they contain more varied workn

automation.n

Reducing the need for awkward postures by, or example:

n

changing the orientation o the part being worked upon to enable the wrist tobe straight

moving the operator so work is more comortable.n

Training is vital, particularly:

to prevent the repetition o old, bad ways o workingn

to protect newer employees rom working too quickly too soon.n

Mostill healtharises from:

n prolonged orceul or repetitive gripping,

twisting, reaching or other movement withoutenough rest or recovery. This causes pain, a

restriction o joint movement and sot tissue

swelling, leading sometimes to permanent

disability, mostly in the hands, arms and

shoulders

liting and handling goods unsaely by hand.n

Consider workstations where both standing and

sitting is possible. In general it is less physically

stressul to sit, provided there are opportunities

or moving around.

A modiied handle design can

lead to a more comortable

hand position

Key reerence: Upper limb disorders in the worplace

HSG60 HSE Books ISBN 0 7176 1978 8


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Health and Saety

Executive

Zone o

convenient

reach

Normal

working

area

Horizontal reach

distances in millimetres

0 100 200 300 400 500 600 700700 600 500 400 300 200 100

100

200

300

400

100

200

300

400

Ergonomic aspects to consider

For operating machinery

make requently operated hand controls easy to reach and workn

i seats are provided leave suicient room or knees and legsn

avoid bending and twisting to load/unload machines by having material/bins onn

racks which can be raised and lowered to keep them at waist height

consider lean-on or sit-stand, wheeled, sliding, suspended or ixed seatsn

see pages 9495 or normal chairs.n

For process or assembly work

arrange the work in a semi-circlen

provide a swivel chairn

bring the work to the workern

consider chairs with orward-tilting seats and backrests to help workers reachn

urther without loss o support, and consider work suraces and component

trays which slope towards the worker

racks or material and inished items should be adjustable so that work isn

comortable to reach and put away.

For precision work

To avoid tense postures, a orward tilting seat and a work surace whichnslopes to the worker may be particularly helpul.

Sit-stand seatTilting seat

Foldaway seat

Key reerence:Seating at worHSG57 1997 HSE Books ISBN 0 7176 1231 7


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Moving vehicles safelyLorries, vans, cars and other vehicles and mobile plant are involved in many accidents,

when reversing and manoeuvring in or around small workshops. These accidents

cause injuries and occasionally deaths when victims are run over or crushed.

To reduce risks:

Identiy and clearly mark sae routes and locations or deliveries andn

despatches which are:

away rom pedestrians as much as possible

in good condition

well lit at all times when being used

away rom vulnerable plant

marked clearly with suitably low speed limits.

Provide loading bays with an exit rom low level or a reuge to prevent crushingn

Do not allow untrained drivers to drive vehiclesn

Avoid reversing (eg by suitable traic routing or example) or provide help orn

reversing drivers i possible (eg a guide)

Use speed bumps to limit traic speeds where necessary and make sure theren

are gaps or any lit trucks which have to cross them

Select and train your own drivers with care.n

Loading and unloading vehicles

Accidents requently happen when people all rom vehicles. Avoid the need

to climb on loads (by using curtains on the sides o vehicles or mechanical or

proprietary sheeting systems), or provide sae access and sae systems o work. I

it is necessary to walk on the top o high loads, saety lines and harnesses should

be provided and worn.

Key reerences:Worplace transport safetyHSG136

HSE Books ISBN 0 7176 0935 9

Managing vehicle safety at the worplace

INDG199 HSE Books (single copies ree)

STOP

Clearance

Let Right

Move towards

Move away


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Lift trucksHow most accidents happen

Lit trucks, (powered and non-powered, pedestrian and rider-operated,) are

involved in many accidents in small engineering workshops. These are requently

caused by reversing unsaely, speeding, overloading, carrying passengers or liting

personnel the truck was not designed or, or drivers not being trained, and result

in many serious injuries and some deaths every year when victims are run over or

crushed.

Most ill health arises rom:

using diesel trucks in enclosed conined working areas, leading to breathingn

problems

poor seating and controls leading to back and upper limb disordersnpoor roadways which may cause vibration leading to back problems.n

The law* on mobile work equipment outlined

mobile work equipment includes ork-lit trucks and any other work equipmentn

which carries out work while it is travelling or which travels between dierent

locations where it is used to carry out work.

where mobile work equipment is used or carrying people, it must be suitablen

or this purpose. Measures must be taken to reduce the risks to the saety o

people being carried, the operator, and anyone else. These include measures

to reduce the risks rom equipment rolling over (most counter-balanced,seated centre-control ork-lit trucks have a vertical mast which prevents

them rolling more than 90). Measures, such as itting restraining systems, eg

seat belts, must also be taken to reduce the risk o anyone being crushed

between any part o the equipment and the ground i it rolls over or overturns.

you must ensure that sel-propelled work equipment (ie work equipmentn

which is propelled by its own motor mechanism) has appropriate acilities to

ensure the saety o people in the workplace, including acilities or preventing

its being started by an unauthorised person.

* Provision and Use of Wor Equipment Regulations 1998.

Approved Code o Practice on rider operated lit trucks operator training outlined

Employers to provide basic training by recognised instructorsn

Trainees to pass a test o their competencen

Records to be kept o training.n


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Sae lit truck operation

Get the right truck or the jobn

Maintain all lit trucks regularly in accordance with the manuacturersn

instructions, ensure seats are maintained to minimise unhealthy postures and

vibration

Select only suitable personnel or training as operators/drivers, authorisen

operators/drivers in writing

Avoid routes near vulnerable plant, eg lammable liquid stores, or protect suchn

plant

Segregate busy lit truck areas/routes rom pedestrian and working areas asn

much as possible, pay particular attention to barriers, layout, visibility, lighting

and warnings where lit trucks and people work alongside each other; enorce

rules or low speed and sae reversing

Ensure operating suraces are strong enough, well maintained and gradientsn

are not too steepTrain all employees on lit truck movements, i the lit truck is used on the roadn

(to load and unload, or example) provide a second person to help with traic,

as necessary

Rider operated lit trucks used regularly on the road or long periods, and theirn

drivers, must be licensed by the Department o Transport

Keep keys secure when trucks not being usedn

Do not use orks, pallets or bins to lit persons to work at heights unless thesen

are suitably modiied; use properly designed mobile work platorms i possible.

Key reerences:Rider operated lift trucs

operator training L117 HSE BooksISBN 0 7176 2455 2; Safety in woring with lift trucs HSE Books 2000

ISBN 0 7176 1781 5


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Controlling hazardous

substancesExposure to hazardous substances most requently occurs when:

machining (see pages 4044 or general control o hazardous substances andn

pages 4850 or the control o metalworking luids)

welding (see pages 7879)n

painting (see pages 85n 86) and

cleaning and degreasing (see page 75).n

The control o dust, ume, spray and vapour and the prevention o skin contact by

adequate personal protection will minimise risks o adverse health eects, but pay

particular attention to precautions when machining, welding, polishing or grinding:

nickel-copper and nickel-chrome alloys (ound in coins, magnets, chemical and oodn

process equipment and in the aerospace industry)

stainless steel and nickel alloys; stainless steel and chromium alloysn

lead and lead alloysn

copper alloys containing beryllium (commonly ound in the electrical industry andn

in high deinition tools and dies used, or example, in plastic injection moulding

machines)

cadmium-plated articles.n

The Health and Saety at Work etc Act 1974, section 6 in relationto the supply o substances or use at work outlined

Suppliers must:

ensure so ar as is reasonably practicable that the substance will be sae andn

without risks to health

provide adequate inormation about any risks to health or saety to which then

inherent properties o the substance may give rise.

Labels and saety data sheets supplied with hazardous chemicals contain important

inormation about hazards (see CHIP reerence page 106) to help you use them saely.

The most common health eects rom hazardous substances are:

skin diseases such as dermatitis rom metalworking luids and oilsn

lung problems, such as asthma, rom isocyanate paints and gluesn

poisonings, such as lead poisoning, andn

very rarely cancer, such as skin cancer rom certain mineral oils.n


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Health and Saety

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The Control o Substances Hazardous to Health Regulationsoutlined

You must:

assess risks to healthn

prevent exposure, or example by usingn

a less hazardous substance

a different process

where prevention is not reasonably practicable, control exposure by, for example,n

isolating or enclosing the process or, if this is not reasonably practicable, local exhaust

ventilation, and

where prevention or control is insufficient on its own, provide personal protectiven

equipmentinform, instruct and train employeesn

carry out air monitoring and health surveillance where necessary.n

A hazard may be deined as something that can cause harm such as the

chemicals in a tin o paint while a risk may be seen as the chance o harm

actually being done which can vary with how the paint is actually used; spraying

in an uncontrolled environment without personal protection could pose high levels

o risk.

Key reerence:Control of Substances Hazardous to Health Regulations 2002.

Approved Code of Practice and guidance L5 (Fourth edition)HSE Books 2002 ISBN 0 7176 2534 6


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Local exhaust ventilation (LEV)Selection and use

LEV is a requently used way o controlling exposure to hazardous substances by

drawing them away rom the breathing zones o workers into a hood and ductwork

connected to an extract an.

In many circumstances LEV may be cheaper and more eective than dilution

ventilation. (Dilution ventilation works by introducing resh air into the workplace to

lower the general level o the hazardous substances in the air.)

Heat losses rom LEV may be minimised by heat recovery systems or recirculation

o iltered air, but the latter only ater specialist advice to prevent the recirculation o

hazardous materials in harmul quantities.

The law* on maintenance, examination and testing o LEV outlined

In most small engineering workshops, employers must ensure that thorough

examinations and tests are carried out:

every 14 months or most processesn

every six months where metal articles are abraded or polished or more thann

12 hours a week.

Employers must also keep appropriate records or at least ive years.

See Appendix 6 for details which should be recorded.

* Control of Substances Hazardous to Health Regulations, regulation 9.

Someone with suicient training, knowledge, skills and experience is required

or the maintenance, examination and testing o LEV, and insurance companies

requently have the competence required.

To make the most o LEV

Get an expert to design andn

install the most appropriatesystem, with the right hoods/

enclosures, ductwork, air

velocities and cleaning and

iltration systems

Keep the hood as close to then

source o contamination as

possible

Make sure the an draws airn

away rom the operator

Make sure partial enclosuresn

are large enough to contain the

work and that sprayers do notstand between the workpiece

and point o extraction;

consider a turntable or heavy

itemsLEV used to help draw welding ume rom the

breathing zone o a welder


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Health and Saety

Executive

Check and maintain the system, regularly particularly lexible ductworkn

Provide suicient lighting (suitably protected) within the enclosure to encouragen

work to be done within the extracted area.

Common causes o LEV ailure, which you can check easily and requently yoursel

to keep it working properly include:

physical damage to and poor positioning o hoods and boothsn

damaged and/or blocked ductworkn

blocked, damaged, unsuitable or incorrectly installed iltersn

too high/low water levels in wet collectorsn

wear or corrosion o an blades leading to build up o contaminant on bladesn

slipping drive belts to ansn

poor lubrication o an bearings.n

It helps to keep a record o these checks.

Key reerence:Introduction to local exhaust ventilation HSG37HSE Books ISBN 0 7176 1001 2

Spraying in the direction o exhaust ventilation air movement; a turntable can help a sprayer avoid

standing between the item being sprayed and the point o air extraction rom the booth


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Health and Saety

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Electricity

How most accidents happen

Most accidents arise rom contact withn live conductors or equipment made

live by aulty wiring and connections.

Equipment using 240 V ac may be as dangerous as that using 415 V ac,n

depending on circumstances.

Each year, the use o electricity causes atal and other injuries (eg burns) rom

electric shock and ire.

The law* on live electrical work outlined

No electrical work should be carried out live where there is a possibility o

contact with a potentially dangerous live conductor unless:

it isn unreasonable in all the circumstances or the equipment to be dead; and

it isn reasonable in all the circumstances or the work to be carried out on or

near it while it is live; and

suitable precautions (including, where necessary, suitable protectiven

equipment) have been taken to prevent injury, such as proper work planning

and the use o adequately trained and supervised sta.

* See key references.

Precautions necessary to prevent accidents require everyone in the workshop

(including the sel-employed) to use equipment saely and co-operate with the

employer where necessary.

Employers in particular need to:

develop a suitable system o maintenance or both ixed installations andn

portable equipment advice rom a competent person may be required

ensure that electrical contractors are competent or the work they are expectedn

to do; or example, are they registered with such organisations as the National

Inspection Council or Electrical Installation Contracting or equivalent?

select equipment which is suitable or the job (using reduced low-voltagen

equipment lowers the risk o serious injury)check that wiring and equipment is sound and properly installed, especially son

that protection equipment such as use and switchgear will operate adequately

in the case o aults. Universally accepted standards are described in BS 7671

Requirements for electrical installations

ensure any electricians working or you are competent. Levels o qualiicationn

established by the Electrical Joint Industries Board may be o help here, but

check that qualiications are relevant; a ully qualiied TV technician may not be

competent to re-wire a building.

Key reerences:Memorandum of guidance on the Electricity at Wor

Regulations 1989 HSR25 HSE Books ISBN 0 7176 1602 9;

Electrical safety and you INDG231 (single copies ree)


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Health and Saety

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Portable electrical equipmentUse this list to check whether you are managing the risks romportable electrical equipment. Have you:

prepared and implemented a system o maintenance or portable (andn

transportable) electrical equipment

made sure that all items o portable electrical equipment are included in then

maintenance system

decided how to deal with unauthorised equipment brought in by employees,n

eg portable, mains-operated radios

collected inormation on where and how equipment is used. This inormationn

will help you decide what sort o checks/inspections/tests are required and at

what requencies

provided straightorward training and inormation or all users (including yoursel)n

to help them carry out user checks when equipment is usedmade sure that all equipment receives a ormal visual inspection at appropriaten

intervals, carried out by someone who has been trained in what to look or

considered preparing brie written guidance relating to visual inspection,n

what to look or, and procedures to ollow when aults are ound (and when

unauthorised equipment is ound)

identiied equipment which will need periodic combined inspection and testingn

established how oten combined inspection and testing is appropriate (basedn

on the type o equipment, how it is used, where it is used and the results o

any previous checks/inspections/tests)

appointed someone with the appropriate knowledge, training and experience ton

carry out the inspection and testing

reviewed the results o checks/inspections/tests to identiy any common trendsn

and to conirm that the chosen inspection/test requencies are appropriate

made sure that the arrangements which you have made are being put inton

practice and that ollow-up action is being taken?

Remember that choosing the right equipment and carrying out visual

inspections are perhaps the most important ways to minimise the risks.


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Health and Saety

Executive

Key reerence:Maintaining portable and transportable electrical equipment

HSG107 HSE Books ISBN 0 7176 0715 1

Activity Preerred equipment

Work inside metal tanks which may be

damp or humid (through condensation,

or example)

Use pneumatic power tools. Lighting, i

essential, should be 25 V dc CTE* max

and ixed out o reach.

Work on apparatus where water may

be present (on a metalworking luid

circulation system on a machine tool)

Work in close contact with metalwork

in cool dry conditions

Use equipment operating at voltages

o 50 V ac, 120 V dc or less. Higher-

voltage equipment should be built

to waterproo standard, eg BS EN

60529: 1992 Specification for degrees

of protectionprovided by enclosures.

The supply to earthed equipment

should incorporate back-up protection

which automatically disconnects the

supply in the event o a ault, preerablyearth monitoring.

Ad hoc maintenance work and outside

work in good weather

Use equipment operating at voltages

o 50 V ac, 120 V dc or less (110 V ac

CTE may be used in conjunction with

all-insulated or double/insulated tools).

Frequent cleaning o ventilation louvres

is necessary.

Reduced low-voltage equipment is

preerred such as 110 V CTE.

* CTE: centre tapped to earth.


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Health and Saety

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Common problems with flexible

leads, their plugs and socketsand how to avoid themMany accidents causing burn and shock injuries which are sometimes atal arise

rom poorly maintained and damaged leads, plugs and sockets.

Problem Precaution

Failure to select the right

equipment or the job/

environment

Choose the right equipment. For example in

a heavy abrication shop, armoured, heat-,

oil- and re-resistant leads will oten benecessary. Select reduced low voltage

equipment (110 V ac CTE max) whenever

possible.

Failure to give adequate support

to suspended cables (such as

on pendant control leads or

overhead cranes)

Use a wire or chain to relieve the cable o

tension.

Poor joints in cables Replace cables rather than repair them,

particularly those used or a long time, or or

short lengths when the cost o repair may be

more than replacement; or longer lengths cut

o the damaged part i it is close to an end oruse a proprietary plug/ socket which provides

both electrical and mechanical protection or

cables. (I a coupler is used the socket must

be on the supply side and the plug on the

cable connected to the apparatus.)

Repairs should be carried out only by

competent personnel; insulation and sheath

damage can be repaired by vulcanising or

using compatible proprietary sel-sealing

material together with a heat shrinkable plastic

sleeve to give the nished joint necessary

insulating value, strength and waterproong.

Insulating tapes alone are unsatisactory.

Leads trailing too long may

prevent circuit protection rom

operating within designed limits

Provide more convenient sockets, closer to

work.

Cables and conductors

insuciently protected and liable

to damage

Where liable to damage, or example in a busy

area, re-route or provide a suitable cover, eg

a conduit.

Cables and conductors too

oten fexed, which may cause

damage to the insulating sheath

or conductor

Check regularly, especially where the cable is

terminated into the apparatus concerned, and

repair or replace as necessary.


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Health and Saety

Executive

Problem Precaution

Damage to cables and

conductors by portableequipment such as soldering

irons and portable grinders

Secure leads as ar as possible out o harms

way, where risk o damage is minimised.

Arcing when plugs withdrawn on

load

Above 16 A provide a switch (interlocked with

plug i possible) to enable currents to be saely

broken beore withdrawing plug.

Weight and leverage o adaptors

damaging socket outlets

Do not use adaptors or other

plug-in devices where their weight and

leverage may damage socket outlets. Provide

sucient socket outlets or, i necessary, use

purpose made, portable multi-socket outlets.

Failure o plug cord grips Ensure that it is the sheath which is being

gripped not the conductors; do not remove

plugs by pulling leads.

Use the correct type o plug (particularly or

armoured lead). Consider heavy-duty industrial

plugs. Ensure it is terminated as per the

manuacturers instructions.

Loss o securing screws or plugs Check them regularly, and replace missing

ones.

Screened and armoured fexible

cables incorrectly terminated in

smaller portable equipment

Secure the whole cable using purpose-made

glands/terminations tted by a skilled person

where necessary.Overheated extension lead drums Unwind lead rom drum completely beore

use.


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Health and Saety

Executive

Pressurised plant and systems

The law* on pressurised plant and systems outlined

All plant and systems must be designed, constructed and installed to preventn

danger

Systems must be properly maintainedn

Modiications or repairs must not cause dangern

There must be a written scheme or examination o certain pressure vessels,n

such as air receivers, steam boilers, ittings and pipework, drawn up by a

competent person

Examinations as set out in the written scheme must be carried out by an

competent person

Records must be kept in most cases.n

Pressure testing

Accidents, some atal, occur during pressure testing when the energyn

contained in the vessel under test is released with explosive orce

Wherever practicable, avoid using compressed air, steam or gas (whichn

contains more than 200 times the energy o water o the same volume)

Use hydraulic (liquid) pressure with suitable precautions and always, i possible,n

beore leak testing (using air, steam or inert gas) components not intended as

pressure vessels, eg vehicle uel tanks, radiators, small castings, storage tanks

and oil drums.

Injection injuries

Injuries, occasionally atal, may be caused by accidental or deliberate injectionn

o material and/or compressed air either through the skin or into a body oriice

Ordinary working clothes do not signiicantly resist the penetration on

compressed air into the body

High-pressure luid guns may inject material at 3n 7000 psi and cause serious

injuries. Care should be taken to avoid accidental injections

Horseplay should be strictly orbiddenn

Because the degree o injury may not always be immediately apparent, medicaln

advice should always be sought ater compressed air penetration occurs or is

suspected.

Key reerences:*Safety of pressure systems. Pressure Systems Safety

Regulations 2000. Approved Code of Practice HSE Books ISBN 0 7176 1767 X

Compressed air safetyHSG39 HSE Books ISBN 0 7176 1531 6


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Health and Saety

Executive

MachiningHow most accidents happen

Most accidents at all types o machine, including automatic and CNC machines,

happen to operators during normal operation when:

loading/unloading componentsn

removing swarn

taking measurements and making adjustments (to the coolant supply inn

particular).

On manually operated machines, the most dangerous machine movements are

the rotating, cutting, shearing, sawing or pressing movements o tools, particularly on:

pressesndrilling machinesn

milling machinesn

lathesn

metal cutting sawsn

guillotines andn

grinding machines.n

Hands are most requently injured, the most numerous injuries being cuts

and abrasions, many o which are severe. Broken bones and dislocations are

numerous. Amputations o ingers and hands are not inrequent and there are

some atalities, oten arising rom entanglements, every year. Eye injuries are also

common.

On automatic and computer controlled machinery, a larger proportion o

accidents happens at automatically and computer controlled clamps, axes, tables,

swar removal equipment, chucks and other work handling equipment.

At all types o machinery a large number o accidents happen to setters,

electricians and maintenance personnel during set-up, inspection, ault-inding,

maintenance and repair.

Most ill health arises rom:

unsae loading/unloading and handling o components, in particular when highlyn

repetitive, which may cause back injuries and upper limb disordersskin contact with metalworking luids, or example when preparing luids orn

handling components, which may cause skin irritation and dermatitis

breathing in aerosols, oil mists and umes rom metalworking luids duringn

machining which may cause irritation o the eyes, nose and throat, and

occasionally breathing diiculties such as bronchitis and asthma

sharp edges and swar which may cause cuts which exacerbate dermatitisn

high noise levels which may cause deaness most requently at machinesn

which generate impacts when operating, higher speed machines or groups o

machines running together

vibration, particularly when grinding.n


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Health and Saety

Executive

Saety measures

To prevent access to dangerous movements during batch production atn

manually operated machines use ixed guards with:

jigs and ixtures (such as sliding trays) to load and unload components away

rom the tools

sae means o removing swar (such as a hook or rake which may be

inserted through small openings in ixed guards) and adjusting coolant (such

as taps outside ixed guards).

Use ixed and interlocking guards or saety devices providing equivalentn

protection at automatic and CNC machines to ensure all dangerous movements,

not only tools, are guarded (see pages 4344 and individual machines or urther

guidance on guarding CNC machines).

Control noise by engineering means at source or adapt and extend guards to serven

as noise enclosures (eg by lining them with noise absorbent materials). (See pages5153.)

Use guards to help enclose and control hazardous substances with LEV wheren

appropriate.

Manually operated machines used inrequently or one-o operations such asn

those oten ound in toolrooms may require constant adjustment and close

observation; guards may also need to be readily adjustable and allow close

observation.

Training essentials

Operators should know:

what the main dangers are, how the main saeguards work and who should ben

notiied o deective ones

how to start, operate and stop the machine saelyn

what to wear (eg protective equipment) and what not to wear (eg loose clothingn

at some machines)

how ton

load and unload components

remove swar, and

adjust coolant low saely

not to clean machines using compressed air to blow material awayn industrialvacuum cleaners or brushes should be used

how to work saely with any metalworking luids used.n

Maintenance and setting personnnel should know:

that beore inspection, cleaning, maintenance and repair, machines must inn

general be switched o and isolated

where power is necessary, how to work saely, or example by using:n

written systems o work

permits to work on complex or hazardous plant, and

warning signs

how to maintain metalworking luids to minimise health risks.n


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Key reerence:Provision and Use of Wor Equipment Regulations 1998 ACOP

and Guidance on Regulations L22HSE Books ISBN 0 7176 1626 6

The Provision and Use o Work Equipment Regulations 1998outlined(equipment includes machinery)

Employers and others must ensure that:

suitable equipment is provided or the jobs involvedn

inormation and instruction are adequaten

equipment is maintained in good working order and repairn

training is provided or operators and supervisorsn

equipment is saeguarded to prevent risks rom mechanical and other speciicn

hazards

equipment is provided with appropriate and eective controlsn

maintenance is carried out saelyn

some work equipment is subject to inspection to ensure that is sae to usen

(see below).

The Regulations also contain requirements relating to mobile work equipment

(see page 28) and power presses (see page63).

The Provision and Use o Work Equipment Regulations 1998 impose requirements

relating not just to preventing access to dangerous parts o machinery, but also to

the ollowing:

inormation and instructionn

inspectionn

sae maintenance operationsn

starting and stopping machines saely (including emergency stops)n

control systemsn

means o isolating work equipment rom sources o energyn

stabilityn

lightingn

markingsn

warning devices.n

You will need to carry out risk assessments on your existing machinery in order

to identiy whether it complies with all o the requirements. You can use the risk

assessment proorma in Appendix 3 to help.

Inspection o work equipment

Inspection o work equipment should be carried out where a signiicant risk o injury

(one which could oreseeably result in a major injury or worse) may result rom:

incorrect installation or reinstallation o the equipmentn

deterioration o the work equipment leading to danger, orn

as a result o exceptional circumstances which could aect the sae operationn

o the work equipment (or example, i it is damaged).

Inspection will be necessary when equipment or parts o equipment deteriorate and

lead to danger and where this will not be adequately controlled through operator

checks and normal servicing regimes. It will not thereore apply to everyday risks at

work equipment, which can be detected and rectiied during routine operator checksand maintenance.


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Key reerences:Provision and Use of Wor Equipment Regulations 1998

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

Engineering machine tools: Retrofitting CNC EIS19 HSE Books (ree)

The purpose o an inspection is to identiy whether the equipment can be operated,

adjusted or maintained saely and that any deterioration (such as damage or wear)

can be detected and remedied beore it results in unacceptable risks.

Inspections should include visual and unctional checks o the equipment, and

sometimes testing. This will depend on the complexity o the equipment, on

where and how it is used, and on what the risks to health or saety could be i the

equipment is operated in an unsae condition.

A risk assessment should be carried out to determine whether an inspection is

necessary and, i so, what orm it should take. The assessment should also state the

intervals at which inspections should be carried out. Records o the assessment and

the inspections should be kept.

Some examples o equipment which is likely to be subject to inspection:

Hydraulic presses and press braesnNon-lifting parts of for-lift trucsn

Die-casting machinesn

Computer controlled (CNC)

machiningHow most accidents happen

From trapping at, or contact with, tools, clamps, tables, swar removal equipment,

chucks and other work handling equipment, during normal operating cycles when

clearing blockages and swar, loading/unloading, cleaning and making adjustments.

Many accidents also occur during ault inding, setting, and repair and maintenance

because saeguarding is inadequately speciied, poorly designed, not understood

by the user, and/or misused.

Most ill health arises in the same ways as at conventional machines, rom poor

handling (see page 20), metalworking luids (see page 48), and noise (see

page 51), but risks rom:

aerosol mists rom metalworking luids may be higher because o highern

operating pressures and speeds, and

noise, particularly rom high-speed cutting (and especially rom groups on

machines operating together) may be higher.


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Key saety measures

As the degree o computer control may vary rom:

complete control o several dierent machines working together with associatedn

equipment (such as loading/unloading devices), to

partial control o one aspect o a single machine (such as constant surace speedn

cutting on a microprocessor enhanced lathe)

provide saeguards appropriate to the risks posed. For example, at a ully

programmable CNC lathe (where many sequences o high-speed, high-power machine

movements may be under computer control) complete enclosure by ixed and

interlocking guards or their equivalents is appropriate.

At a microprocessor enhanced mechanical lathe, however, where only constant

surace speed cutting is under computer control, complete enclosure may not benecessary and saeguards more appropriate to a manually operated lathe may suice.

Where the speed and power o machine movements under computer control leads to

risks o injury:

provide ixed and interlocking guards (or equivalent saeguards) to prevent access ton

all such machine movements, not only to metalcutting tools work zone enclosures

may be necessary

arrange interlocking so that power to dangerous machine parts is removed whenn

interlocking guards are open or movements are limited to sae increments or speeds,

which are automatically prevented rom rising to unsae levels

use enclosing guards to help reduce noise, and control emissions o mists, ume andn

vapour, either rom metalworking luids or the material being machined

make sure you understand which saety unctions depend on computern

control and how to check and maintain them. I you dont understand, ask your

supplier to explain

check that vision panels intended to contain parts which may be ejected rom then

machine are suitably designed and constructed, have suicient strength and are well

maintained.

A range o CNC systems are available that can be itted to previously manually

operated machine tools, such as milling machines or lathes. Theses systems provide

a selection o eatures which can signiicantly improve the productivity o the machine

and the quality o the work produced. When machines are retroitted, new hazards and

the increased risks to the operator that are associated with CNC machines may beintroduced. Automation also changes the way the operator interacts with the machine

and, to some extent, the way the hazards may be presented to the operator.

Because o the change rom manual to automatic operation a retroitted machine should

be subject to a risk assessment. Fixed and interlocked guards which prevent access

to the danger zone during the automatic cycle should be normally provided. Where it is

necessary to have powered movement o a machine element, with the interlocked guard

open, eg or setting purposes, this should be done under limited speed conditions with

hold-to-run controls.

Detailed consideration should be given to the saety-related parts o the machines

control system. A number o BS EN standards provide speciic guidance on thismatter and urther inormation should be available rom the control system component

supplier.


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Buying and selling machinery

New*

A buyer o new machinery should look or the CE mark, which should indicate:

the suppliers claim to conormity with the Supply o Machinery (Saety)n

Regulations, which implements the Machinery Directive in the UK

the machinery meets essential health and saety requirements to eliminate risksn

o injury rom most sources

there should be little i anything urther to do to make the machinery sae in

Instructions or use are ollowed.

I you buy a machine with a CE mark, assess that it is sae and without risks to

health by, or example, checking it against the standards on any similar machinesyou may already have; it should at least meet current standards. You can use the

risk assessment proorma in Appendix 3 to help check the machine.

An outline of what is defined as machinery from the Supply oMachinery (Saety) Regulations

An assembly o linked parts or components, at least one o which movesn

including the appropriate actuators, control and power circuits, joined

together or a speciic application, in particular or the processing, treatment,

moving or packaging o a material

An assembly o machines which, in order to achieve the same end, aren

arranged and controlled so that they unction as an integral whole

Interchangeable equipment modiying the unction o a machine which isn

supplied or the purpose o being assembled with an item o machinery by

the operator himsel save or any equipment which is a spare part or tool

A saety component placed on the market separately rom machinery ton

ulill a saety unction when in use and the ailure or malunction o which

endangers saety or health.

For a seller o new machinery the CE mark among other things should be a

claim or the most commonly used machine tools in engineering that at least:

hazards, where reasonably practicable, have been designed outnmechanical dangers are saeguarded with guards and saety devices itted andn

working together with clear instructions provided on how risks not saeguarded

are to be avoided

the machine is as quiet as is reasonably practicable with noise reduced atn

source or enclosed (the noise emission level must be stated in Inormation or

use)

steps have been taken to control emissions o harmul substances when then

machine is working by, or example, containment or by providing or connection

to extraction equipment

* New means new to the European Union. An old, second-hand machine from the Far East or EasternEurope, for example, is regarded as new to the European Union for the purposes of the Supply of

Machinery (Safety) Regulations 1992. Carrying out substantial refurbishment, such as fitting a CNC control

to a previously manual machine, may also result in a new machine subject to these Regulations.


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instructions or use are provided to indicate clearly in English how the machinen

may be saely installed, operated, maintained, removed or dismantled; where it

is not immediately clear how saeguards work as on some computer controlled

machinery clear inormation should be provided on:

how they work

how they may be checked

how to maintain them, and

what to do in case o aults/ailures

inormation on vibration is provided and vibration minimised or hand-heldn

machines

metalworking luids can be cooled where necessary, delivered and removedn

saely with risks o contamination minimised, eg rom ilter blockages or high

working temperatures; inormation or use should speciy how to use luids

saely at the machine.

Supply o Machinery (Saety) Regulations 1992 and Amendment

Regulations 1994 outlined

I you are a responsible person or the supply o new machinery or, rom outside

the EU, new or secondhand machinery or the irst time:

AS A COMPLETE MACHINE (such as a lathe)n

AS INTERCHANGEABLE EQUIPMENT TO MODIFY THE FUNCTION OFn

Hse.health and Safety in Engineer In Workshops

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Transcript of Hse.health and Safety in Engineer In Workshops